FOREWORD

This manual is primarily for the operator and the maintenance crew and contains information which is
vital to the correct and secure operation and proper maintenance of the LIEBHERR excavator.

It includes:
Accident Prevention Guidelines
Operating Instructions
Maintenance Instructions.

This Operation and Maintenance manual should be given to the OPERATOR and any other person,
who might work on the machine. It is very important that should read the manual carefully before
operating or working on the LIEBHERR excavator and at regular intervals thereafter, for example:

Operation, including installing and removing the attachments, trouble,

shooting during operation, removing production residue, care, disposing of operating and auxiliary
fluids,
Maintenance work (maintenance, inspection, repair),
Transportation.

The manual will make it easier for the operator to get accustomed to the hydraulic excavator and to
prevent any problems due to improper handling.

All maintenance personnel should follow the operating and maintenance instructions and your
LIEBHERR excavator will give you constant and reliable service with excellent performance, reducing
repair costs and downtime.

In addition to the operating and maintenance guidelines in this manual, additional local and national
accident prevention guidelines and environmental regulations might be applicable and must be
observed.

The Operation and Maintenance Manual is part of the machine and should be left in the glove
compartment of the operator's cab.

Please take notice that we cannot honor any claims which could arise due to careless handling,
improper operation, inadequate maintenance, use of unauthorized oils or lubricants, non-observance
of the safety instructions, etc.

LIEBHERR reserves the right to cancel any warranty claims, service contracts etc. without prior notice
if any other than Original LIEBHERR parts or parts sold by LIEBHERR are being used for
maintenance and repairs.

This Operation and Maintenance manual contains all necessary information to operate and maintain
your Litronic track type excavator. However, should you need additional information or explanations,
please contact LIEBHERR's Technical Documentation, Service school or Customer Service
Department.

0.1
 INDEX
Foreword............................................................................................................................0.1
Index...................................................................................................................................0.3
Information to the operation and maintenance manual..................................................0.5

1/ MACHINE DECRIPTION, TECHNICAL DATA

Technical description, technical data ..............................................................................1.1
Digging envelope for backhoe attachment......................................................................1.4
Digging envelope for shovel attachment.........................................................................1.5
Dimensions, operating weights........................................................................................1.6

2/ SAFETY INFORMATION
Destined use......................................................................................................................2.1
General safety information ...............................................................................................2.2
Crushing and burn prevention .........................................................................................2.3
Fire and explosion prevention..........................................................................................2.3
Machine start up safety.....................................................................................................2.4
Engine start up and operating safety...............................................................................2.4
Machine operating safety .................................................................................................2.4
Machine parking safety.....................................................................................................2.6
Machine transporting safety.............................................................................................2.6
Machine towing safety ......................................................................................................2.6
Machine maintenance safety ............................................................................................2.7
Hydraulic lines and hoses ................................................................................................2.9
Additional safety guidelines for cab elevation ..............................................................2.10

3/ CONTROLS AND INSTRUMENTATION

The access ladder .............................................................................................................3.1
The air cushioned operator’s seat ...................................................................................3.3
Controls and instrumentation in the cab .........................................................................3.4
The control unit .................................................................................................................3.6
The control board..............................................................................................................3.8
The monitoring system of the diesel engine .................................................................3.10
The monitoring display ...................................................................................................3.12
Information provided in the menus of the LCD screen.................................................3.18

4/ OPERATING PROCEDURES
Pre starting inspection......................................................................................................4.1
Machine start up safety.....................................................................................................4.3
Diesel engine operation ....................................................................................................4.4
Engine shutdown procedure ............................................................................................4.6
Emergency shutdown .......................................................................................................4.6
Emergency operation of the engine.................................................................................4.7
Machine operating safety .................................................................................................4.9
Travel functions...............................................................................................................4.10
Location of the two joysticks .........................................................................................4.12
Control of the swing........................................................................................................4.12

0.3
Working position ...............................................................................................................4.14
Attachment control ........................................................................................................... 4.14
The heater and air conditioner.........................................................................................4.18

5/ LUBRICATION
General safety information................................................................................................. 5.1
Lubricants and fuel charts ................................................................................................. 5.2
Lubricants and fuel specifications .................................................................................... 5.4
Lubrication chart ............................................................................................................... 5.10
The service trap................................................................................................................. 5.11
Diesel engine .....................................................................................................................5.13
Changing the oil in the splitterbox ..................................................................................5.16
Changing the oil in the coupling......................................................................................5.19
Changing the oil in the travel gears ................................................................................ 5.20
Changing the oil in the swing gears................................................................................5.21
Oil in the hydraulic system............................................................................................... 5.22
The centralised hydraulic system....................................................................................5.24

6/ MAINTENANCE
Machine maintenance safety.............................................................................................. 6.1
The fuel system ...................................................................................................................6.4
The air system ..................................................................................................................... 6.4
The diesel engine ................................................................................................................ 6.6
The track components ........................................................................................................ 6.8
The hydraulic system........................................................................................................ 6.10
The air filter........................................................................................................................6.16
The electrical system ........................................................................................................6.18
The heater and air conditioner.........................................................................................6.23
Checking mounting screws for tightness.......................................................................6.25
Replacing wear and tear items.........................................................................................6.27
Welding .............................................................................................................................. 6.27
Maintenance schedule ......................................................................................................6.28

7/ TRAVELING PROCEDURES
..............................................................................................................................................7.1

8/ OPTIONAL ATTACHMENT
The Centinel system ........................................................................................................... 8.1
Use of environmentally friendly hydraulic fluids ............................................................. 8.2
Preheating of the hydraulic excavator .............................................................................. 8.4
Winter position of air filter..................................................................................................8.8
Lubricants specifications for –40°C .................................................................................. 8.9
Fire suppression system ..................................................................................................8.10

0.4
 INFORMATION ABOUT THE OPERATION AND MAINTENANCE
MANUAL R 994 B Litronic

ISSUE : …………… 06 / 05
ID. / NO : ………... 8504502
This Operation and Maintenance Manual is valid for R994 B excavators from the following serial
numbers:

Valid from
TYP
Serial Number
411 1001

We recommend that you fill in the following table as soon as you receive your excavator. This will also
be helpfull when you order parts.

Product Id. No (PIN No.): ... / ....

Manufacturing Date : CE 2006

Delivery Date : .. / .. / ..
This excavator meets EC Safety guidelines 89/392/EEC, 89/336/EEC and 91/368/EEC.
Noise emission data has been measured according to EC guidelines 86/662/EEC and 89/514/EEC.
Die Abgaben für Schall – Emission wurden nach EG Richtlinie 89/662/EWG gemessen.

We reserve the right to make any technical changes compared to data and illustrations given in
this manual.

Warranty and liability are subject to LIEBHERR’s general business terms and conditions are not
changed in any way by instructions in this manual.

Instructions and photos or drawings in this manual may not be reproduced, used for any
reason and / or distributed without written permission from the publisher.
All rights reserved.

Manufacturer : LIEBHERR France S.A.S 2 Avenue Joseph Rey, F-68005 COLMAR, FRANCE

0.5
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 2. SAFETY INFORMATION
Working with an excavator can be dangerous, it could result in injury or death if proper precautions are
not taken! WE URGE YOU TO READ THIS MANUAL CAREFULLY! This safety information is
provided to operators and maintenance mechanics to ensure the safe operation and maintenance of
the excavator. It is essential that you read and familiarise yourself with this information, which explains
safety requirements, precautions and specific hazards of which you should be aware. This also
applies to any personnel, who might be working on the machine only occasionally, such as during set
up or maintenance. It is essential that you read and familiarise yourself with this information, which
explains safety requirements and precautions and specific hazards of which you should be aware.
Careful adherence to these safety guidelines will permit safe operation and maintenance and
potentially prevent personal injury to yourself and others, and possible damage to the excavator.
Important safety notes such as DANGER, CAUTION or NOTE are used throughout this manual to
emphasise important or critical instructions.
In this manual, DANGER, CAUTION or NOTE are defined as follows :

DANGER

Denotes an extreme intrinsic hazard, which could result in a high probability of death or serious injury
if proper precautions are not taken.

CAUTION

Denotes a reminder of safety practices or directs attention to unsafe practices if proper precautions
are not taken.

NOTE describes operation and maintenance procedures, which should be followed to keep your
excavator in operation and to insure long machine life and / or to facilitate certain procedures.

In addition to these instructions you must follow the safety regulations applicable to your work
environment and job site and any federal, state and local safety requirements (a model
excavators must also follow local and federal highway regulations).

For EC countries, guidelines 89 / 655 / EWG contain the minimum safety guidelines for users.

DESTINED USE
The excavator with the standard backhoe, grapple or bucket attachment may only be used to loosen,
pick up, move, load and dump soil, gravel, rock, or other material and to load trucks, barges, conveyor
belts, or rock crushing systems.
Special guidelines are applicable for machines used for lifting applications and special safety devices
must be installed.
Any other use above and beyond the applications described above, such as breaking out rock or
demolishing buildings, pounding in posts etc. requires special attachments and safety devices.
If the machine is exposed to the risk of falling down objects during operation, the cab machine must be
fitted with a safety device according to the FOPS prescriptions
Transporting personnel or loads etc. is not considered destined use and is therefore prohibited. The
manufacturer / dealer is not responsible for any resulting damage. Any risk must be carried by the
user himself.
Destined use is considered part of observing and adhering to all regulations and inspection and
maintenance guidelines given in this Operation and Maintenance Manual.

2.1
 Park excavator on firm and level ground. Rest
GENERAL SAFETY INFORMATION the attachment on the ground.
Study the Operation and Maintenance Place all control in neutral position and raise the
Manual before operating or working on the safety lever.
excavator. Turn the engine off and remove the ignition key.
Make sure that you have additional information for
special attachments of your machine, read it and Before working on the hydraulic circuit, move all
understand it! joysticks and pedals with the ignition key in contact
position and the safety lever tilted down to relieve the
Allow only authorized personnel informed servo pressure and the remaining pressures in the
about the safety rules to operate, service or repair different main circuits. In addition, relieve the
the excavator. Make sure to observe any minimum pressure in the hydraulic tank as described in the
applicable age requirement. Operation and Maintenance Manual.
Allow only properly trained personnel to Secure all loose parts on the excavator.
operate or work on the excavator, make sure to
clearly specify the person who is responsible for Never operate the excavator without a
set up, maintenance and repairs. complete walk around inspection. Check if all warning
decals are on the machine and if they are all legible.
Make sure the operator knows his
responsibility regarding the observance of traffic Observe all danger and safety guidelines.
regulations and permit him to refuse any unsafe For certain special applications, the excavator
instructions given by a third person. must be equipped with specific safety equipment.
Any persons still in training should only Use the excavator only, if they are installed and
operate or work on the machine under the functioning properly.
supervision and guidance of an experienced Never perform any changes, additions or
person. modifications on the machine, which could influence
Check and observe any person working or the safety, without obtaining the written permission
operating the excavator periodically and regularly, from the manufacturer. This also applies to the
if they observe safety instructions and guidelines installation and adjustment of safety devices and
given in the Operation and Maintenance Manual. safety valves as well as to any welding on load
carrying parts.
Wear proper work clothing when operating or It is forbidden to repair the cab.
working on the excavator. Rings, watches,
bracelets and loose clothing such as ties, scarves, Do not install any equipment or attachments
unbuttoned or unzipped shirts and jackets are made by other manufacturers or any which are not
dangerous and could cause injury! specifically authorized by LIEBHERR for installation
Wear proper safety equipment, such as safety without first obtaining the written permission from
glasses, safety shoes, hard hats, work gloves, LIEBHERR.
reflector vests and ear protection. LIEBHERR will issue any required technical
Consult your employer or supervisor for documentation for approved installations.
specific safety equipment requirements and safety Should the electrical circuit be modified or
regulations on the job site. additional components be installed, so the
modification must be performed according to the
Always tilt up the safety lever before leaving
national standards and safety regulations (such as
the operator’s seat.
OSHA per the USA).
Do not carry tools, replacement parts or other The installation must be certificated by an approved
supplies while climbing on or off the excavator. organization and a copy of the certification has to be
Never use the steering column, control levers or sent to the LIEBHERR company.
joysticks as handholds.
Never jump off the excavator, climb on and
off the excavator using only the steps, rails and
handles provided.
When climbing on or off the excavator, use both
hands for support and face the machine.
If needed, use the front window as an escape
hatch.
If no other guidelines are given, perform
maintenance and repairs utilizing the following
precautions :

2.2
 Check the electrical system regularly and
CRUSHING AND BURN PREVENTION frequently.
Never work underneath the excavator unless All defects, such as loose connections, burnt out
it is safely resting on the ground and / or is properly fuses and bulbs, burnt or damaged cables must be
blocked and supported. repaired immediately by a licensed electrician or
specially trained personnel.
Never use damaged or insufficient wire
ropes, slings or chains. Always wear gloves when Never store flammable fluids on the machine
handling wire ropes. except in storage tanks intended for the excavator’s
operation.
Never reach into bores during attachment
installation or removal. Never align bores with your Inspect all components, lines, tubes and hoses
fingers or hands. Use proper alignment tools when for oil and fuel leaks and / or damage.
installing, changing or servicing attachments by Replace or repair any damaged components
qualified mechanics immediately.
Any oil, which escapes from leaks, can easily cause
Keep objects away from the radiator fan. a fire.
Rotating fans will swirl and throw out objects,
which can become very dangerous and cause Be certain that all clamps, guards and heat
severe injury to yourself and others. shields are installed. These components prevent
vibration, rubbing, chafing and heat build-up. Install
Avoid contact with any components tie wraps to fasten hoses and wires, as required.
containing coolant.
At or near operating temperature, the engine Cold start ether is extremely flammable. Do not
coolant is hot and under pressure and could cause use together with preheat. Use ether only in
severe burns. ventilated areas and as directed. Never use it near
heat sources or open flames, do not permit anybody
Check the coolant level only after the radiator to smoke.
cap is cool enough to touch. Remove the radiator
cap slowly to relieve pressure . Know the location of the excavator's fire
extinguisher and be familiar with its operation. Make
Do not allow your skin to come into contact sure you know your local fire regulations and fire
with hot oil or components containing hot oil. At or reporting procedures.
near operating temperature, engine and hydraulic
oil is hot and can be under pressure. A fire extinguisher can be attached inside the
operator's cab, using the four threaded holes
Always wear safety glasses and protective provided in the rear left support of the cab.
gloves when handling batteries. Keep sparks or
open flames away!
Never permit anyone to hand guide the
bucket or grapple into position.
When working in the engine area, make sure
the top covers and side doors are properly secured
or closed with the appropriate supports.
Never work underneath or on the excavator
unless it is properly blocked and supported.

FIRE AND EXPLOSION PREVENTION

Always turn off the engine while refuelling the
excavator.
Never smoke or allow an open flame in
refuelling areas or where batteries are being
charged, or where batteries or flammable materials
are stored.
Never leave machine unattended while
fuelling. During this operation, no one but the
employee in charge of refuelling is allowed to stay
on the excavator.
Always start the engine as described in the
Operation and Maintenance Manual.

2.3
 your hand and lock it in its opened position, making
MACHINE START UP SAFETY sure it is securely fixed in this position, so it can not
Before excavator start up, perform a be slammed by the wind.
thorough walk around inspection. If the weather conditions are bad, increase
your attention to realise climbing or descent from the
Visually inspect the excavator, look for loose cab with a maximum of precautions, and do or let do
bolts, cracks, wear, any leaks and any evidence of the preliminaries operations of preparation which are
vandalism. necessary so you can move safely.
Never start or operate an unsafe excavator. With those conditions be especially vigilant.
Report all defects to your foreman or Go on climbing up, always holding yourself by
supervisor and make sure they are corrected three points, enter the cab and seat down to the seat
immediately. If applying fasten the seat belt. Unlock the door
Make sure all covers and doors are closed using the unlocking lever and close the door holding
and all warning decals are on the machine. it by the handle designed for this purpose. Only
thereafter lower the safety lever and start the
Make sure all windows, as well as inside and machine.
outside mirrors are clean, and secure all doors and It is essential to have your seat belt fastened if
windows to prevent any unintentional movement. you want to operate the machine with the cab door
Be certain that the area surrounding the opened.
excavator is free of other personnel, and that no Should the belt be missing on your machine, so you
one is working on or under the excavator before must compulsorily get one installed before you start
starting the engine. working with opened cab door.

Covers and boxes locks have to be unlocked, After entering the cab, adjust the operator’s
to facilitate the fight against fire in case of. seat and controls, the inside and outside mirror, the
armrests and fasten and adjust the seat belt. Be
Proceed with the same precaution while certain that all controls can be reached comfortably.
climbing up and down the cab, as for the ascension
of the machine All noise protection devices on the machine
must be functional during operation.
Keep ladders, footsteps, handles and
handrail in clean condition and always free them
from mud, oil, grease, ice, snow or any other
obstacles.
To guarantee an easy opening of the cab
door in all weather conditions, coat the rubber
seals around the door with silicon oil or talcum
every two months and more often if necessary.
Regularly grease the hinges and lock of the cab
door as well the fixing device of the door in
opened position.
During maintenance works, always wear safety
glasses and proper protective clothes..
To climb up or down the cab, the excavator
must be parked on firm, flat and level ground and
the uppercarriage must be swung so to align
ladders and steps on upper and undercarriage.
Face the excavator when climbing up or
down and always hold on to the machine at three
points, i. e. keep the contact with the access
components at the same time with two hands and
one foot or with one hand and the two feet.
As soon as you can reach the handle of the
door with your free hand unlock it, and keeping
yourself apart from the slewing range of the door,
open the door before climbing up any more. Some
external influences, and especially the wind, may
make the opening of the door uneasy. For this
reason, keep and guide the door all the way with

2.4
 Keep sufficient distance to electrical lines.
ENGINE START UP AND OPERATING SAFETY When working in the vicinity of high voltage
Before start up, check if all indicator lights electrical lines, keep proper distance to assure that
and instruments are functioning properly, place all the attachment does not come close to the lines.
controls in neutral position and tilt the safety lever DANGER! You must inform yourself about safe
up. distances.

Before starting the engine, alert any nearby Preferably have the electrical lines de-energized
personnel that the excavator is being started by (and lockout / tagged out according to the
sounding the horn. regulations applicable on the job-site) each time it is
possible, and in any case if the closeness of the
Start the machine only when seated in the working area make it necessary.
operator’s seat, and with the seat belt fastened (if
installed). In case you do touch a high voltage line by
accident, proceed as follows:
If you have no other instructions, start the
engine as outlined in the Operation and do not leave the machine,
Maintenance Manual. move the machine, if possible, from the danger
zone until you obtain sufficient distance,
Tilt the safety lever down and check all warn any personnel in the vicinity not to come
indicators, gauges, warning devices and controls close to the excavator and not to touch it,
for their proper indication. instruct or initiate that someone turns off the
Start and operate the engine only in a well voltage.
ventilated area. If necessary, open doors and Do not leave the machine until you are
windows. absolutely sure that voltage in the line, which
Warm up the engine and hydraulic system to had been touched or damaged, has been
operating temperatures. Low engine and hydraulic turned off!
oil temperatures can cause the excavator to be Before moving the machine, make sure that the
unresponsive. attachments and equipment is secured properly to
Check that all attachment functions are avoid accidents.
operating properly. When travelling on public roads, make sure to
Move the excavator slowly into an open area observe traffic regulations, and make sure that the
and check all travel functions for their proper machine meets federal and local public highway
operation, check travel and swing brakes, the standards.
steering function as well as the turn signals and Always turn on the lights if visibility is bad or if
lights. you are still working during dusk.
Never allow other personnel on the excavator.
MACHINE OPERATING SAFETY Operate the excavator only while seated and
Familiarize yourself with job site rules. Be with the seat belt fastened, if installed.
informed about traffic and hand signals and safety
signs. Ask who is responsible for signalling. Report any problems or needed repairs to your
Check your surrounding for any obstacles in the foreman or supervisor and make sure they are
working and movement range, check the load corrected immediately.
carrying capacity of the terrain, and secure the job Do not move the excavator until you are certain
site to shield it from any public highway traffic. that no one is endangered by moving the excavator.
Rope off the working area of the machine and
On machines without negative brakes check
install the necessary signs to forbid any non
the brake system before starting to work, as outlined
authorized person entering the area.
in the Operation and Maintenance Manual.
Always keep a safe distance from overhangs,
walls, drop offs, and unstable ground. Never leave the operator’s seat while the
machine is still moving.
Be alert of changing weather conditions, bad
Never leave the machine unattended (within
or insufficient visibility and of changing ground
view of machine), with the engine running.
conditions.
When moving the excavator, keep the
Be alert for utility lines, check the location of uppercarriage in lengthwise direction and keep the
underground cables, gas and water lines, and load as close as possible to the ground.
work especially careful in that vicinity. If
necessary and/ or if required, call local
authorities to mark the location, and take
precaution against contact with underground
utilities.

2.5
 Prevent any working movements, which Repeated strikes against an object leads to
could tip the machine over. If the excavator begins damage to the steel structures and machine
to tip or slip on a grade, immediately lower the components.
attachment and load to the ground and turn the Please refer to your LIEBHERR dealer if
excavator facing downhill. special teeth for heavy-duty or special applications
If possible, always operate the excavator with the are required.
attachment positioned uphill or downhill, never Do not attach too large bucket or bucket with
sideways. side cutters or that are during operations with rocky
Always travel slowly on rough or slippery material. This would prolong the work cycles and
ground and on slopes, and on loose soils. may lead to damage to the bucket as well as further
Always travel downhill at permissible speed, machine components.
so you don’t loose control over the machine. The With the 2x45° offset articulation, the offset
engine must run at nominal speed, use only the position may only be employed if the working tool or
foot pedals to brake and slow down the machine. the attachment does not touch the material.
Never shift during down hill travel, always shift to Operation of the offset articulation to drill into
a lower gear before travelling downhill. the material is not permitted.
Load an occupied truck only if all safety
requirements are fulfilled, notably in order to Do not lift the machine during operation. Should
protect the truck operator. this happen, lower the machine slowly back to the
ground.
For demolition work, clearing, crane
operation, etc. always use the appropriate Do not let the machine fall heavily on the
protection device designed for this specific ground and do not hold it back with the hydraulics.
application. This would damage the machine.
If operating in visually obstructed terrain or During operation with the attachment it is
whenever necessary, have another person guide forbidden to raise the machine with the dozing blade
you. Always have only one person signal you. (e.g. carving at the ceiling when tunnelling).
Allow only experienced persons to attach The hydraulic hammer must be selected with
loads or to guide operators. The guide must be particular care. When using a hydraulic hammer not
visible by the operator and / or must be in voice permitted by LIEBHERR, steel structures or the
contact with him. other machine components can become damaged.
Depending on the attachment combination, it Before beginning breaking tasks, position the
is possible for the bucket teeth to hit the cab, the machine on firm and level ground.
cab protection or the boom cylinders. Be very Use a hydraulic hammer designed exclusively
careful when the bucket teeth get in this range to for breaking stone, concrete and other breakable
prevent any damage. materials.
In case of a thunderstorm : Only operate the hydraulic hammer in the
longitudinal direction of the machine and with the
lower the attachment to the ground and if windshield closed or with a front protective grid.
possible anchor the digging tool into the soil.
Ensure during hammer operation that no
leave the cab and move away from the cylinder is entirely extended or retracted and that the
machine before the storm breaks out. stick is not in the vertical position.
Otherwise, you must stop the excavator, turn
off the radio and keep inside the closed cab In order to avoid damages to the machine, try
until the end of the storm. not to break stone or concrete while performing
retraction and extension motions of the hydraulic
Auxiliary control units can have various hammer.
functions. Always check their functions when
starting up the machine. Do not apply the hydraulic hammer
uninterrupted for more than 15 secs. at a time to the
Stop the swinging motion of the same place. Change the breaking point. Too long
uppercarriage when lowering the attachment into uninterrupted operation of the hydraulic hammer
a ditch without striking the attachment on the ditch leads to an unnecessary overheating of the
walls. hydraulic oil.
Inspect the machine for damage if the Do not use the drop force of the hydraulic
attachment has been swung into a wall or any hammer to break stone or other materials. Do not
other obstacles. move obstacles with the hydraulic hammer. Misuse
Applications in which the attachment is to be of this nature would damage both the hammer and
used to strike the material being extracted are not the machine.
permitted, even when working in a longitudinal Do not use the hydraulic hammer to lift objects.
direction.

2.6
 incline is less than 30° and covered with wooden
MACHINE PARKING SAFETY planks to prevent skidding.
Park the excavator only on firm and level Remove all mud, snow or ice from track
ground. components before moving up the ramp.
If it becomes necessary to park the machine on a Before loading, secure the uppercarriage with
grade, properly block and secure it with wedges. the undercarriage with the lock pin (if lock pin is
Lock the uppercarriage with the lock pin (if installed).
lock pin is installed). Align the machine with the loading ramp.
Lower the attachments to the ground and Attach the manual control levers to the foot
anchor the bucket lightly in the ground. pedals for sensitive control.
Bring all operating levers in neutral position Have another person guide and signal the
and engage the travel and swing brakes. operator.
Turn the engine off as outlined in the Have blocks or wedges ready to block the
Operation and Maintenance Manual and raise machine, if necessary, to prevent the machine from
the safety lever before you leave the operator's rolling backwards. Be careful to crushing risks when
seat. handling and applying these wedges. Keep clear of
Proceed with the same precaution while wheels and do not attempt to chock or block the
climbing up and down the cab, as for the ascension machine before its complete standstill.
of the machine Retract the attachment as far as possible and
lower the attachment as close as possible to the
Before climbing down the cab, you must
loading surface and carefully drive up the ramp and
make sure the machine is parked on a flat, firm
onto the flat bed trailer.
and level ground and the ladders and steps are
aligned on upper and undercarriage. When the excavator is on the trailer, release
the uppercarriage lock pin, turn the uppercarriage
Then open the cab door and lock it in back and lower the attachment.
opened position and make sure it is securely fixed
in this position. If the backhoe attachment is attached, tilt the stick and
Be aware of difficult weather conditions and bucket in and relock the uppercarriage (if lock pin is
anticipate their possible consequences. The wind installed).
for example could slam the cab door. If necessary Carefully secure the uppercarriage and other
unfasten the seat belt. parts with chains, wedges and blocks to prevent
slipping.
Carefully begin climbing down, facing the
machine and always holding the contact at three Release the hydraulic pressure, remove the
points, keeping the contact with the access ignition key, raise the safety lever, close and lock
components at the same time with two hands and the cab and close and secure all other doors and
one foot or with one hand and the two feet, until leave the machine.
you reach the height where you can close the cab Carefully check out the transport route. Make
door in the best conditions, keeping yourself apart sure that width, height and weight allowances are
from its slewing range. Unlock the door using the within the permitted limits.
unlocking lever designed for this purpose and Check that there is enough clearance
close the door guiding it by the handle. underneath all bridges, underpasses, utility lines,
If you want so lock the door and take away the and in tunnels.
key.
Slowly and carefully go down to the floor. During the unloading procedure, proceed with
the same care and caution as during the loading
Lock the cab, covers and boxes, remove all procedure. Remove all chains and wedges. Start
keys and secure the excavator against vandalism, the engine as outlined in the Operation and
unauthorized use, and any attractive nuisance. Maintenance Manual. Carefully drive off the loading
platform. Keep the attachment as close as possible
to the ground level. Have another person guide and
MACHINE TRANSPORTING SAFETY signal you.
Use only suitable transporting and lifting
devices with sufficient capacity.
Park the machine on firm and level ground
and block the chains or wheels.
If necessary, remove part of the attachments
during transport.
When loading the machine on a flatbed trailer
or railroad car, be sure that the loading ramp

2.7
 manufacturer. This is assured by using only original
MACHINE TOWING SAFETY Liebherr replacement parts.
Observe the correct procedure: check the Always wear proper work clothing when
index in your Operation and Maintenance manual maintaining the excavator. Certain work may only
and refer to the appropriate section : ”Towing the be performed with a hard hat, safety shoes, safety
Excavator“. glasses and gloves.

Only tow the excavator if absolutely During maintenance, do not allow unauthorized
necessary, for example to remove it for repairs personnel to enter the maintenance area.
from a dangerous job site. Secure the maintenance area, as necessary.
Be sure all towing and pulling devices such Inform the operator before any special or
as cables, hooks, and couplers are safe and maintenance work. Make sure he knows the
adequate. person, who is in charge of the work.
Make sure that the cable or the towing rod If not otherwise noted in the Operation and
are strong enough and are routed around the Maintenance Manual, always make sure the
centre of the undercarriage or to the towing hook excavator is parked on firm an level ground and the
on the undercarriage, which is designated for this engine is turned off.
purpose. Be aware that any damage to the
machine caused by towing is never covered by During maintenance and service work, make
the manufacturer's warranty. sure you always retighten any loosened screw
connections!
Never allow anyone to stand near the cable
when pulling or towing the excavator. If it is necessary to disconnect or remove any
safety devices during set up, maintenance or repair,
Keep the cable tight and free of kinks. make sure that after completion of repairs, the
Engage travel slowly, and do not jerk. With a safety devices are reinstalled and checked for
slack cable, the sudden impact of the load being proper function.
towed could snap and break. Before any maintenance work and especially
Keep personnel out of area. If cable breaks when working under the machine, make sure a ”Do
while under stress, it could cause severe injury. not operate’ tag is attached to the starter switch.
Remove the ignition key.
During the towing procedure, keep within the After end of maintenance works or repair, restart
required transport position, permissible speed the machine according to the instructions "Machine
and distance. start up", in this manual.
After the towing procedure is completed, Before any repairs or maintenance work, clean
return the machine to its previous state. any oil, fuel and / or cleaning substances from any
fittings and connections .
Proceed as outlined in the Operation and
Don’t use any harsh cleaners and use only lint free
Maintenance Manual when putting the excavator
cloths.
back in service.
Use only non-flammable cleaning fluids to clean
the machine.
MACHINE MAINTENANCE SAFETY Any welding, torch or grinding work on the
The machine may not be made unsafe when machine must be explicitly authorized. Written
performing maintenance work. Never attempt authorization is necessary for welding on carrying
maintenance procedures or repairs you do not structures. Before any using a welder, torch or
understand. grinder, clean off any dust and dirt and remove any
flammable materials from the surrounding area.
Check the Operator’s and Maintenance Make sure the area is sufficiently ventilated.
Manual for service and maintenance intervals. Danger of Fire and Explosion!
Make sure you use only appropriate tools for all
maintenance work. Before cleaning the machine with water or
steam (high pressure cleaning) or other cleaning
Refer to your Operator’s and Maintenance fluids, make sure that all openings, which , for
Manual to see, who is authorized to perform safety and/ or functioning reasons should not be
certain repairs. The operator should only perform exposed to water / steam/ cleaners, are covered
the daily / weekly maintenance procedures. and / or masked off. Especially sensitive are
The remaining work may only be performed by electrical motors, control boxes and plug
especially trained personnel. connectors.

Use only replacement parts corresponding to

the technical requirements specified by the

2.8
 Make sure that the temperature sensors of the operator and / or must be in direct voice contact
the fire alarm and extinguishers system do not with the operator.
come in contact with the hot cleaning fluids, which When working overhead, use appropriate and
could trigger the fire extinguishing system. safe ladders, scaffolding or other working platforms
Remove all coverings and masking material after designated for that purpose.
completing the cleaning procedure. Never step on parts or components on the machine
Then check all fuel lines, engine oil lines and when maintaining or repairing items overhead.
hydraulic oil lines for leaks, loose connections, When working high above ground, make sure you
chafing and / or damage. are fitted with ropes and appropriate safety devices
Fix any problems immediately. which will prevent a possible fall.
Always keep handles, steps, railings, platforms and
If you use a high pressure cleaner with ladders free of dirt, snow and ice!
steam or hot water to clean the machine, observe
following recommendations : When working on the attachments, for example
the distance between the nozzle and the when replacing the bucket teeth, makes sure the
surface to be cleaned must be no lower than attachment is supported properly. Never use metal
20 inches on metal support!
the water temperature should not exceed 60°c
For safety reasons, never open and remove a
(140°F)
track chain unless having previously totally released
limit the water pressure to 80 bar maximum the pretension of the chain tensioning unit.
(11500 PSI)
if you employ cleaning fluid, only use neutral Never work underneath the machine if it is
cleaning agents such as customary car raised or propped up with the attachment. The
shampoos diluted to 2 or 3 percent maximum undercarriage must be supported with wooden
blocks and supports.
Never employ high pressure cleaning
apparatus during the two first months following Always support the raised machine in such a
machine delivery or repainting. way that any shifting to the weight change will not
influence the stability. Do not support the machine
Observe all product safety guidelines when with metal on metal support.
handling oils, grease, and other chemical
substances. Only qualified, especially trained personnel may
work on travel gear, brake and steering systems.
Make sure service fluids and replacement
parts are disposed of properly and in an environ- If it becomes necessary that the machine must
mentally sound manner. be repaired on a grade, block the chains with
wedges and secure the uppercarriage to the
When using hot service fluids, be very undercarriage with the lock pin.
careful. (They can cause severe burns and
injury!). Only qualified, especially trained personnel may
work on the hydraulic system.
Operate combustion motors and fuel
operated heaters only in well ventilated areas. Never check for leaks with your bare hands,
Before operating these units, check ventilation. always wear gloves. Fluid escaping from a small
In addition, always follow applicable local hole can have enough force to penetrate the skin.
regulations.
Never loosen or remove lines or fittings before
Never try to lift heavy parts. Use appropriate the attachment has been lowered to the ground and
lifting devices with sufficient load carrying the engine has been turned off. Then turn the
capacity. When replacing or repairing parts or ignition key to contact position with tilted down
components, make sure they are mounted very safety lever, move all servo controls (joysticks and
carefully on lifting devices, to prevent any foot pedals) in both direction to release pressures.
possible danger. Use only suitable and Then release the tank pressure as outlined in this
technically sound lifting devices, make sure that Operation and Maintenance Manual.
lifting tackle, wire cables, etc. has adequate load
Always disconnect the battery cable before
carrying capacity.
working on the electrical system or before any arc
Never position yourself, walk or work underneath
welding on the machine. Always disconnect the
suspended loads.
negative (-) cable first and reconnect it last.
Never use damaged lifting devices, or
devices which are not sufficient to carry the load.
Always wear gloves when handling wire cables.
Ask only experienced personnel to attach
loads and guide and signal the crane operator.
The guide must be within the visibility range of

2.9
 Check the electrical system regularly. working cycles, extremely high impulse frequencies,
Make sure that any problems, such as loose multi shift or around the clock operations).
connections, burnt out fuses and bulbs, scorched Hoses and lines must be replaced if any of the
or chafed cables are fixed immediately by an following points are found during an inspection (see
electrician or qualified personnel. guidelines ISO 8331):
Use only Original fuses with the specified Damage on the external layer into the inner
amperage. Never use a different size or stronger layer (such as chaffing, cuts and rips);
fuse than the original fuse. Brittleness of the outer layer (crack formation of
the hose material);
On machines with electrical medium or high Changes in shape, which differ from the natural
voltage systems: shape of the hose or line, when under pressure
If there is any problem with the electrical or when not under pressure, or in bends or
energy supply, turn the machine off curves, such as separation of layers, blister or
immediately. bubble formation, crushing or pliers.
Follow established lockout / tag out Leaks;
procedures where applicable. Non observance of installation requirements;
Any work on the electrical system may only Damage or deformation of hose fittings, which
be performed by a qualified electrician or might reduce the strength of the fitting or the
qualified personnel under the guidance and connection between hose and fitting;
supervision of an electrician, according to Any movement of hose away from the fitting;
electro - technical regulations. Corrosion on fittings, which might reduce the
If any work is required on any parts which function or the strength of the fitting;
carry current, use a second person to turn off the When replacing hoses or lines, always use Original
main battery switch, if necessary. Rope the work replacement parts.
area off with a safety rope or chain, and set up Route or install the hoses and lines properly.
warning signs. Use only insulated tools. Do not mix up the connections!
When working on medium and high voltage Always take care to avoid torsional strain when
components, shut off the voltage and connect the installing a new hose. On high pressure hydraulic
supply cable to the ground and ground the hoses, the mounting screws must be first mounted
components, such as the condenser, with a on both hose ends (full flange or half clamp) and
grounding rod. tightened only thereafter.
Check all disconnected parts if they are truly On high pressure hoses having one curved end,
free of current, ground them and close them off always tighten first the screws on the curved hose
quickly. Insulate any close-by, current carrying end and only then the screws on the straight hose
parts. end.
Install and tighten the hose clips that may be
mounted on the hose middle only when the both
HYDRAULIC LINES AND HOSES hose ends are already tightened.
Hydraulic lines and hoses may never be Always install hoses so to avoid any friction
repaired! with other hoses and parts.
All hoses, lines and fittings must be checked We recommend to keep a distance between hose
daily, but at least every 2 weeks for leaks and any and other parts of at least one half of the hose outer
externally visible damage! Never check for leaks diameter. Keep a minimum gap of 1/2 inch in any
with your bare hands, use a sheet of paper or case.
something else. Any damaged sections must be After mounting a hose connecting two parts that are
replaced immediately! Escaping oil can cause movable to each other, check during the return to
injuries and fires! service that the hose is not rubbing in the whole
moving range.
Even if hoses and lines are stored and used
properly, they undergo a natural aging process. Check daily that all flanges and covers are fixed
For that reason, their service life is limited. correctly. It will prevent vibrations and damage
Improper storage, mechanical damage and during operation.
improper use are the most frequent causes of hose
failures. Concerning the hoses, you must follow the
safety regulations applicable to your work
environment and job site and any federal, state
and local safety requirements.
Using hoses and lines close to the limit
ranges of permitted use can shorten the service life
(for example at high temperatures, frequent

2.10
 2. Check the vibration absorption and adjustment
PROTECTION AGAINST VIBRATION mechanisms of the seat regularly and ensure
that condition of the seat always adheres to
Stress caused by vibration in mobile construction the specifications of the seat manufacturer.
machinery is predominantly a result of the way in Check the maintenance condition of the machine, in
which it is operated. The following parameters particular: tyre pressure, brakes, steering,
have a particularly significant influence: mechanical connections, etc.
Terrain conditions: Unevenness and potholes; Do not carry out steering, braking, acceleration and
Operational technique: Speed, steering, braking, switching, or move or load the machine’s working
control of the machine’s operating elements attachment, in jerky movements.
during travel and during operation.
Adapt the machine speed to the travel path to
The machine operators themselves are largely reduce vibrational stress:
responsible for the actual stress caused by
vibration as the operators determine speed, gear Reduce the speed when negotiating rough terrain;
transmission, manner of handling and travel Travel around obstacles and avoid very rough
routes. terrain whenever possible.
Thus, a wide range of different forms of vibrational Ensure that the terrain over which the machine is
stress are resulted for the same machine type. being driven or operated is well maintained:
Vibrational stress of the machine operator’s body Remove large stones and obstacles;
can be reduced by noting the following
Fill in ditches and holes;
recommendations:
Ensure that machines are on-hand for the
Select the correct machine, equipment and preparation and upkeep of practical terrain
accessories for each respective application. conditions and that sufficient time for this work is
Use a machine which features a suitable seat allowed for.
(thus, for earthmoving machines, e.g. hydraulic
excavators, a seat which complies with EN ISO Travel over longer distances (e.g. on public roads)
7096). with adequate (average) speed.
Ensure that the seat remains in good condition For machines which are used primarily for
and adjust the seat as follows: travelling, use special auxiliary systems for the
1. Adjustment of the seat, and thus the journeys (wherever available), allowing a vibration
vibrations being produced from the seat, reduction for this application type.
should be carried out in relation to the Should these auxiliary systems not be available,
weight and size of the operator regulate the speed so that a "vibrational build-up" of
the machine is avoided.

2.11
3. CONTROLS AND INSTRUMENTATION
THE ACCESS LADDER

The access ladder can be swung either into lower position to permit
access to the uppercarriage or into upper position during operation
via a hydraulic cylinder.
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 control box E1022-1, which is installed to the catwalk next to
the upper ladder section leading to the cab (Fig. 1).
Fig. 1

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 lower position:

Push the switch S157 to unlock the ladder (the red indicator light
H68 will go on), then push the switch S158 to swing the ladder until
it has reached the lowest position (the red indicator H67 is on).

To bring the ladder into upper position (working position):

Push the switch S155 until the ladder has reached its top position (i.
e. the red indicator light H67 goes out), then push the switch S156 to
lock the ladder (when locked the red indicator light H68 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 H68 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 at the right front of the control panel (see
Fig. 3).

The ladder can only be locked after it has reached its upper stop
position (H67 is off). Fig. 2
The ladder can only be swung up or down when the locking device
is in unlocked position (H68 is on).

Fig. 3
3.1
 E1022-1 Control box / access ladder

H67 Control light red / ladder not in

upper position

H68 Control light red / ladder not

locked

S125 Switch / lighting of cab access

S141 Switch / lighting of main ladder

S155 Push button / access ladder up

S156 Push button / access ladder

locking

S157 Push button / access ladder

unlocking

S158 Push button / access ladder

down

E1022-2 Control box / service trap

H69 Control light red / service trap

not in upper position

H70 Control light red / service trap

locked

S127 Switch / temporised lighting for

cab and access ladder

S159 Push button / service trap up

S160 Push button / service trap

locking

S161 Push button / service trap

unlocking

S162 Push button / service trap down

3.2
 THE AIR CUSHIONED OPERATOR'S SEAT

CAUTION

Before adjusting the operator's seat and the joysticks, make

sure that the safety lever (fig. 9) is in the uppermost position
to avoid any unexpected movements of the hydraulic
excavator.

ADJUSTING THE OPERATOR'S SEAT

Adjusting the operator's seat horizontally with respect to the two

control panels is possible after lifting lever 1 (Fig. 4). Fig. 4

Independent of this adjustment, the entire seat including the two

control panels can be slid horizontally after lifting lever 2 (Fig. 4).

Adjusting the seating suspension to body weight is done via key 7

(Fig. 6).

Adjusting the seat cushion angle and the seat height is done via
levers 4a and 4b (Fig. 6).
By lifting lever 4a the seat cushion in back can be tilted up or
down.
By lifting lever 4b the seat cushion in front can be tilted up or
down.

Adjusting the angle of the backrest is done via lever 6 ((Fig. 6).
Lift lever 6 Fig. 5
Move the backrest to the desired angle
Release lever 6

Adjusting the lower back support in the backrest occurs via keys 8 and 9
((Fig. 6),

The angle of the right and left armrests can be adjusted. Turn the
knurled screws 3 (Fig. 5) beneath the arm rests in the appropriate
direction.

VIBRATION DAMPING
The seat mounted in the excavator corresponds to ISO 7096
standards.

When used according to the excavator's specifications, the values of Fig. 6

the vibration load transmitted by the operator's seat are less than or
equal to the test vibrations of the corresponding machine type
according to ISO 7096 standards. The resulting vibration
acceleration values "azw", measured according to ISO 2631, part1,
standards, meet the demands for vibration protection of the entire
body according to EN 474-1 (acceleration " azw" between 0,5 and 2,5
m.s-2).
NOISE EMISSION
ISO 6396 LpA (inside cab) = 76 dB(A)

3.3
 CONTROLS AND INSTRUMENTATION IN THE CAB

2 Arm rests S1 „Contact“ key

8 Heater vent S2 Switching unit
15 Control board for safety operation of S5 Switch / horn
engine & hydraulics pumps, control of S6 Switch / float position attachment
floodlights, … S7 Safety lever / servo control
A2 Radio S57 Swing brake
A1001 Printplate ESP01 U20 Pedal for bottom dump shovel flap
E14 Cigarette lighter U21 Left joystick
E1010 Switching box central lubrication U22 Right joystick
E1031 Central lubrication control U23 Pedal for right travel gear
H1 Monitoring display U24 Pedal for left travel gear
H7 Horn
P5 Hourmeter
* Optional equipment

3.4
SAFETY LEVER - SERVO CONTROL S7

For safety reasons, a safety lever is installed on the left control

console, and the operator must raise this lever before he leaves the
operator's seat.
He must be safely seated before lowering the safety lever to start a
new working cycle.
When the safety lever is raised, the servo pressure supply is
interrupted, and no working movements can be carried out when the
servo controls are actuated.
At the same time, the swing brake is applied. If the safety lever is
raised, the swing brake cannot be released via the button S17 (see
next page).
When changing the safety lever back to the lower position, the brake
is returned to the same condition it was in before the lever was
raised (released or applied).

ADJUSTING OF THE AUXILIARY SEAT

The lever (Fig. 7, pos. 1) serves to lock the auxiliary seat into
position either beside the operator's seat or against the cab's wall.
To rotate the seat, pull the lever (Fig. 7, pos. 1).

To seat pull down the seating.

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.
Fig. 7

Fig. 8

3.5
 CONTROL UNIT

S86 Operation mode selection

61 LED for mode selection
indication

Controls for engine

P4 LED indicator for engine RPM

S10 Attachment floodlight
S11 Windshield washer
S12 Heater blower
S14 Windshield wiper
S17 Swing brake
S18 Not used
S19 Not used
S20 Not used
S21 Travel speed increase
S22 Not used
S36 Cold start system
S41 Dome light
S56 Not used
S87 Not used
S228 Engine RPM increase
S229 Engine RPM decrease
S354 Not used

Fig. 9

3.6
S10 - Floodlights
Depressing the push button will successively:
- turn on the floodlights on the uppercarriage,
- turn on only the working floodlights on attachment,
- turn on all the above floodlights,
- switch off all the above floodlights.

S11 - Windshield washer

S12 - Heater
When depressing this push button, the heater fan will be successively switched to
stage 1, switched to stage 2, turned off, ... etc.

S14 - Windshield wiper

Depressing the Push button S14 will successively:
- turn on the windshield wiper in intermittent mode (the light diode I is
on),
- turn on the windshield wiper in continuous (the light diode C is on),
- switch off the windshield wiper (both light diodes are out).
In addition the pause time for the intermittent mode can be adjusted as follows
using push button S14:
- Select the intermittent mode and keep the button S14 depressed;
after a few seconds the light diode I will start blinking rapidly,
- Release the push button when the blinking duration has reached the
desired pause time. Adjustment is possible between 2 and 9 seconds.

S17 - Swing brake

Pushing the button alternately applies and releases the brake. If the brake is
applied, the red diode in the button is on.

S21 - Travel speed increase

The travel speed increase function is turned on and off via this button. The button
is operative only if the safety lever is pushed down. With the travel speed increase
on (indicator light in the button is on) a higher travel speed can be reached each
time the travel area is easy, also see page 4.11.

S36 - Cold start system

Depressing this impulse switch will improve starting the engine at low
temperatures.

S86- Engine speed adjustment with mode pre-selection (see page 4.4-4.5)
Depressing the button S86 causes to change from one mode into the next, in the
order L, F, E, P, L, ... and so on.
L (Mode LIFT) = RPM stage 1
F (Mode FINE) -- RPM stage 10
E (Mode ECD) = RPM stage 8
P (Mode POWER) = RPM stage 10

LED indicator P4 for engine RPM

Via this indicator, the engine RPM is displayed. The complete RPM range is
divided into 10 stages.

3.7
 CONTROL BOARD

Indicator lights and gauges Control switches

H6 Clock R6 RPM adjustment by safety operation
H38 Failure in central lubrication S12-1 Side window wiper*
H41 Electrical enclosure heating on* S12-2 Back window wiper*
H60 Engine monitoring system / Red light stop S23 Safety operation for diesel engine
H61 Engine monitoring system / Yellow light warning S26 Switch select air conditioner unit*
H62 Engine monitoring system / Red light protection S73 Safety operation for working pumps
H81 Supervision hydraulic tank S74 Flow reduction on working pumps
P4 Engine-RPM gauge S82-1 Quantum diagnostic switch – DEC
P8 System voltage / Service Batteries S82-2 Quantum diagnostic switch – INC
P9 System voltage / Main Batteries S85 Quantum diagnostic switch – ON/OFF
P10 Air conditioner control S100-1 Emergency stop
S122 Cancel of movement locking through
ladder or service trap
S126 Floodlight on cab roof

*Optional

3.8
Dial H6 : clock
Indicator H38 : Lights up if a failure appears in central lubrication
Indicator H41 : Lights up if the electric box heating is on (optional equipment)
Indicator H60 (Engine monitoring system / Red light stop) : Lights up when an important fault,
which could cause serious engine damages, is detected (see page 3.10).
Indicator H61 (Engine monitoring system / Yellow light warning) : Lights up if another fault, which
does not necessitate an immediate engine shutdown, is detected (see page 3.10).
Indicator H62 (Engine monitoring system / Red light protection) : Lights up if any parameter
supervised by the system has come out of its normal operation range.
Indicator H81 : Lights up if the hydraulic tank valve is closed.
Dial P4 : Engine RPM gauge
Dial P8 : Electrical system voltage (safety circuit)
Dial P9 : Electrical system voltage (main circuit)
Control unit P10 : Control of the air conditioner unit (see page 4.19)
Throttle control knob R6 (see page 4.7) : In emergency operation of diesel engine, the knob R6 is
used for the RPM adjustment.
Switch S12-1 : Side wiper
Switch S12-2 : Back wiper
Switch S23 : Use this button to switch the diesel engine operation in emergency control function (see
page 4.7). When the emergency control is turned on, the indicator light in the button is on.
Switch S26 : A second air conditioner unit can be mounted as optional equipment. This button is used
to select the desired air conditioner unit.
Switch S73 : During normal operation of the excavator, the electronic horsepower control continuously
adjusts the pumps 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 pump power) by pushing the switch
S73.
Switch S74 : During safety operation, the pre-set value for the flow of the hydraulic pumps is activated
by pushing this button.
Switch S82-1 (Quantum diagnostic switch-INC) : Use this button to see the code of the next error
detected by the Quantum system (see page 3.10).
Switch S82-2 (Quantum diagnostic switch-DEC) : Use this button to see the code of the previous
error detected by the Quantum system (see page 3.10).
Switch S85 (Quantum diagnostic switch-MASTER) : ON/OFF switch of the Quantum system.
Switch S100-1 (emergency stop) : Using the emergency switch will shut down the diesel engine and
disconnect the electrical system (see page 4.6). Use this shut off method only in emergencies. There
are 4 others emergency switches on the excavator: near the engine, near the hydraulic pumps, near
the access ladder and on the uppercarriage.
Switch S122 (see page 3.1 and 5.12) : For safety reasons, the swing and travel movements remain
locked if the access ladder or the service trap are not locked in the uppermost position. This safety
measure can be bypassed for as long as the button S122 is depressed.
Switch S126: Additional floodlights

3.9
 MONITORING SYSTEM OF THE DIESEL ENGINE (QSK SYSTEM)
INDICATOR LIGHTS H60, H61 AND H62

All the troubles appearing on the Diesel engine

or in its monitoring circuit are centrally indicated
via the 3 indicator lights H60, H61 and H62.

These 3 control lights are connected to the ECM

(Electronic Control Module) of the QSK system,
which is mounted to the engine, next to the fuel
pump.

Apart from its monitoring function, the QSK fuel

system has been designed to control the engine
speed and fuel pressure so to optimise the
exhaust emissions.

The red indicator light STOP (H 60) lights up when an important fault which could cause serious
engine damage is detected.
If the stoplight comes on while the engine is running, it may be automatically stopped by the
monitoring system in case an important trouble is detected.
For the other faults, the monitoring system protects the engine while reducing its power or RPM.
Also in this case the engine has to be brought to low idle and stopped in a safe manner as soon as
possible.
Afterwards recognise the detected error(s) using the diagnostic switches S85, S82-1 and 582-2.
Depending on the kind and severity of the recognised trouble, the system may cause automatic
engine shutdown, power or speed derating.
The yellow indicator light WARNING (H 61) indicates an engine error, which does not necessitate
an immediate engine shutdown.
Recognise the detected error using the diagnostic switches, after stopping the engine
Get the cause of the problem remedied as soon as is convenient regarding the cause of the problem.
The detected error can result in a power loss.
The red indicator light PROTECTION (H 62) shows that any parameter supervised by the system
has come out of its normal operation range.
The engine is automatically stopped by the monitoring system if one of the following troubles is
detected:
- Low engine oil pressure
- High coolant temperature
- Low engine coolant pressure
- High intake air manifold temperature
For some other parameters the monitoring system achieves protection by derating the engine speed
or the torque correspondingly.
The engine may be kept in operation temporarily, (eventually the engine power is reduced by the
monitoring system), the problem must be diagnosed via the switches S85, S82-1 and S82-2.
Automatic torque derate will happen in case one of the following troubles is detected:
- High fuel temperature
- High blowby pressure ( = pressure in crankcase housing)
- Low coolant pressure (first stage), also causes speed derate
- Low oil pressure (first stage)
- High coolant temperature (first stage)
- High intake air manifold temperature (first stage)

3.10
DIAGNOSTIC SWITCHES S82-1, S82-2 AND S85 FOR ENGINE MONITORING SYSTEM

These switches permit to recognise the faults, which are detected by the engine monitoring system
(electronic control module). These faults are connected to the centralised warning lights H60, H61 and
H62 of the control desk.

There are two types of fault codes:

- the engine electronic system fault codes which will light up the indicator lights H60 and H61.
- the engine protection system fault codes which will light up the indicator light H62.

All fault codes recorded will either be active (fault code is presently active on the engine) or inactive
(fault code was active at some time, but is not presently active).

All active fault codes can be diagnosed as described below using both lamps H60 and H61.
Inactive fault codes can only be viewed with the optional equipment "Insite”.

Diagnostic of the detected faults using the switches S82-1, S82-2 and S85

If an indicator light H60, H61 and H62 is lighting, proceed as follows to recognise the detected errors:
- turn the ignition key to "OFF" then to "contact" position
- depress the switch S85 to position "ON", the indicator lamp inside the switch lights up.
If no active fault codes are recorded, all three lights will come on and stay on.
If active fault codes are recorded, all three lights will come on momentarily and then...
- first the yellow lamp H61 will flash one time
- then the red indicator light H60 will blink, the sequence of blinking corresponds to the code of
the error detected by the system. Between two consecutive blinking sequences for indication of the
fault code, the yellow light H61 comes on.

Also see the section "Diagnostic fault codes" and the chart for diagnostic fault codes in the
Cummins operation and maintenance manual.
- The sequence is repeated as long as the switch S85 remains on "ON" position, the yellow
indicator light H61 goes briefly on between two consecutive flashing sequences.
- Remaining errors, which are still detected, can be recognised on the same way, using the
switches S82-1and S82-2. Briefly depressing the switch S82-1 "INC" causes the blinking sequence
of the error with the code directly above to be displayed on indicator light H60, depressing briefly
S82-2 "DEC" will display the error with the code directly below.

3.11
 MONITORING DISPLAY

LED INDICATOR RANGE

Fuel gauge P3
The LED indicator lights show the fuel level. When the both red LED 62 light up, about 10°/o to ZO°r6
fuel are left in the tank as reserves.

Engine coolant temperature gauge P2

During operation, the indication must remain in the green range. If the engine coolant overheats
(coolant is above 98°C = 204°F), the red LED indicator lights 63 start to light up on the right end of the
indicator and the buzzer sounds in the cab. Simultaneously, the red indicator protection H62 on the
control board will light up (see page 3.10). The QUANTUM system will cause an engine shutdown
(See "diagnostic fault codes in the Cummins Operation Maintenance Manual). Locate the reason for
the trouble and get it repaired. If a coolant overheat is detected, the error code E503 will be stored on
the error statistics (see on page 3.20, menu "i-errors").

3.12
 Indicator light H2 - low engine oil pressure
If the engine oil pressure drops during operation below a pre-set value, which depends on the
momentary engine RPM, the corresponding indicator light H2 lights up and the buzzer will
sound to alert the operator that the oil pressure is too low. At the same time, the red indicator
protection H62 on the control board will light up (see page 3.10). The QUANTUM System will
cause an engine shutdown (See "diagnostic fault codes in the Cummins Operation
Maintenance Manual).
Locate the reason for the trouble and get it repaired.
If a low engine oil pressure is detected, the error code E501 will be stored on the error
statistics (see on page 3.20, menu "i-errors").

Charge indicator light H12

Indicator light H12 lights up if the starter key is moved to contact position and turns off as
soon as the engine start. During operation, this indicator light lights up if the alternator V-belt
or the electrical charge system is defective.
Turn the engine off and correct the problem.

LCD SCREEN

Adjust the contrast on the LCD screen

The contrast on the LCD monitor can be changed by simultaneously pushing the ' MENU 'key and the
"UP" or "DOWN" key. The new setting will be stored in the system.
To retrieve the original contrast setting, depress the both arrow keys "UP" and "DOWN" at the same
time during system start (when all the light diodes are on).

Adjust the background lighting on the LCD screen

The background lighting on the LCD monitor can be changed by simultaneously pushing the
“RETURN” key and the "UP" or "DOWN" key. The new setting will be stored in the system.
A light sensor on the upper left-hand side of the display controls the LCD lighting, depending on the
ambient light conditions. The follow up control by the light sensor is performed around the basic setting
adjusted via the keys.
If the ambient light conditions are low, the background lighting will be reduced accordingly.

LCD screen control keys

The display can be controlled via the four keys S349 "RETURN", S350 "DOWN", S351 "UP” and S352
"MENU" (see above illustration).
These keys are used to change from the main display to the menu selection and to scroll through
various other menus.

3.13
MAIN SCREEN

The main screen appears after the unit is turned on and remains in place until the "MENU" key is
pressed to change to the menu selection.
Main screen view (Fig. 45)
SY field: The upper field of the monitor shows warning and indicator symbols, up to maximum 4
symbols at the same time. If more than 4 symbols must be shown, then every 10 seconds, the
symbols move to the left by one symbol.
The following list shows all symbols, which can appear in this field.
EC field: The EC window displays any applicable error codes far any electrical errors in the
excavator electronics, (line errors, sensor errors,...). Max. 7 error codes can be displayed at the same
time. If more than 7 errors occur, an arrow next to the error code window points to additional error
codes on the list.
Press the arrow key to move the error code window in the selected direction on the error code list. For
detailed error code list, refer to page no. 3.15.
INF field:

The INF field on the right hand side of the main screen
displays temporary information, also in graphic form.
If more than 3 symbols must be shown, then every 10
seconds, the symbols move to the left by one symbol.
Displays are shown as graphics or text to show actuated
flow reduction or emergency operation of Diesel engine or
hydraulic pumps.

Fig. 10

3.14
TI field:
This field, at the bottom right of the screen displays the main hourmeter and the daily hourmeter of the
machine.
The symbol is displayed when a flow limitation is activated for the pumps.
During the display start-up phase, the operator will be alerted about a possible upcoming service
interval, by a graphic symbol displayed instead of the machine hourmeter (see example on fig. 48).
The recalling of upcoming service interval lights up to about 8 seconds.
Control of the screen at error recognition
In case a new error, displayed in field SY, is recognised, the presentation will return to main screen,
and the corresponding symbol is displayed. Depending on the default (urgency step), the buzzer will
alert acoustically at the same time, either buzzing in continuous or emitting intermittent sounds.

The symbol signals that the Buzzer of the control unit is activated.

Using the key , it is possible to quit the defaults indicated by a continuous buzzing.
Symbols for operating errors displayed in field SY
Each one of the following symbols has one error code assigned to it, which is displayed as "E 5xx". As
soon as an error appears, the control unit enters the corresponding error code in the stored error
statistics.
Low engine oil pressure
(see page 3.13)

E 501
Low coolant level
This symbol appears simultaneously with the red indicator protection H62 (see on pages
3,10 & 3.11) if the coolant level drops below the minimum level. Effect: see Cummins
E 502 Operation Maintenance Manual. Find and repair the coolant loss. Add coolant until the level
is correct (see page 5.14).

Engine coolant overheat

This symbol appears simultaneously with the lightning of the red LED 63 on the engine coolant
temperature gauge P2, see on page 3.12.
E 503
Engine coolant pressure
This symbol appears simultaneously with the red indicator protection H62 (see on pages 3.10 & 3.11)
if the coolant pressure is too low. Effect: see Cummins Operation Maintenance Manual. Locate the
reason for the trouble and get it repaired.
E 540
Manifold overheat
This symbol appears simultaneously with the red indicator protection H62 (see on pages 3.10 & 3.11)
if the manifold temperature is too high (above 104°C=220°F).Effect: see Cummins Operation
Maintenance Manual. Locate the reason for the trouble and get it repaired.
E 597
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 506
Low oil level in splitterbox
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 oil level is correct (see page 5.16).
E 562
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 (see page 5.16).
E 564
Splitterbox oil pressure low
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.
E 591
Low servo pressure
This indicator lights up if the servo pressure drops below 20 bar. In that case, the machine can not be
controlled properly. Find and correct the problem.

3.15
 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 pumps 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
E 504
one of the return filters (see page 5.23).
High hydraulic oil temperature
This symbol appears if the hydraulic oil temperature in the tank exceeds 98°C (208°F).
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
E 505
defective,...).
Low hydraulic tank pressure
This symbol appears if the hydraulic tank pressurisation drops below 0.15 bar.
Stop operation and turn the engine off. Find and correct the problem: check the air pressure system
(see page 6.4).
E 590
Main pumps 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 left corner of the symbol). Stop operation, turn
E 566-E568 the engine off and notify the maintenance personnel.
E 567-E569
Swing pumps are contaminated
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 left corner of the symbol). Stop operation, turn
E 572-E573 the engine off and notify the maintenance personnel.
Main pumps overheat
This symbol appears if the temperature on one of the main pumps increases above 105°C (221°F)
(the pump number appears in the top left corner of the symbol).
E 578-E579 Turn the engine off, find and correct the problem.
E 580-E581
Swing pumps overheat
This symbol appears if the temperature on one of the swing pumps increases above 105° C (221° F)
(the pump number appears in the top left corner of the symbol).
E 584-E585 Turn the engine off, find and correct the problem.
Low oil level in the Centinel System (optional)
This symbol appears if the oil level in the Centinel tank drops below the minimum level. Effect: see
Cummins Operation Maintenance Manual. Full the Centinel tank as soon as possible (see page 5.13).
E 592
High fuel temperature
This symbol appears simultaneously with the red indicator protection H62 (see on pages 3.10 & 3.11)
if the fuel temperature is too high (above 104°C=220°F).Effect: see Cummins Operation Maintenance
Manual. Locate the reason for the trouble and get it repaired.
E 593
High fuel rail pressure
This symbol appears simultaneously with the red indicator protection H62 (see on pages 3.10 & 3.11)
if the fuel rail pressure exceeds a normal limit. Effect: see Cummins Operation Maintenance Manual.
Locate the reason for the trouble and get it repaired.
E 594
High blow-by pressure
This symbol appears simultaneously with the red indicator protection H62 (see on pages 3.10 & 3.11)
if the blow-by pressure exceeds a normal limit. Effect: see Cummins Operation Maintenance Manual.
Locate the reason for the trouble and get it repaired.
E 595
Low engine oil level
This symbol appears simultaneously with the red indicator protection H62 (see on pages 3.10 & 3.11)
if the engine oil level drops below the minimum level. Effect: see Cummins Operation Maintenance
Manual. Full the engine oil tank (see page 5.13).
E 596
Oil change required
This symbol appears simultaneously with the red indicator protection H62 (see on pages 3.10 & 3.11)
if an engine oil change is required. Do it as soon as possible (see page 5.13).
E 598

3.16
ERROR CODES FOR ELECTRICAL ERRORS OF THE ELECTRONIC CONTROL SYSTEM

Detected errors Error code

Coolant level B3 Accidental ground E 004
Accidental + E 005
Broken wire E 006
Coolant temperature B2 Accidental ground E 007
Accidental E 008
Broken wire E 009
ERROR IN THE Hydraulic oil level B14 Accidental ground E 010
CIRCUIT OF Accidental + E 011
THE SENSOR Broken wire E 012
WHICH Hydraulic oil temperature B67 Accidental ground E 013
MONITORS Accidental + E 014
Broken wire E 015
Swing speed B53 Accidental ground E 454
Accidental + E 455
Broken wire E 455
Fuel level transmitter B1 Accidental ground E 456
Broken wire E 458

Engine speed B12 Accidental ground E 022

Accidental + E 023
Broken wire E 024
Solenoid valve for flow control Y3.1 EV1 Cable defect E 036
Solenoid valve for flow control Y3.2 EV2 Cable defect E 039
ERROR IN THE
Solenoid valve for flow control Y3.3 EV3 Cable defect E 042
REGULATING
CIRCUIT FOR Solenoid valve for power control Y4 LR1 Cable defect E 027
Output ventilator water Y10.1 Cable defect E 033
Output ventilator oil Y10.2 Cable defect E 030

Coding plug is missing in control unit E 302

No CAN 1 Connection between control unit S2 and circuit board BST. E 303
(Error detected also if BST is not operative : no power supply, ...)
No CAN 2 Connection between control unit and circuit board ESPO1. E 305
(Error detected also if ESP01 is not operative)
No CAN 2 connection between Control unit and Display or no function E 308
of the Control unit
OTHERS No CAN 1 connection on E1036 E 311
ERRORS
No CAN 1 connection between Control unit and E1036 (connection box E 312
pump transmitters)
No CAN 1 connection between Control unit and A1020 (FSG plate) E 313
BST coding not compatible with control unit coding E 319
No CAN 1 connection between E1036 (connection box pump E 320
transmitters) and translater J 1939
Unknown excavator type from BBT E 321
Unknown hardware coding from BST E 322

DIESEL Diesel engine Quantum error code : see electric scheme step 25A D ..…
ERRORS

3.17
 INFORMATION PROVIDED IN THE MENUS OF THE
LCD SCREEN
MENU SELECTION

Depressing the “MENU” key when the main screen is displayed

shows the list of the accessible menus (see Fig. 11).
The current menu selection can be changed by pressing the “UP”
and “DOWN” keys (the selected menu is inverse displayed, as an
example in Fig. 11 the menu “reset hours” is selected).
When depressing the “MENU” key again, the inverse displayed
Fig. 11
function is branched out.

MENU (“i-hours”)

Information about operating hours for various components and

movements.
The information screens 1 and 2 (see Fig. 12) shows an overview
about operating hours for various components, functional flows and
operating modes.
As an example, the screen (page 1/3) indicates the operating hours
for:
- Diesel engine
- Diesel engine in mode P (RPM stage 10).
- Diesel engine in mode E (RPM stage 8).
- Hydraulic operation.
- Swing movements.
- Travel movements.
- Diesel engine at low idle.

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. 12 Manual operation for diesel engine RPM control.

And the screen Fig. 13 gives information about the machine type
and serial number and about software version actually mounted to
the machine.

These both indications are determined by the position of a coding

bridge on the print plate U16 (BST regulator).

The last line provides indication for the instantaneous operating

voltage.

Fig. 13
MENU

a) Information about the engine, information screen Fig. 14.

This screen gives information from the Quantum system of the
engine.

b) Information about the hydraulic pumps, information screen

Fig. 15 and Fig. 16.
This screen gives information about the operating position of the
hydraulic pumps.

Fig. 14

3.18
The screen 2 (see Fig. 15) gives following indications for each
working pump:
If a flow limitation is activated for the pump. If it occurs, the
symbol “R” is displayed in the field TI, see main screen.
The Fig. 15 shows an example with the flow limitation M1
activated, which limits the pump P1 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.
Fig. 15
The present LR solenoid current (current value for power control)
is showed on screen 3 (see Fig. 16).

c) Information about the fans

The screen 4 (see Fig. 17) indicates for the fan pumps the
amount of the momentary flow control signal.

d) Information about the status of input terminals –

information screens 5, 6 and 7
(see Fig. 18, Fig. 19 and Fig. 20)
Fig. 16
This screen shows an overview about the status of different
electrical inputs.

The sign “ “ means “input not active”.

The sign “ “ means “input active”.

The indication “NC” under the terminal description means that the
corresponding input is deactivated in the software.

The status of the inputs can be changed using the menu “set data”
– “set E-code”.

The screen 5 (Fig. 18) indicates the status of the inputs for the Fig. 17
different movements.

The screen 6 (Fig. 19) indicates the status of the flow limitation.
M1,M2,… correspond to machine specific (internal) oil flow
limitations. I1, I2, … corresponds to predefined oil flow limitations
(see also menu “set option”).

Fig. 18

Fig. 19

3.19
 The screen 7 (Fig. 20) indicates the status others inputs. For the
frequency inputs B53 and B12, the sign “ ” 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

The duration indicated on the last line M4 / time correspond to the

time lags for the intermittent operation of the windshield wiper.

Menu (“i-errors”):
Fig. 20 Information about detected errors (operating and electrical system
errors)
In this menu (see Fig. 21):
Select “list Exxx” to list all the operating errors detected by the
switches and sensors for machine parameters monitoring (see
Fig. 22).
Select “list S-Exxx”, to show a listing of the above mentioned
errors which occurred during service operation.
Select “list E-elec.”, to show a listing of all the electrical errors
(systems errors) detected during operation of the machine.

When selecting the operating errors “list Exxx” all the errors
Fig. 21 according to the list in chapter are listed, with error code and
number of occurrence (see Fig. 22).

Move the arrow key “UP” and “DOWN” to select the desired error.

By pressing the “MENU” key, the overview of the selected error

appears (see Fig. 23), with the indication of the operating hour and
duration for the 10 first and the 10 lest occurrences of the error.

Move the arrow keys “UP” and “DOWN” to page in this overview.

When selecting the electrical errors “list E-elec.” all the system
errors according to the list on page 3.17 are listed, with error code
Fig. 22
and number of occurrence (see Fig. 24 and Fig. 25).

Fig. 23

Fig. 24

3.20
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).

Selecting “list S-Exxx” also shows the errors according to the list
in pages 3.15 and 3.16, but this time only the errors that occurred
during “service operation” (see Fig. 26 and Fig. 27). Fig. 25

For each error, an overview can be shown and paged in just like
for the “list-Exxx” selection (see Fig. 28). The column “Sum”
shows the number of all errors that were ever noted.

Fig. 26

Fig. 27

Fig. 28

3.21
 Menu (“set option”):
Allocation of flow limit options to external inputs
(special attachment input; as an example when operating a hammer
pedal).
In this menu, pre-defined flow limitations (options) are allocated to
the hardware input I1.

The arrow near the symbol gives the actual allocation.

In example Fig. 29, the option 1 is active for the input l1, this
Fig. 29 means, if the external hardware input l1 is activated, then the
nominal pump values allocated in option 1 for the excavator control
are given as maximum nominal values.

If another option must be allocated to input l1 (as an example due

to a modification of the working attachment), so first select another
attachment in the vertical symbol range via the key “UP” or
“DOWN”.

Confirm the selected option by pressing the “MENU” key, the new
option must then appear in the column.

The right part of screen provides indication for the currently set
Fig. 30 pump values corresponding to the option shown in the selection
window.

Menu (“set service”):

Information and confirmation of service interval.

This screen is an information screen and can be used to confirm a

completed service interval.

The screen shows the operating hour for the next service interval
(in example Fig. 30 = “500 hrs”) and the current operating hours
(“174 hrs”).
Fig. 31
An upcoming service interval can be confirmed within max. 50
operating hours before the next service interval (see Fig. 31).

When this time frame is reached, the screen will display a question
regarding completion of the service works for this interval.

If the question is answered with “OK” then this menu will be

discontinued.

If it is answered with “OK”, then the current operating hour will be

stored as the last confirmed service interval.

Fig. 32 Menu (“set option”):

Deletion of the daily hourmeter

This menu allows to reset the daily hourmeter (see Fig. 32).

To reset the daily hourmeter, first select “OK” via the key “UP” or
“DOWN”, then confirm this choice by pressing the “MENU” key.

3.22
 4. OPERATING PROCEDURES
PRE-STARTING INSPECTION

CHECK AIR FILTERS FOR C0NTAMINATION

Check the, two dry air filters on top of the Diesel engine to determine
degree of contamination.
When the maximum permissible vacuum has been reached, a red
trip will appear in the inspection port of the maintenance indicator 16 Fig. 1
(see Fig. 1) and the filters must be serviced, see page 6.16.

CHECK ENGINE OIL LEVEL

Check the engine Oil level with the machine parked on level ground.
After engine has shut down, allow five minutes for the oil to drain into
the oil pan. The oil level must be between the MIN. and MAX. mark
on the dipstick 1 (see Fig. 2).

CAUTION
The engine oil is very hot at or near operating temperature.
Avoid contact with hot oil and components containing oil,
since it could cause severe burns.

Fig. 2
CHECK COOLANT LEVEL

CAUTION
At or near operating temperature, the engine coolant is hot
and under pressure.
Avoid contact with components containing coolant, since it
could cause severe burns.
Check coolant level only after the cap 6 is cool enough to be
touched.
To check the coolant level, first depress the red button in the
cap 6 to relieve pressure.

Check the coolant level when cold. It should reach the middle range
of the indicator 7 (Fig. 3).
Fig. 3
The excavator is delivered from the factory with a cooling system
protection to –35°C, which corresponds to a concentration of about
50% antifreeze. This proper antifreeze concentration must be
maintained all year long.

The coolant filters installed on the engine contain a corrosion

protector (Fig. 4). Regularly check its concentration in the coolant
circuit, see Cummins Operation and Maintenance Manual.

Fig. 4

4.1
 CHECK FUEL SYSTEM / FUEL LEVEL
The condensation in the fuel system and fuel tank must be drained
regularly (see page 6.4).

For interval, see maintenance schedule and Cummins Operation and

Maintenance Manual.
Check the fuel gauge P3 (Fig. 6) on the monitoring display before
starting to work.
If the red diodes 62 on the left of the indicator P3 lights up, only a
little reserve of fuel remains in the tank.
For remaining quantity, see page 3.12.
Refill the tank, if fuel level is low.
Fig. 5 Note : Maintain a high fuel level in tank to reduce
condensation. Add fuel at the end of the day.

OIL IN THE HYDRAULIC SYSTEM

When checking the oil level or when adding oil,

- park the machine on level ground,
- Rest the attachments on the ground, with stick and tilt cylinders
fully extended and bucket closed
- Shut off the engine.

Checking oil level in hydraulic tank :

In this position, the oil level should not be below the centre of the
sight gauge (Fig. 7, pos. 2). If the oil level is low, add oil via the
return filter until the oil level reaches the centre mark.

Fig. 6 See page 5.23 for description of procedure for adding oil.

The upper mark (MAX) shows the maximum oil level when all
cylinders are fully retraced.

The lower mark (MIN) shows the minimum oil level when all cylinders
are fully extended.

If the oil level drops below the lower mark (MIN), the corresponding
symbol on the LCD screen will appear (Fig. 8). At the same time the
pumps will return to minimum angle.

Fig. 7

Fig. 8 4.2
 MACHINE START UP SAFETY

Before excavator start up, perform a thorough Make sure all windows, as well as inside and
walk around inspection. outside mirrors are clean, and secure all doors
and windows to prevent any unintentional
Visually inspect the excavator, look for loose movement
bolts, cracks, wear, any leaks and any Be certain that the area surrounding the
evidence of vandalism. excavator is free of other personnel, and that
no one is working on or under the excavator
Never start or operate an unsafe excavator. before starting the engine.

Report all defects to your foreman or After entering the cab, adjust the operator's
supervisor and make sure they are corrected seat and controls, the inside and outside
immediately. mirror, the armrests and fasten and adjust the
seat belt. Be certain that all controls can be
Make sure all covers and doors are closed reached comfortably.
and locked and all warning decals are on the
machine. All noise protection devices on the machine
must be functional during operation.

4.3
 DIESEL ENGINE OPERATION

IGNITION KEY POSITIONS (FIG. 9)

-0- Off
-1- Contact position
-2- Not used
-3- Start

TURN ON THE ELECTRICAL SYSTEM

Turn the key to contact position –1-.
Fig. 9 Immediately after turning the system on, the display and the control
unit will run through a self 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 indicator
200 turns momentarily black (the matrix indicator is energised
completely for a short time).
Only the diode in the button S22 (Fig. 10) turns not on at that time.

STARTING THE ENGINE

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
starter stops and after another 3 seconds, the principal starters start
the Diesel engine.
To start the engine:
- Turn the ignition key to starting position 3.
- Maintain the key on this position during the prelub time.
- As soon as the engine is running, release the key.

The engine can not be cranked for more than 10 seconds!

If the engine does not start, repeat the starting procedure at 20

seconds intervals to allow the starter motor to cool off.

STARTING PROCEDURE AT AMBIENT TEMPERATURES

BELOW 0° C (32° F)
Fig. 10
A cold start system is standard equipment on the engine, which
makes it easier to start at low temperatures.
The cold start system is actuated electrically via the button SF1
(S36, Fig. 10). 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).

4.4
ENGINE SPEED ADJUSTMENT

The LED indicator P4 (Fig. 11) displays the engine RPM. It divides
the complete RPM range into 10 Stages.
The engine RPM can be set either using the arrow keys S228 and
S229, or using the MODE key S86 (Fig. 11).

With the arrow keys

Depressing an arrow key causes the RPM to jump in the next higher or
lower RPM stage.

With mode pre-selection

Via the MODE key, different pre-set RPM can be selected. Depressing the
button S86 causes to change from a pre-selected mode into the next, in the
following order L, E, P, L, ... and so on (the mode F is not available).

Immediately after starting, the engine will run on RPM stage 1 (low
idle).One of the four light emitting diodes (Fig. 11, pos. 61) blinks to
show which mode L, E or P is pre-selected (the pre-selected mode,
which was in use before the machine was turned off remains stored).
L Mode LIFT = RPM stage 1 Fig. 11
F Mode FINE = RPM stage 10 (not used)
E Mode ECO = RPM stage 8
P Mode POWER = RPM stage 10
RPM stage 8 corresponds to the most favourable specific fuel
consumption, RPM stage 10 is full engine RPM.

By pushing the mode key S86, the initial condition is confirmed, the
corresponding engine speed is transferred to the running Diesel
engine, and the LED remains on.

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 do not correspond to the pre-selected mode

(either because the engine speed had been changed via the arrow
keys or lowered via the low idle automatic), the LED blinks to
indicate the mode selected before.

4.5
 AFTER THE ENGINE IS RUNNING
After the engine is running, the indicator lights H2 (engine oil
pressure) and H12 (charge indicator light) on the display must turn
off (Fig. 12).
Let the engine idle at approx. 1000 RPM during the first 3 to 5
minutes, but at least until the warning symbols for low hydraulic tank
pressurization and for low servo pressure turnoff on the LCD screen.
Slowly increase the engine load until the coolant temperature is 40°
C, in that case the second green lighting diode goes on, on the
temperature gauge P2 (Fig. 12).
Do not run the engine at low idle for extended periods (not more than
10 minutes), this can damage the engine! Turn the engine off if the
machine is not used for a longer period of time.
Fig. 12

CAUTION

Bring the engine and the hydraulic oil to operating

temperature.
Low oil temperatures causes the excavator to be sluggish
and unresponsive.
Move the machine carefully to an open area and check the
function of the travel and swing brakes.
Check if all attachment functions are operating properly.

ENGINE SHUT DOWN PROCEDURE

Do not suddenly turn the engine off when it is running at high idle.
Reduce the engine RPM to low idle via the arrow key 570, and
continue to run the engine run for 3-5 minutes to lower the
temperature.
Then turn the ignition key to the "0" position to turn the engine off
and remove the key.

EMERGENCY SHUT DOWN

Turn the starter key to the 0- position or push one of the emergency
off switches 5100-1( see fig. 26), 5100-2, 5100-3, 5100-4 or 5100-5
(see location page 6.19) . This action will shut down the Diesel
engine and disconnect the electrical system.

CAUTION

Fig. 13 Use this shut off method only in emergencies. After an

emergency shut down, it is very important to let the engine
run again for a short time at low idle after restarting.

Using one of the emergency off switches S100-1, S100-2, S100-3,

S100-4 or S100-5 will cause the hydraulic tank to be depressurised
quickly. After a shut down via an emergency off switch, you must
unlock it before attempting to restart.

CAUTION

You must wait at least ten minutes after an emergency shut

down before attempting to restart..

4.6
 EMERGENCY OPERATION OF THE DIESEL ENGINE

If the Diesel engine can not be started, monitored or operated safely

due to a functional problem in the control electronic of the excavator,
the Diesel engine operation can be continued via the emergency
control function.

To turn on the emergency control circuit for Diesel engine, use

button S23 (fig.25). When the emergency control is turned on, the
indicator light in the button is on.
Fig. 14
START THE DIESEL ENGINE

Turn the throttle control knob R6 (fig.25) fully counterclockwise to low

idle RPM.
The starting procedure is the same as during the normal starting
procedure, see page 4.4.

Release the key as soon as the engine starts.

The engine can not be cranked for more than 10 seconds.

If the engine does not start, wait 20 seconds before restarting.

When the emergency control circuit is turned on, the engine control
switches S20, S70 and S86 (fig. 18) are not functioning.
All remaining switches on the control panel remain fully functional, if
they are not affected by the existing problem.
Fig. 15
1 Monitoring the engine
In emergency function, the indicator P4 (fig. 26) remains fully
functional and must be monitored regularly and carefully, because all
remaining indicators and warning symbols may no longer be reliable
(depending on the problem) or fully functional.

TURN THE DIESEL ENGINE OFF

Do not suddenly turn the engine off when it's running at high idle.
Reduce the engine RPM via the rotary switch R6 to low idle and
continue to run the engine for 3-5 minutes to lower the temperature.
Then turn the ignition key to the "0" position to turn the engine off
and remove the key (fig. 27).

Fig. 16

4.7
 MACHINE OPERATING SAFETY
Familiarise yourself with job site rules. Be Do not move the excavator until you are
informed about traffic and hand signals and certain that no one is endangered by moving
safety signs. Ask who is responsible for the excavator.
signalling. On machines without negative brakes check
Check your surrounding for any obstacles in the brake system before starting to work, as
the working and movement range, check the outlined in the Operation and Maintenance
load carrying capacity of the terrain, and Manual.
secure the job site to shield it from any public Never leave the operator's seat while the
highway traffic. machine is still moving.
Always keep a safe distance from overhangs, When moving the excavator, keep the upper-
walls, drop offs, and unstable ground. carriage in lengthwise direction and keep the
Be alert of changing weather conditions, bad load as close as possible to the ground.
or insufficient visibility and of changing ground Prevent any working movements, which could
conditions. tip the machine over. If the excavator beg ins
Be alert for utility lines, check the location of to tip or slip on a grade, immediately lower the
underground cables, gas and water lines, and attachment and load to the ground and turn
work especially careful in that vicinity. If the excavator facing downhill. If possible,
necessary and/ or if required, call local autho- always operate the excavator with the
rities to mark the location. attachment positioned uphill or downhill, never
Keep sufficient distance to electrical lines. sideways.
When working in the vicinity of high voltage Always travel slowly on rough or slippery
electrical lines, keep proper distance to assure ground and on slopes.
that the attachment does not come close to Always travel downhill at permissible speed,
the lines. so you don't loose control over the machine.
DANGER! You must inform yourself about safe The engine must run at nominal speed, use
distances. only the foot pedals to brake and slow down
In case you do touch a high voltage line by the machine. Never shift during down hill
accident, proceed as follows: travel, always shift to a lower gear before
- do not leave the machine, travelling downhill.
- move the machine, if possible, from the Never load over an occupied truck. Request
danger zone until you obtain sufficient that the driver leave the cab, even if a rock
distance, protection is installed.
- warn any personnel in the vicinity not to For demolition work, clearing, crane
come close to the excavator and not to touch operation, etc. always use the appropriate
it, protection device designed for this specific
- instruct or initiate that someone turns off the application.
voltage. If operating in visually obstructed terrain or
- Do not leave the machine until you are whenever necessary, have another person
absolutely sure that voltage in the line, which guide you. Always have only one person
had been touched or damaged, has been signal you.
turned off! Allow only experienced persons to attach
Before moving the machine, make sure that loads or to guide operators. The guide must
the attachments and equipment is secured be visible by the operator and I or must be in
properly to avoid accidents. voice contact with him.
When travelling on public roads or highways, Depending on the attachment combination, it
make sure to observe traffic regulations, and is possible for the bucket teeth to hit the cab,
make sure that the machine meets federal and the cab protection or the boom cylinders. Be
local public highway standards. very careful when the bucket teeth get in this
Always turn on the lights if visibility is bad or if range to prevent any damage
you are still working during dusk. In case of a thunderstorm:
Never allow other personnel on the excavator. - lower the attachment to the ground and if
Operate the excavator only while seated and possible anchor the digging tool into the soil.
with the seat belt fastened, if installed. - leave the cab and move away from the
Report any problems or needed repairs to machine before the storm breaks out.
your foreman or supervisor and make sure Otherwise, you must stop the excavator, turn
they are corrected immediately. off the radio and keep inside the closed cab
until the end of the storm.

4.9
 TRAVEL FUNCTIONS

When traveling, align the uppercarriage up with the

undercarriage (idlers in front, sprocket wheels in the rear).

STRAIGHT TRAVEL
- Travel forward :
Push both foot pedals equally forward with your toes (Fig. 17, pos.
5a and 6a).

- Travel reverse :
Push both foot pedals equally downward with your heels (Fig. 17,
pos. 5b and 6b).

DANGER

Before you travel in reverse make sure , it is clear and nobody

is in your way!
Fig. 17
TO TURN OVER ONE TRACK
- To turn left forward (Fig. 18):
Push the right foot pedal forward (pos. 6a).

- To turn right forward (Fig. 18):

Push the left foot pedal forward(pos. 5a).

CAUTION

To protect the track components, reverse turns should be

avoided.

COUNTER ROTATION
- To turn left (Fig. 19):
Fig. 18 Push the right foot pedal forward (pos. 6a) and at the same time
push the left pedal down with your heel (pos. 5b).

- To turn right (Fig. 19):

Push the right pedal down with your heel ( pos. 6b) and at the same
time push the left pedal forward (pos. 5a).

DANGER

If the uppercarriage is turned by 180°, note that the direction of

travel is reversed when you push the pedals!

Fig. 19

4.10
HAND LEVERS FOR TRAVEL
A more sensitive travel control can be achieved by using the two hand levers
included in the tool kit (Fig. 41, pos. 1 and 2).

CAUTION

2 Attach the levers to the foot pedal and use this manual
control when loading or unloading the machine from a
flat bed trailer.
Fig. 20
THE TRAVEL BRAKE

3 Hydraulic brake:

Releasing the foot pedals (Fig. 17, pos. 5 and 6) will automatically
return them to neutral position, and a maximum hydraulic braking is
achieved.
Run away of the machine traveling down a slope is prevented by the
automatically acting brake valves.

The maximum travel speed can not be exceeded.

Mechanical brake:

A negatively acting, hydraulic multi-disc brake is integrated in each

travel gear.

These brakes serve as parking brake. They are released

automatically at travel pedal actuation and apply again as soon as
the travel pedals return to neutral position.

TRAVEL SPEED INCREASE

The oil motors mounted to the travel gears can work with two
different displacements :
position1: maximum oil volume, this resulting in maximum track
forces combined with moderate travel speed.
position 2: reduced oil volume, i. e. reduced track forces and
maximum travel speed.

For forward travel, when the push button for travel speed increase Fig. 21
(fig.43, pos. S21) is turned on (left indicator light 1 of the button is
on), the motors shift from position 1 to position 2 (high speed).
With the button turned on, when the ground conditions become
difficult or when the excavator is descending a steep gradient, the
motors will automatically shift from position 2 to position 1 (low
speed) to prevent a power loss or an overspeeding.
As soon as the ground conditions become easier or as soon as the
slope become gentle, the motors will automatically shift back from
position 1 to position 2.

With push button S21 turned off, the travel motors remain
permanently in position 1.

For backward travel, the motors are automatically in position 2 (high

speed). The motors shift from position 2 to position 1 (low speed)
only if the ground conditions become difficult or if the excavator is
descending a steep gradient.

4.11
 LOCATION OF THE TWO JOYSTICKS
The right lever (Fig. 22, pos. 3) controls the boom and the bucket
movements.

The left lever (Fig. 22, pos. 4) controls the stick and the swing
movements

CONTROL OF THE SWING (LEFT JOYSTICK)

Moving the joystick (Fig.46, pos. 4) to the left (c) causes the
uppercarriage to turn to the left (Fig.47).
Fig. 22
Moving the joystick 4 to the right (d) causes the uppercarriage to turn
to the right (Fig.47).

SWING BRAKE

1) Hydraulic service brake

A sufficient deceleration of the uppercarriage is achieved by moving the

swing joystick to neutral position.

By moving the joystick to the opposite direction, maximum hydraulic braking

action is achieved.

2) Mechanical parking brake

Fig. 23
A multi disk swing brake, which is integrated in the swing gear,
serves as an additional mechanical brake.

The brake is negatively acting, hydraulically actuated and serves as

a holding or parking brake.
When working, the swing can be locked in any position with this
brake.
When the push button indicator light is off, the brake is released.
The swing brake is actuated via the push button S17 (Fig. 25):
When the brake is applied, the red indicator light fights up.
When the push button indicator light is off, the brake is released.

CAUTION

Fig. 24
APPLY THE BRAKE ONLY WHEN THE UPPERCARRIAGE IS
NOT MOVING!
In order to stop the uppercarriage when working on a slope,
first stop its movement with joystick 4.
Then apply the brake via push button 517 and move joystick 4
to "O" position.

Fig. 25
4.12
4 To check the swing brake
Apply the swing brake via rocker S17 (Fig. 25). Then move the left
joystick 4 (Fig. 26) to the right and then to the left to stop. The brake
is working properly if the uppercarriage does not move.

OPTIONAL EQUIPMENT: SWING BRAKE CONTROLLED IN SEMI

AUTOMATIC.

With this equipment, the function of the push button is not to apply
and release the brake as described before, but to pre-select the
operating mode of the mechanical swing brake, as follows:

in one position the brake remains always applied.

In the other position, the brake is in semi-automatic mode and is

controlled via the rocker switch S57 (Fig. 27) mounted to the
right joystick lever as follows:
- with the rocker switch S57 tilted down, the brake is applied,
respectively it applies as soon as the uppercarriage speed gets
lower than a limit value.
- with the switch tilted up, the brake remains released.
Notice: The red control light in the button S17 lights up each time the
brake is applied.
If this light does not go out when the rocker switch S57 is Fig. 26
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 4.
Move the joystick 4 back to "0"position only when the
uppercarriage is quite immobile, the brake will apply.

5 Emergency stop of the uppercarriage swing motion:

Fig. 27
The swing brake can be applied independently of the uppercarriage
RPM by switching the button S17 from position "semi-automatic" into
position "applied".

CAUTION

Perform this braking via button S17 only in emergency cases,

since it causes fast abrasion of the brake discs.

4.13
 WORKING POSITION
When working in a straight line, the machine should work over the
idlers (Fig. 28), the sprockets should be at the rear.

ATTACHMENT CONTROL

CONTROL OF THE STICK CYLINDER

(left joystick 4-Fig. 29)

Fig. 28 6 For backhoe attachment (Fig. 30)

Pull joystick 4 backwards (a) to move the stick in.
Push joystick 4 forward (b) to move the stick out.

7 For shovel attachment (Fig. 31)

Pull joystick 4 backwards (a) to move the crowd in.
Push joystick 4 forward (b) to move the crowd out.

Fig. 29

Fig. 30

Fig. 31 4.14
CONTROL OF THE BOOM CYLINDER
(right joystick 3 -Fig. 32)

8 For backhoe attachment (Fig. 33)

Push joystick 3 forward (g) to lower the boom.

Pull joystick 3 forward (h) to lift the boom.

9 For shovel attachment (Fig. 34)

Fig. 32
Push joystick 3 forward (g) to lower the boom.
Pull joystick 3 forward (h) to lift the boom.

CONTROL OF THE BUCKET OR GRAPPLE CYLINDER

(right joystick 3 -Fig. 32)

10 For backhoe attachment (Fig. 33)

Push joystick 3 to the left (e) to tilt the bucket in.

Push joystick 3 to the right (f) to tilt the bucket out.

11 For shovel attachment (Fig. 34)

Push joystick 3 to the left (e) to tilt the bucket in.

Push joystick 3 to the right (f) to tilt the bucket out.
Fig. 33

Fig. 34

4.15
 CONTROL OF THE BOTTOM DUMP SHOVEL BUCKET
(optional equipment)

The bottom dump shovel bucket is moved via two pedals, 7a and 7b
(Fig. 35).

- Push pedal 7a to open the shovel bucket (Fig. 36).

- Push pedal 7b to close the shovel bucket (Fig. 36).

Fig. 35

Fig. 36

4.16
FLOAT POSITION OF BOOM CYLINDER FOR BUCKET
OPERATION
(optional equipment)

To turn on the float position for the lift cylinders, move the right
joystick 3 forward (g) and push the button S5 or S6 on top of the
handle at the same time (Fig. 37).
Now the bucket can be used for grading work while moving the
joystick 4 forward to extend the crowd cylinders(Fig. 39).
Fig. 37
The attachment can then move freely up or down depending on
grade and the bucket will automatically follow the ground contour
(Fig. 38).

COMBINATION OF JOYSTICK MOVEMENTS

A diagonal movement of the joystick combines the movements

of the attachment functions.
This makes is possible for all attachment movements to be
controlled at the same time.

The operator can do the following movements without any additional

manipulations

When the swing movement is actuated, all working functions/

Fig. 38
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.

Fig. 39

4.17
 THE HEATER AND AIR CONDITIONER

A heater and an air conditioner are installed in the cab as standard

equipment.

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 engine cooling radiator.

CAB VENTILATION
The heater as well as the air conditioner can both be used, at the
same time and independently of each other to ventilate the cab.
Fig. 40
12 Ventilation via the heater

For cab ventilation during the summer time, the two coolant shut off
valves which join the Diesel engine to the cab (Fig. 41) should be
closed.
Push the lever (Fig. 42, pos. 1) all the way forward to close off the
water supply.

Push button S12 (Fig. 40) to select desired air flow.

The fresh air enters the cab via openings on the steps (Fig. 43) and
via the vents on the left and right front (Fig. 43).

Move the lever 2 (Fig. 42,) to regulate the amount of fresh air /
recirculated air coming into the cab.
Fig. 41 If lever 2 is pushed forward, the fan recirculates the air in the cab.

13 Ventilation via the air conditioner

To ventilate the cab via the evaporator in the roof of the cab, turn the
air conditioner off via button S2. Turn the blower fans on, and
select the desired air flow via the rotary switch S1 (Fig. 44) and the
vents of the evaporator.

FOR HEATER OPERATION

Open the coolant shut off valves on the Diesel engine (Fig. 41).

The amount of water running through the heat exchanger can be

regulated by moving the lever 1 (Fig. 42). If the regulator is pushed
all the way to the rear, the maximum amount of coolant flows to the
Fig. 42 heater.

Set the desired air flow via button S12 .

Move the lever 2 to regulate the amount of fresh air recirculated air
entering the cab.

The best heating effect can be reached when the air is recirculated,
which means, the lever 2 should be pushed all the way to the front.
In this position, a small amount of outside air is mixed with the
recirculating air in the cab.

4.18
Fig. 43
To quickly defrost the windshield, direct the warm air flow via the
vents to the front, and push the sliding regulator 3 all the way to the
rear, so that the maximum air flow is blown via the vents in the step
onto the windshield.

When the lever 3 is pushed all the way to the front, part of the warm
air flow is blown against the left side window.

AIR CONDITIONER OPERATION

Adjust the air conditioner fan via button S1.

The Diesel engine must be running before the air conditioner blower
is turned on.

Turn on the air conditioner compressor and the condenser fan via
button S2 (Fig. 44).

The air conditioner can only be turned on if the evaporator fan unit is
turned on via button S1.

Select the desired air flow via the rotary switch S1 .

Set the desired air temperature via the rotary switch S2.
Fig. 44
The direction of the cold air flow can be adjusted via the vents on the
evaporator unit (Fig. 45).

For air conditioner operation during the summer time, preferably

close the coolant shut off valves on the Diesel engine, push the lever
(Fig. 42, Pos. 1) all the way to the front and turn the heater blower
off via button S12.

To dehumidify the air in the operator's cab

In case of very high humidity inside the cab during the colder
season, the air conditioner can be operated for a short while
simultaneously with the heater in order to eliminate the excess of
humidity and the condensation.

For best efficiency, select a high evaporator air flow via the rotary Fig. 45
switch S1 and operate the heater with recirculated air.

4.19
 5. LUBRICATION

GENERAL SAFETY INFORMATION

It is very important that all guidelines describing lubrication, checking the oil level, replacing the oil are
strictly adhered to!
This maintenance increases the life of the excavator and improves its dependability.

It is especially important to change the oil regularly and in the intervals noted on the maintenance
schedule! Only use specified lubricants and oils!

CAUTION

When checking or replacing the oil, observe the following :

Park the machine on level ground, if not otherwise stated, and turn the engine off.
When working in the engine area, make sure the covers and side doors are secured.
Only add fuel when the engine is turned off.
Never smoke or allow an open flame in refuelling areas.
Cleanliness is especially important when changing engine, gear or hydraulic oil.
Before removing fittings or plugs, make sure the surrounding areas are cleaned.
When changing the oil, clean the fill or drain plugs.
The machine's zone of operation must always remain clear of lubricating materials to
prevent the personnel working in the area from slipping. Be sure to clean excess oil or
grease from the machine, especially where the various bearings are connected to the
central lubrication devices.

IMPORTANT!

Be sure to drain oil into a suitable container and dispose of oil and filter cartridges properly.

5.1
 LUBRICANTS AND FUEL CHART R 994 B LITRONIC
VISCOSITY
COMPONENTS SYMBOL SAE SPECIFICATION QUANTITY
DIN 51 512

DIESEL ENGINE
In engine
280 l.
74 USgal.
- Lubricant
In Centinel
See the Operation and Maintenance Manual for CUMMINS engine Tank
(optional)
300 l.
optional 80 USgal.

5350 l.
- Fuel See the Operation and Maintenance Manual for CUMMINS engine
1415 USgal.

320 l.
- Coolant See the Operation and Maintenance Manual for CUMMINS engine
84,6 USgal.

SAE 10W
HYDRAULIC
SAE 20W-20 2500 l.
SYSTEM
660 USgal.
SAE 30 In hydraulic
°C -40 -30 -20 -10 0 +10 +20 +30 +40 +50 tank

°F -40 -31 -22 -13 -4 5 14 23 32 41 50 59 69 77 86 95 104 113 122 4100 l.

1083 USgal.
SAE 15W-40
In whole
SAE 10W-40 circuit
SAE 10W-30

Warming up the hydraulic system

o
1. For temperatures 18°F (10 C) below the lower limits :
Run engine at half speed. Warm up the hydraulic system by fully actuating
hydraulic cylinders and motors for short periods. Continue to warm up during
about 10 minutes or until operating temperature is reached.
2. For temperatures below the limits listed under 1:
Preheat hydraulic oil in the tank before starting the engine.

2×37 l.
SAE 80
SWING GEAR 2×9,8 USgal
SAE 80W90 or SAE 90
SAE 85W140
°C -40 -30 -20 -10 0 +10 +20 +30 +40 +50 2 × 50 l.
TRAVEL GEAR 2×13,2
°F -40 -31 -22 -13 -4 5 14 23 32 41 50 59 69 77 86 95 104 113 122 USgal

5.2
 LUBRICANTS AND FUEL CHART R 994 B LITRONIC
VISCOSITY
COMPONENTS SYMBOL SAE SPECIFICATION QUANTITY
DIN 51 512

API GL-5 AND 75 l.

SPLITTERBOX SAE 90 or SAE 80W90
MIL-L-2105 B, C or D (19,8 Usgal)

COUPLING
1,5 l.
SPLITTERBOX / SAE 15W40 MB 228.1
ENGINE (0,4 US gal)

SWING RING 80 l.
TEETH
Special grease See lubricant specification
(21 US gal.)

GENERAL MULTUPURPOSE GREASE

CONSISTENCY 2
LUBRICATIÓN Down to 0°C (32°F) KP2k or EP2
POINTS NL GI N°2 Grade
(Extreme pressure N°2 Grade)
200 l.
Swing ring, Down to -15°C (5°F) NL GI Grade CONSISTENCY 1 53 USgal.
Attachment
bearings,
Track SPECIAL GREASE
tensioner,… Down to -40°C (40°F)
As an example Mobilith SHC 460 o SHC PM

Hinges,
couplings, locks
Engine oil

Rubber seal on
doors and covers
Silicon Spray or talcum

WINDSHIELD
Commercial Windshield washer 75 l.
WASHER
SYSTEM fluid or denatured alcohol (19,8 Usgal)

REFRIGERATING
7 kg
AGENT FOR AIR R 134a
CONDITIONER (15,5 lbs.)

REFRIGERATOR
OIL IN AIR 1 l.
CONDITIONER
PAG SP 20
(34,8 oz.)
COMPRESSOR

5.3
 LUBRICANTS AND FUEL SPECIFICATIONS

INFORMATION TO THE LUBRICANTS AND LUBRICATION CHARTS

The capacities in the lubricants chart and on the lubrication inside the cab are only given for your
guidance.

Always check the level of a component after replacing its oil or when topping it up.

1) LUBRICANT FOR DIESEL ENGINE

Standard or with the Centinel system

See the Operation and Maintenance Manual for CUMMINS engine

5.4
4) HYDRAULIC OIL :

Hydraulic oil specifications

1. Mineral oils
Recommended and approved are engine oils, which conform to the following specifications
For single viscosity oils : API - CD / CCMC- D4 / ACEA - E 1
Mercedes-Benz specifications -page No 226.0 and 227.0

For multi viscosity oil : API - CD +SF / CCMC - D5 / ACEA - E3

Mercedes-Benz specifications -page No 227.5, 228.1 and 228.3
2. Environmentally friendly hydraulic fluids (also called "BIO oils" -biodegradable oils-)
The "environmentally friendly hydraulic fluids" recommended by LIEBHERR are limited to synthetic
ester based hydraulic fluids with a viscosity according to ISO VG 46.
Initial filling is performed ex works according to customer desires. The use of environmentally
friendly hydraulic fluids must be arranged with the LIEBHERR Co beforehand.
Organic oils should not be used due to their poor temperature consistency.

Note: It is absolutely necessary never to mix different brands of environmentally friendly

hydraulic fluids or to mix fluids with mineral oils.
For further information on operating while using environmentally friendly hydraulic
fluids, see page 8.7.

5.7
Hydraulic oil change intervals

1. Oil changes in pre-set intervals

Note: Oil changes in pre-set intervals are only permitted for mineral oils. When using environmentally
friendly hydraulic fluids, oil sample analysis reports must be used to determine the time of the oil
change, see §2

Operating
hours

0 500 1000 1500 2000 2500 3000 3500 4000 4500

2. Optimised oil change intervals determined through 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 separately (Id. No. 8145666).

st °nd
1 2
Oil Oil
Other oil samples every 500 hours,…
MINERAL
OILS sample sample

0 500 1000 1500 2000 2500 3000 Operating hours

st
1
"BIO" sample 2nd oil 3rd oil
OILS (New oil sample sample Other oil samples every 500 hours,…
sample)

… time for oil change determined by lab report

5.8
5) SWING AND TRAVEL GEAR OILS
Use gear oil meeting specifications API-GL-5 and MIL-L-2105 B, C or D.

6) SPLITTERBOX OIL
Use gear oil with viscosity classification SAE90 or SAE 80W90 and meeting specifications API
-GL-5 and MIL-L-2105 B, C or D.

7) LUBE OIL FOR ELASTIC COUPLING

Use engine or gear oil with viscosity classification SAE 15W40 and meeting specification MB228.1.

8) GREASE FOR SWING RING ROLLER BEARING RACES AND GENERAL LUBRICATION
POINTS

This grease must meet specifications, consistency 2 of NL GI -classification per

DIN51818 and DIN 51825 or EP 2 per NF-T-60132.

The grease must be lithium-complex based, with a UKA value of at least 2300 N per DIN 51350 or
ASTM D 2596.

Between 0°C and –15°C Use a grease with consistency classification 1 NL GI or EP1 grease.
(32°F and 5°F)

Between -15°C and -40°C Only employ grease synthetic greases. We recommend the grease
(5°F and -40°F) Mobilith SHC 460 or Mobilith SHC PM.

LIEBHERR part N°: 8502769 for a 50 kg (110 Ibs) container

8503731 for a 180 kg (400 Ibs) container
9) GREASE FOR SWING RING TEETH

This grease must comply with following recommendations:

- be of consistency classification 2 in NL-GI viscosity per DIN 51818,
- have a VKA value of at least 5500N per DIN 51350 or ASTM D 2596,
- show a water resistance of 1-90 per DIN 51807.

LIEBHERR recommends the use of:

Grease BP Energol OGL 461 F Liebherr order n°: 8503629 for a 50 kg (110 Ibs.) barrel

10) REFRIGERATOR OIL IN AIR CONDITIONER COMPRESSOR

From the factory, the air conditioner compressors are filled with oil: PAG SP 20.

LIEBHERR part No: 850441410,25 liter (.066 Gal.) container of PLANETELF PAG SP20 oil.

PAG oils (Polyalcylen - Glycol oils) are the only oils presently authorized by the compressor.

5.9
5.10
 THE LUBRICATION CHART
Components and maintenance work symbols, fluids quantities*
280 l Grease / swing ring 80 l
Engine
74 US gal teeth 21 US gal

300 l 200 l
Centinel system Grease
79 US gal 53 US gal

350 l 1.5 l
Engine coolant Coupling
92 US gal 0.4 US gal

2500 l 75 l
Hydraulic system Windshield washer
660 US gal 19.8 US gal

2 x 37 l
Swing gear Check oil level
2 x 9.8 US gal

2 x 52 l
Travel gear Oil change
2 x 13.7 US gal

80 l
Splitterbox First oil change
21 US gal

5100 l
Fuel Oil analysis
1347 US gal
*the given quantities are only guidelines. Check fluid level after each change or refilling.

THE SERVICE TRAP

To simplify the oil change and the refilling procedure, the drain of major components are centrally
connected to a service trap.
The diesel engine system The hydraulic oil tank
The replenishing tank for the Centinel system The windshield washer fluid tank
The splitterbox The grease tank for general lubrication
The two swing gears The grease tank for swing ring teeth lubrication
The fuel tank

Adapter
Component Flow max.
WIGGINS
Swing gear OSP 2 50 l/mn
Splitterbox C-1807 50 l/mn
Engine oil OSP 2 50 l/mn
Centinel oil OSP 2 50 l/mn
Hydraulic oil 6600 B12 100-200 l/mn
Fuel ZZ 9A1 400 l/mn
Windshield washer EC 280 B8 25 l/mn

Principal grease OSP 2

15-30 l/mn
Pmini 100 bar
Teeth ring grease 6000 B12

5.11
 For safety reasons and for ease of maintenance, oil for the
connected components should only be drained and refilled via the
quick-change couplings in the service trap.
However, these components are also equipped with oil drain valves,
see description for oil change procedure of these components in this
chapter.

TO LOWER AND RAISE THE SERVICE TRAP

When the service trap is lowered, the service plate is accessible from
the ground level.
The service flap can be moved up and down via the 4 push buttons
on the control box (Fig. 1) at the lower end of the access ladder .
The service flap can also be actuated with the engine shut down.
It should only be moved out if the uppercarriage and the
undercarriage are aligned.
To lower the service flap from its uppermost position, first push the
switch S161 to unlock the flap and then push the switch S162 to
move the flap downward.
In reverse, to retract the flap, first push the switch S159 until the red
indicator light H69 goes out, and then push the switch S160 to lock
the flap until the lock pin has reached its stop position.
The lighting of the red indicator light H70 shows that the locking pin
of the flap is not in end (locked) position.
Fig. 1 The lighting of the red indicator light H69 shows that the flap is not in
upper end position.
The locking of the flap via switch S160 is possible only when light
H69 is out.

CAUTION
For safety reasons, the excavator can only be operated if the
service flap 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 (Fig. 2) is depressed.
Fig. 2 LOCATION OF OIL SAMPLE POINTS

To make the oil sampling easier, the following components of the

excavator have been fitted either with an oil sample extraction valve
(Diesel engine, splitterbox, the hydraulic circuit), or with a special
drain valve allowing good accessibility and sampling conditions (both
travel gears).

Remove the cap 5 and attach a sampling hose as a high-pressure

hose for pressure gauge.
Turn the valve 6 to adjust and close off the oil flow.
The location of these sample valves is indicated in the description for
oil change for the concerned components on next pages.

Fig. 3

5.12
 THE DIESEL ENGINE

TO CHECK THE ENGINE OIL LEVEL

Park the machine on firm and level ground to check the engine oil
level. Turn the engine off and wait for a few minutes for the oil to
collect in the oil pan.
The oil must be between the min. and max. mark on the dipstick 1
(Fig. 4).

CAUTION
Fig. 4
The engine oil is very hot at or near operating temperatures.
Avoid contact with hot oil and components containing oil,
since it could cause severe burns.

TO CHANGE THE ENGINE OIL

Drain the engine oil sump
Bring the engine to operating temperature, and drain the oil via the
quick change coupling in the service center (Fig. 5, pos. 5).
As a help way, the oil can also be drained via the drain valve on the
oil pan of the Diesel engine.
To do so, remove the cap of the drain valve, attach the drain hose
(supplied in the toolbox) to the drain valve and drain the oil into a
suitable container.
Remove the hose, reinstall the cap on the drain valve and add oil via
the filler neck 2 (Fig. 4).
Replace the oil filter elements (Fig. 6)
Fig. 5
Unscrew and remove the 3 filter elements, pos.3.
Each filter element is a combination oil filter comprising a full flow
element and a by-pass element.

CAUTION
When removing the engine oil filters, be careful to avoid
contact with hot oil, it could cause severe burns.

Clean the sealing surfaces on the filter mounts.

Lightly lubricate the rubber seal on the new filters with oil, install and
tighten the filters with both hands (see also enclosed CUMMINS
engine operation and maintenance manual).
Check after every oil change or after adding oil to ensure that the oil
level has reached the upper mark on dipstick 1.
Fig. 6
REFILL THE ENGINE OIL SUMP
Refill via the quick change coupling 5, until the max. mark is reached
on dipstick 1. A small amount of oil can also be refilled via the filler
neck 2 (Fig. 4) or via the Centinel valve if the excavator is equipped
with Centinel system (see page 8.1).For oil quantities, oil
specifications and oil change intervals, see lubrication and
maintenance charts.

Note
To extend the oil change interval, it is advised to use the chart method of
CUMMINS.

5.13
 TO TAKE AN ENGINEOIL SAMPLE
The valve for engine oil sampling is mounted to the front side of the engine
(Fig. 7 ).

TO CHECK THE COOLANT LEVEL

CAUTION
At or near operating temperature, the engine coolant system
is hot and under pressure.
Avoid contact with coolant and components containing
coolant, since it could cause severe burns.
Check the coolant level only after the cap 6 is cool enough to
Fig. 7 touch. To check the coolant level, first depress the red button
in the cap 6 to relieve pressure!

Check the coolant level when cold. It should reach the middle range
of the indicator 7 (Fig. 8).

ANTIFREEZE AND CORROSION PROTECTION OF COOLANT

The proper antifreeze and corrosion protection must be maintained
all year long.

The excavator is delivered from the factory with a cooling system

protection to -35°C (-31°F) (This corresponds to approx. 50 %
antifreeze).

System capacity of the cooling circuit : 320 I (84 US gal.)

water ratio : 160 I (42 US gal.)
antifreeze ratio : 160 I (42 US gal.)
Fig. 8
In addition, the corrosion protection concentration in the cooling
circuit must be constantly maintained.

Normally, changing the coolant filters (Fig. 10, pos. 10) regularly is
sufficient to maintain the proper concentration.

However, check the concentration regularly, and, if necessary,

corrosion protective additives must be added to the coolant, see the
CUMMINS engine operation and maintenance manual for details.

TO CHANGE THE COOLANT

For coolant change interval, see CUMMINS Operation and
Maintenance Manual.
To drain the coolant:
The drain plug is located under the radiator (Fig. 9, pos. 1).
For the procedure to drain and refill the engine cooling system refer
Fig. 9 to the CUMMINS engine operation and maintenance manual.

Important !
When refilling the system, make sure that the expansion tank is
refilled to the middle range of the indicator 7 and until the water level
will no longer drop.

5.14
TO CHANGE THE COOLANT

The filters contain a paste-like corrosion protection additive, which

ensures the proper corrosion protection properties of the coolant.

The filters (Fig. 10) must be replaced every 250 operating hours:

- Turn the shut off valve on the filter head to the OFF position,
- Unscrew and remove the filter elements
- lightly oil the seal rings on the new filter element,
- Screw on the new elements until the seal ring touches the filter Fig. 10
housing, and then turn it by hand 1/2 - 314 turns (Do not use any
tools to tighten the filters!),
- Turn the shutoff valve to the ON position.

For detailed information, refer to the CUMMINS engine operation

and maintenance manual.

5.15
 CHANGING THE OIL IN THE SPLITTERBOX

TO CHANGE THE OIL IN THE SPLITTERBOX

Check the splitterbox oil level

To check the oil level, turn the engine off and wait 15 minutes for the
oil to collect into the oil pan.

Drain and refill the oil

We recommend to drain and refill the oil in the splitterbox via the
quick change coupling 4 on the service plate (Fig. 11), when the oil
Fig. 11 is at operating temperature.
Refill the splitterbox up to the mark on dipstick 2. Do not overfill.

As a help way, the oil can also be drained via the drain valve 1(Fig.
12) on the bottom of the box.
To drain the oil,
- remove the cap on the drain valve,
- screw on the drain hose, which is part of the toolbox,
- drain the oil into a suitable container.
- remove the hose and reinstall cap on drain valve 1.
To refill, add oil via the threaded bore hole of the removed breather
cap 3 up to the mark on dipstick 2.
After each oil change, allow the engine to run for a few minutes, turn
the engine off and wait a few minutes and recheck the oil level with
dipstick 2.

For oil quality (specifications) and filling quantity, refer to the

lubrication chart.
For oil change intervals, refer to the Maintenance Schedule.

LOW OR HIGH OIL LEVEL IN THE SPLITTERBOX

The splitterbox oil is supervised by a level gauge triggering the

indication on the display when the level is below the minimum (Fig.
13, pos.1) or above the maximum allowable level (Fig. 13, pos.2).
In case of low level indication:
Find out and remedy the leak on the splitterbox or splitterbox oil
circuit as soon as possible, and top up to the dipstick mark.
If continuing to work in the meanwhile, correct oil level must be
maintained.
In case of high level indication: Stop working immediately.
The problem is due to a defective shaft seal on a hydraulic pump
Fig. 12
causing some hydraulic oil to flow into the splitterbox.
In this case locate and repair the defective pump and change the oil
in the splitterbox before restarting.

Fig. 13
5.16
TO TAKE A SPLITTERBOX OIL SAMPLE

The valve for taking splitterbox oil sample is mounted to the exit of
the splitterbox oil pump (Fig. 14).

Fig. 14

5.17
 CHANGING THE OIL IN THE ELASTIC COUPLING

TO REPLACE OIL
The elastic coupling between Diesel engine and splitterbox is filled
with oil.

Note: The coupling may remain installed during an oil change.

Execute an oil change in a warm service condition of the
coupling and with a preheated new coupling oil (oil
temperature min 40°C).

Use the tool Id. 9943251 (see Fig. 17) to change the coupling oil.

- Turn the Diesel engine until the coupler plugs 907 (and 909) are
accessible. The Diesel engine can be turned via the pin on the
SAE- housing (see fig.36 and the CUMMINS operation and
maintenance manual).
- Fill the oil container of the tool (on pump side) with 6 liters of
flushing oil.
- Connect the filling hose 1 of the filling pump to the connection
coupling 907 of the inner star 9.
- Connect the return line 2 of the tool to the connection coupling
909 of the flange 5.
- Switch on the pump and press an amount of flushing oil into the
coupling (approx. 6 liter: 1,5 liter to fill the coupling and the Fig. 15
holdover to rince the coupling).

CAUTION

Do not suck in any air.

- Switch off the oil pump and pull the filling hose 1 off the inner
star 9.
- Leave the return hose connected until no more oil emerges, i.e.
until the filling pressure has sunk to the ambient pressure again.
- Pull off the return hose 2.

For oil specification, see lubrication chart. Fig. 16

For oil change intervals, see maintenance schedule.

Fig. 17

5.19
 CHANGING THE OIL IN THE TRAVEL GEARS

If possible, drain the oil when the oil is at operating

temperature.

Each travel gear is equipped with two plugs to check the oil level and
to add oil (Fig. 18, pos.2) and with two oil drain plugs. One drain
plug (Fig. 19, pos.3) is mounted to the lower inner section, the
second drain plug (Fig. 18, pos.5) to outer ring which rotates with
the sprocket.

TO DRAIN THE OIL

Move the travel gear, until the plug 5 is straight below the centre axle
Fig. 18 of the gear.
Remove one plug 2 and then both plugs 3 and 5 and drain the oil
into a suitable container.

DANGER
When the oil is hot, the travel gear may be under pressure.
Before draining the oil, carefully loosen the oil filler plug 2 to
allow the internal pressure to escape.

TO ADD OIL
With the drain plugs 3 and 5 installed, slowly add oil via bore 2 until
oil runs out.
Reinstall plug 2.
For oil specification and oil quantity, refer to the lubrication chart. For
Fig. 19
oil change intervals, refer to the Maintenance Schedule.

5.20
 CHANGING THE OIL IN THE SWING GEARS
The oil in the swing gears must be changed via the quick-
change couplings 6 in the service plate Fig. 20 and when the oil is
at operating temperature.

To drain and also to refill oil, remove the caps 4 on the expansion
reservoirs 7, Fig. 21.
The oil level must reach the middle of the lower sight glass "L" of the
expansion reservoir 7 when the oil is cold, and must not overpass
the sight gauge "H" when the oil is hot.
If at operating temperature the oil level is lower than the sight glass
"L", oil must be refilled. Fig. 20

For small quantities, the oil refilling may be done via the filler tubes 3.

Each expansion reservoir is connected to the upper section of a

swing gear via two hoses 8 and 9.
The lower fitting for oil drain of each gear (Fig. 22, pos. 1) is directly
connected to a coupling 6 of the service plate.
No oil drain is possible at the lower section of the gears.

For oil specification and oil quantity, refer to the lubrication chart. For
oil change intervals, refer to the Maintenance Schedule.

Fig. 21

Fig. 22
5.21
 OIL IN THE HYDRAULIC SYSTEM

When checking the oil level or adding oil (Fig. 23):

- park the machine on level ground,
- rest the attachment on the ground, with stick and tilt cylinders
fully extended, and bucket closed.
- turn the engine off.

CHECK THE OIL LEVEL IN THE HYDRAULIC TANK

In this position, the oil level should not be below the center mark on
Fig. 23 the sight gauge (Fig. 24).
If the oil level is low, add oil via the service plate coupling or a return
filter until the level reaches the center mark.

The upper mark (MAXI) shows the maximum oil level when all
cylinders are fully retracted.

The lower mark (MINI) shows the minimum oil level when all
cylinders are fully extended.

Fig. 24

5.22
Fig. 25
TO ADD OIL TOTHE HYDRAULIC TANK AND TO CHANGE
HYDRAULIC OIL

CAUTION
Before draining the oil or before adding oil via the service
plate coupling or a plug on a filter cover, always open the tank
pressure release valve (Fig. 25) located at the back of the
cabin.
Fig. 26
We recommend to add and to drain the hydraulic oil to the tank only
via the coupling 8 in the service center.
As a help way, the hydraulic system can be drained using the hose
supplied in the tool kit via the drain coupling and the shut-off valve 1
at the bottom of the tank (Fig. 27).

As a help way, or for small quantities oil can also be added via the
cover of a return filter:
- remove the cover 3 (Fig. 28) of on of the return filters
- add oil via the return filter until the level is exactly at the center
mark of the sight gauge.
- reinstall the cover 3
- After refilling, close the tank pressure release valve (Fig. 25) to
repressurize the hydraulic tank.
Fig. 27

CAUTION
The hydraulic pumps must be bled after every oil change (see
page 6.14).

For oil specification and quantity, refer to the lubrication chart.

For oil change intervals, refer to the Maintenance Schedule.

Fig. 28

TO TAKE AN HYDRAULIC OIL SAMPLE

The valve for taking hydraulic oil samples is mounted next to the rear
bearing of the splitterbox housing (Fig. 29).

Fig. 29
5.23
Operating Instructions
Centralized lubrication system for Liebherr hydraulic excavator
R 994B AB SN 1001
994B_1001A.1A

THE CENTRALISED LUBRICATING SYSTEM

1 Function of the lubrication system
1.1 Description of the entire system: see the diagram under item 1.3

The lubrication points of the hydraulic excavator are supplied by two mutually independent centralized lubrication
systems:

System 1 – Equipment lubrication- Slewing rim lubrication

Single-line system

Main components: Hydraulic pump "P1" 609-28942-1

Injectors SL 1
Progressive metering devices SSV 6

System 2 – Gear rim lubrication

Main components: Hydraulic pump "P2" 609-28910-1

Progressive metering devices SSV 10

1.2 Sequence of a lubrication cycle

1.2.1 Systems 1

Upon expiration of the pause time the pump begins operating and supplies the lubricant to the injectors 9 (SL1)
via the main line. The pistons in the injectors are actuated by the lubricant under pressure and discharge a pre-
dosed quantity of lubricant to the connected lubrication points.
The pressure continues to rise in the main line until the value (280 bar) set at the pressure switch (B69) is
reached. The control unit stops the pump and, at the same time, the main line is discharged via the solenoid valve
(Y79). The relieved lubricant reaches the pump reservoir via a bypass.
The pistons in the injectors 9 (SL 1) return to their initial position by spring force.
The pause time begins. The system is ready to carry out a new lubrication cycle.

1.2.2 System 2

After the pause time has elapsed, the pump supplies the lubricant to the connected progressive metering devices.
A progressive metering device 8 (SSV 10) is equipped with a proximity switch for control and monitoring.
A lubrication cycle is completed after the SSV 10 has supplied twice, and the pump is switched off again.

Subject to changes

LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259 Tx
466088
Operating Instructions
Centralized lubrication system for Liebherr hydraulic excavator
R 994B AB SN 1001
994B_1001A.1A
1.3

P1 Lubrication pump –attachment B69 Pressure switch / end of lube cycle for P1
P2 Lubrication pump -swing ring teeth B51 Limit switch on progressive distributor for P2
Y79 Solenoid valve / pressure release (attachment) 8 Progressive distributor SSV
Y95 Solenoid valve / hydraulic pressure drive for P1 9 Grease injector banks SL1
Y93 Solenoid valve / hydraulic pressure drive for P2 B50-1 “High level“ and “Low level“ sensor for P1
U15 Lubricating system monitor B50-2 “High level“ and “Low level“ sensor for P2
1 Grease tank

Subject to changes

LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259 Tx
466088
Operating Instructions
Centralized lubrication system for Liebherr hydraulic excavator
R 994B AB SN 1001
994B_1001A.1A

2 Operation

CAUTION
Only allow operation by properly instructed personnel
Do not exceed permissible system pressures
Top up lubricant or change drum in good time

When the machine is started all centralized lubrication systems are automatically pressurized.
Each pump triggers one lubrication cycle, stops only for the pre-adjusted pause time, ... etc.
When the excavator is delivered from the factory the time period between two lubrication cycles is 6 minutes for
pump P1 and 8 minutes for pump P2. This corresponds to a grease consumption of approx. 850 g/h for P1, 40 g/h
for P2.

The time intervals for P1, (or P2 respectively) can be readjusted at the lubrication system monitor.

Subject to changes

LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259 Tx
466088
Operating Instructions
Centralized lubrication system for Liebherr hydraulic excavator
R 994B AB SN 1001
994B_1001A.1A

3 The Lubrication System Monitor

The green indicator lights 1.1 resp. 1.2 light up as long as the
corresponding pump is pressurized and thereby shows the frequency of the
lubrication cycles.
The lighting up of the green lights 3.1 and 3.2 shows that the maximum
pressure has been reached in the lubrication lines, this causing the pump to
stop and the pressure in the lube line to be released.
The signal lamp 2.1 indicates that the feed line of the corresponding pump
is relieved to the reservoir.
A new lubrication cycle can any time be started at once by depressing the
push button 8.1 or 8.2.
If a red indicator light 7.1, 7.2 lights up, then the grease container for the
corresponding lubrication pump is empty. In this case, the empty grease
container must be filled up as soon as possible.
The signal lamp 9.1 resp. 9.2 indicates “container full”.
The red indicator light H38 "problem in the lubrication circuit" lights up if a
lubrication cycle is not finished after 15 minutes.
The LCD-indicator of the defective lubrication circuit will display, alternately
with the pump pause time an error code locating the trouble:

Possible error code in LCD-indicator:

5.1 - E 1: Error in circuit of pump P 1
5.2 - E 2: Error in circuit of pump P 2

Possible causes are:

a) a defective switch or a defect in its supply cable
b) insufficient grease in the grease container
(indicated via indicator light 7)
c) a problem in the electrical control circuit or in the hydraulic drive circuit
of a lubrication pump
d) a leaking main supply line

Safety lubrication of circuits P1 and P2

When an error code is displayed, the corresponding lube pump will
automatically be operated so that the going on of the cycles is no longer
controlled by the installed pressure switches, but the duration of the
lubrication cycles is fixed to preadjusted values, that can be set on the
printplate U 15 inside the control box of the left armrest.

CAUTION
When an error code is displayed, the corresponding circuit always must get
repaired as soon as possible!
The automatic operating mode change in case an error is detected may
only permit to release from a trouble in the circuit of a pressure switch
(above mentioned error cause a). However it must be made sure that
greasing is effective, i. e. that the grease injectors move during lubrication.

Subject to changes

LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259 Tx
466088
Operating Instructions
Centralized lubrication system for Liebherr hydraulic excavator
R 994B AB SN 1001
994B_1001A.1A

4 Inspection and maintenance

Do not perform any repairs while system is pressurized.

To relieve pressure open a threaded connection carefully
Caution: Lubricant may escape while pressurized

Regular inspection and maintenance are the prerequisites for proper operation of the centralized lubrication
system over a prolonged period of time. The warranty on our product can only be valid if the prescribed
maintenance intervals are adhered to.
The regular inspections and maintenance procedures are described below:

1. System as a whole

Daily: Visual check of the lubrication points for escaping lubricant

Visual check of the hose connections for leaks or wearing

Weekly: Visual check of the screwed pipe connections for leakage

Determining the time for one operating cycle. If the time determined differs from the usual operating
time, the individual components (pump station, injectors, pipes) must be checked.
Functional check of the pressure switch

2. Pump station

Weekly: Check that threaded connections and hoses are firm and tight.
Visual check of pump tube gland seal
Check function of the solenoid valve
Check electrical cable connections
Clean outside of pump station

1000 hours: Clean filter element of grease filter

7500 hours: Hydraulic pump: Change gland seal

3. Injectors

Subject to changes

LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259 Tx
466088
Operating Instructions
Centralized lubrication system for Liebherr hydraulic excavator
R 994B AB SN 1001
994B_1001A.1A
Daily: Check movement of control pins: During the work cycle the pins must be retracted depending on
the metering quantity; in the resting phase all the pins must be extended.

Weekly: Visual check for leaks

4. Two-line Lubricant Metering Device

Weekly: Visual check for leaks

5. Progressive Plunger Metering Device

Weekly: Visual check for leaks

Subject to changes

LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259 Tx
466088
Operating Instructions
Centralized lubrication system for Liebherr hydraulic excavator
R 994B AB SN 1001
994B_1001A.1A

5 Exchanging / topping up grease reservoirs

CAUTION Lines are pressurized. Be careful when decoupling.

Observe extreme cleanliness when exchanging or topping up the grease reservoirs.
Contaminated lubricant causes malfunctions and premature wear of the grease pump and
other components of the system.
Clean surroundings before exchanging or topping up
Switch off centralized lubrication system (turn off engine)

5.1 P1 and P2: Filling of the container

Filling of the container through service-plate

Remove dust protective cap at the filling coupling and the dust
protective cap at the filling nipple
Couple the filling hose at item 10 (P1) resp. 11 (P2) and switch on
the filling pump
When the reservoir is full, the ultrasonic sensor transmits an
electric signal to the control unit. Visual control is possible by
screwing off a lid
the filling pump is switched off
Disconnect the filling coupling and reinstall the dust protective
caps

Subject to changes

LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259 Tx
466088
Operating Instructions
Centralized lubrication system for Liebherr hydraulic excavator
R 994B AB SN 1001
994B_1001A.1A

6 Malfunctions and their remedy

In the following, only malfunctions of the system as a whole are described. You will find detailed remedies for
malfunctions of the individual units in the respective User’s Information.

Malfunction: No pressure build-up in the system

Cause: Remedy:

Malfunctions of the pump See Troubleshooting: Pump

Leakage in the main line Check main lines, eliminate leaks, tighten threaded
connections, replace defective hoses

Air trapped in the main line De-aerate the line

Two-line metering devices leaky or worn Replace u-cup sealing at control pin if necessary
Change complete metering device if pistons are worn

Injectors leaky or worn See Troubleshooting: Injectors

Malfunction: No pressure relief or too slow pressure relief in the main line

Cause: Remedy:

Pressure control device faulty Replace pressure control device, check electric cable

Solenoid valve faulty Replace solenoid valve, check voltage supply

Grease too hard or not suitable for low temperatures Change lubricant

Subject to changes

LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259 Tx
466088
Operating Instructions
Centralized lubrication system for Liebherr hydraulic excavator
R 994B AB SN 1001
994B_1001A.1A

Subject to changes

LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259 Tx
466088
 MAINTENANCE

MACHINE MAINTENANCE SAFETY

The machine may not be made unsafe when
Before any repairs or maintenance work, clean
performing maintenance work. Never attempt
any oil, fuel and / or cleaning from any fittings
maintenance procedures or repairs you do not
and connections.
understand.
Don’t use any harsh cleaners and use only lint
Check the Operators and Maintenance Manual free cloths.
for service and maintenance intervals. Make
Use only non flammable cleaning fluids to clean
sure you use only appropriate tools for all
the machine.
maintenance work.
Any welding, torch or grinding work on the
Refer to your Operators and Maintenance
machine must be explicitly authorised. Written
Manual to see, who is authorised to perform
authorisation is necessary for welding on
certain repairs. The operator should only
carrying structures. Before any using a welder,
perform the daily / weekly maintenance
torch or grinder, clean off any dust and dirt and
procedures.
remove any flammable materials from the
The remaining work may only be performed by
surrounding area.
especially trained personnel.
Make sure the area is sufficiently ventilated.
Use only replacement parts corresponding to Danger of fire and explosion.
the technical requirements specified by the
Before cleaning the machine with water or
manufacturer. This is assured by using only
steam (high pressure cleaning) or other
original Liebherr replacement parts.
cleaning fluids, make sure that all openings,
Always wear proper work clothing when which, for safety and / or functioning reasons
maintening the excavator. Certain work may should not be exposed to water / steam /
only be performed with a hard hat, safety cleaners, are covered and / or masked off.
shoes, safety glasses and gloves. Especially sensitive are electrical motors,
control boxes and plug connectors.
During maintenance, do not allow Make sure that the temperature sensors of the
unauthorised personnel to enter the fire alarm and extinguishers system do not
maintenance area. come in contact with the hot cleaning fluids,
Secure the maintenance area, as necessary. which could trigger the fire extinguishing
system.
Inform the operator before any spezial or Remove all coverings and masking material
maintenance work. Make sure he knows the after completing the cleaning procedure.
person, who is in charge of the work. Then check all fuel lines, engine oil lines and
If not otherwise noted in the Operation and hydraulic oil lines for leaks, loose connections,
Maintenance Manual, always make sure the chafing and / or damage. Fix any problems
excavator is parked on firm and level ground immediately.
and the engine is turned off. If you use a high pressure cleaner with steam
During maintenance and service work, make or hot water to clean the machine, observe
sure you always retighten any loosened screw following recommendations:
connections. The distance between the nozzle and the
surface to be cleaned must be no lowerthan 20
If it is necessary to disconnect or remove any
inches.
safety devices during set up, maintenance or
The water temperature should not exceed 60°C
repair, make sure that after completion of
(140°F).
repairs, the safety devices are reinstalled and
Limit the water pressure to 80 bar maximum
checked for proper function.
(11500 PSI)
Before any maintenance work and especially If you employ cleaning fluid, only use neutral
when working under the machine, make sure a cleaning agents such as customary car
„Do not operate“ tag is attached to the starter shampoos diluted to 2 or 3 percent maximum.
switch. Remove the ignition key. After end of
Never employ high pressure cleaning apparatus
maintenance works or repair, restart the
during the two first months following machine
machine according to the instructions
delivery or repainting.
„machine start up“ in this manual.

6.1
Observe all product safety guidelines when Only qualified, especially trained personnel may
handling oils, grease, and other chemical work on travel gear, brake and steering
substances. systems.
Make sure service fluids and replacement If it becomes necessary that the machine must
parts are disposed of properly and in an be repaired on a grade, block the chains with
environmentally sound manner. wedges and secure the uppercarriage to the
undercarriage with the lock pin.
When using hot service fluids, be very careful
(they can cause severe burns and injury). Only qualified, especially trained personnel may
work on the hydraulic system.
Operate combustion motors and fuel operated
heaters only in well ventilated areas. Before Never check for leaks with your bare hands,
operating these units, check ventilation. always wear gloves. Fluid escaping from a
In addition, always follow applicable local small hole can have enough force to penetrate
regulations. the skin.
Never try to lift heavy parts. Use appropriate Never loosen or remove lines or fittings before
lifting devices with sufficient load carrying the attachment has been lowered to the ground
capacity. When replacing or repairing parts or and the engine has been turned off. Then turn
components, make sure they are mounted the ignition key to contact position with tilted
very carefully on lifting devices, to prevent any down safety lever, move all servo control
possible danger. Use only suitable and (joystick and foot pedals) in both direction to
technically sound lifting devices, make sure release pressures. Then release the tank
that lifting tackle, wire cables, etc. has pressure as outlined in this Operation and
adequate load carrying capacity. Maintenance Manual.
Never position yourself, walk or work
underneath suspended loads. Check all lines, hoses and screw connections
regularly for leaks and externally visible
Never use damaged lifting devices, or devices damage. Fix any damage immediately. Oil
which are not sufficient to carry the load. escaping from fittings etc. can cause serious
Always wear gloves when handling wire injury and fires.
cables.
Before any repairs, always relieve pressures
Ask only experienced personnel to attach before opening up any system sections and
loads and guide and signal the crane operator. pressure lines (hydraulic lines and air pressure
The guide must be within the visibility range of lines).
the operator and / or must be in direct voice
contact with the operator. Always route and install hydraulic and air
pressure lines properly. Do not interchange the
When working overhead, use appropriate and connections. The length and quality of hoses
safe ladders, scaffolding or other working must match specifications and requirements.
platforms designated for that purpose.
Never Stepp on parts or components on the Change all hydraulic hoses in specified or
machine when maintening or repairing items appropriate time intervals, even though no
overhead. damage or defects are visible.
When working high above ground, make sure Always disconnect the battery cable before
you are fitted with ropes and appropriate safety working on the electrical system or before any
devices which will prevent a possible fall. arc welding on the machine. Always disconnect
Always keep handles, Stepps, railings, the negative (-) cable first and reconnect it last.
platforms and ladders free of dirt, snow and
ice. Check the electrical system regularly.
Make sure that any problems, such as loose
When working on the attachments, for connections, burnt out fuses and bulbs,
example when replacing the bucket teeth, scorched or chafed cables are fixed
makes sure the attachment is supported immediately by an electrician or qualified
properly. Never use metal on metal support. personnel.
Never work underneath the machine if it is Use only original fuses with the specified
raised or propped up with the attachment. The amperage. Never use a different size or
undercarriage must be supported with wooden stronger fuse than the original fuse.
blocks and supports.
On machines with electrical medium or high
Always support the raised machine in such a voltage systems:
way that any shifting to the weight change will
not influence the stability. Do not support the - If there is any problem with the electrical
machine with metal on metal support. energy supply, turn the machine off
immediately.

6.2
 - Any work on the electrical system may under pressure or when not under
only be performed by a qualified electrician pressure, or in bends or curves, such as
or qualified personnel under the guidance separation of layers, blister or buble
and supervision of an electrician, formation;
according to electro – technical
- leaks;
regulations.
- non observance of installation
If any work is required on any parts which
requirements;
carry current, use a second person to turn off
the main battery switch, if necessary. Rope the - damage or deformation of hose fittings,
area off with a red and white safety rope or which might reduce the strength of the
chain, and set up warning signs. Use only fitting or the connection between hose and
insulated tools. fitting;
When working on medium and high voltage - any movement of hose away from the
components, shut off the voltage and connect fitting;
the supply cable to the ground and ground the
- corrosion on fittings, which might reduce
components, such as the condensor, with a
the function or the strength of the fitting;
grounding rod.
- storage or service life has been exceeded.
Check all disconnected parts if they are truly
free of current, ground them and close-by, When replacing hoses or lines, always use
current carrying parts. original replacement parts.
Route or install the hoses and lines properly.
Do not mix up the connections!
Hydraulic lines and hoses – Maintenance safety
Always take care to avoid torsional strain when
Hydraulic lines and hoses may never be
installing a new hose. On high pressure
repaired!
hydraulic hoses, the mounting screws must be
All hoses, lines and fittings must be checked first mounted on both hose ends (full flange or
daily, but at least every 2 weeks for leaks and half clamp) and tightened only thereafter.
any externally visible damage! Any damaged On high pressure hoses having one curved
sections must be replaced immediately! end, always tighten first the screws on the
Escaping oil can cause injuries and fires! curved hose end and only then the screws on
the straight hose end.
Even if hoses and lines are stored and used Install and tighten the hose clips that may be
properly, they undergo a natural aging mounted on the hose middle only when the
process. For that reason, their service life is both hose ends are already tightened.
limited.
Always install hoses so to avoid any friction with
Improper storage, mechanical damge and other hoses and parts.
improper use are the most frequent causes of We recommand to keep a distance between
hose failures. hose and other parts of at least one half of the
The service life of a hose may not exceed six hose outer diameter. Keep a minimum gap of ½
years, including a storage period of not more inch in any case.
than two years (always check the After mounting a hose connecting two parts that
manufacturer’s date on the hoses). are movable to each other, check during the
return to service that the hose is not rubbing in
Using hoses ans lines close to the limit ranges the whole moving range.
of permitted use can shorten the service life
(for example at high temperatures, frequent
working cycles, extremely high impulse
frequencies, multi shift or around the clock
operations).
Hoses and lines must be replaced if any of the
following points are found during an inspection:
- Damage on the external layer into the
inner layer (such as chaffings, cuts and
rips);
- Brittleness of the outer layer (crack
formation of the hose material);
- Changes in shape, which differ from the
natural shape of the hose or line, when

6.3
 THE FUEL SYSTEM

TO DRAIN AND CLEAN THE FUEL TANK

A drain valve is installed on the bottom of the tank (Fig. 1).

To drain condensation, turn the drain plug 1 on the valve two turns
counterclockwise until clean fuel appears, tighten the drain plug.
To empty the tanks, remove the tank cover, on the rear of the cab door
and remove the drain valve on the bottom of the tank and drain the
fuel into a suitable container.
The tank and the strainer in the tank filler neck should be checked
regularly for contamination.
Fig. 1
Change the strainer, and / or flush the tank, if necessary.

DRAIN THE WATER SEPARATOR ON THE FUEL FILTER

Open the water separator drain valve (Fig. 2, pos 3) on the filter
cartridge at the interval specified in the maintenance schedule.
Drain the contaminants until clean fuel emerges, retighten the valve.
For other maintenances on the fuel system, refer to the CUMMINS
engine Operation and Maintenance Manual.

THE AIR PRESSURE SYSTEM

During operation, the pressure on both pressure gauges (15) must be
between 6,2 and 7,25 bar.
Fig. 2
PRESSURE REGULATOR AND COMPRESSOR (Fig. 2, pos. 1 and
2).

Check if you can hear the pressure regulator 2 at regular intervals click
the compressor on and off.
To check, proceed as follows:
- Run the diesel engine at low idle,
- Slowly move the open the tank pressure release valve located
at the back of the cabin and let out the air in the tank until the
air pressure drops to approx. 6,2 bar.
- The pressure regulator 2 must now shift the compressor into
the working cycle.
- Continue to run the engine at low idle. When the pressure
reaches 7,25 bar, the regulator shifts the compressor to the
neutral cycle.
Adjust the pressure regulator if necessary until both pressures are
correct.
For maintenance intervals, refer to the maintenance schedule and to
the CUMMINS Operation and Maintenance Manual.

Fig. 3
6.4
THE AIR DRYER
The air dryer in the air pressure circuit (Fig. 4, pos 4) dries and
filters the pressurised air.
the air filter element must be replaced at intervals specified in the
maintenance schedule.

CAUTION

Open the air dryer only when the air pressure system is
without pressure. If necessary, empty the air pressure tank. Fig. 4

To replace the air cleaner element

Relieve the pressure in the air pressure system via the drain valves
(Fig. 7).
Disconnect the air pressure line on the outlet to the air tank (Fig.
4, pos. 5).
Remove nuts 1 and cover 2 (Fig. 5).
Unscrew the threaded rod 5.
Remove the centering piece 6 and spring 7.
Slowly pull out the air cleaner cartridge 8; turn the cartridge back
and forth if necessary.
Lubricate the o-rings 9 and 10 with oil.
Push in the new air filter cartridge, using a turning motion and Fig. 5
make sure that the o-ring 9 on the upper end of the cartridge is
inserted into the filter housing.
Reinstall spring 7, the centring piece 6, o-ring 10, cover 2 and
tighten nuts 1.

TO DRAIN THE AIR TANK

Condensation in the air tank is automatically discharged via the

drain valve when the pressure in the system drops.
However, we still recommend to drain condensation manually by
pushing the pin on the bottom of the drain valve (Fig. 7), regularly
as specified in maintenance schedule.

Fig. 6

6.5 Fig. 7
 THE DIESEL ENGINE
Refer to the CUMMINS Operation and Maintenance Manual for
detailed description of maintenance work to be performed.
In addition, accurately observe the following items and perform all
maintenance work according to the intervals given in the maintenance
schedule.

COOLING CIRCUIT

Clean the radiator with pressurised air or a steam cleaner, if

necessary.
Fig. 8
Change the pressure relief valve (in the radiator cap 6, Fig. 8) in case
of leaks.
Regularly check the connector hoses between the radiator and the
engine, as well as the heater hoses for condition and leaks. Check
tightness of hose clamps.

ENGINE AND SPLITTERBOX MOUNTING SCREWS

Check the mounting screws 2 on the engine brackets (Fig. 9) and the
engine or gear mounts (Fig. 9, pos.4 orFig. 10, pos. 5) regularly for
tightness, retorque if necessary.
Tightening torque for screws, pos. 2: 280 Nm (207 ft. lbs.).
Tightening torque for screws, pos. 4: 280 Nm (207 ft. lbs.).
Tightening torque for screws, pos. 5: 560 Nm (413 ft. lbs.).
Fig. 9

CAUTION

The screws 4 and 5 of the rubber mounts must never be

tightened as long as the engine and the splitterbox are not
firmly fixed together, or if the mounts are pretensioned by
any force but the weight of the engine and splitterbox.

Any improper fastening would greatly reduce the expected life of the
rubber mounts.

SPLITTERBOX MOUNTING SCREWS

Fig. 10
Check the tightness of mounting screws 3 (Fig. 11) from splitterbox to
the diesel engine SAE housing regularly. Retorque if necessary.

Tightening torque for screws 3: 117 Nm (87 ft.lbs)

ELASTIC BEDDING OF ENGINE AND SPLITTERBOX –

REPLACEMENT OF RUBBER BUFFERS

The four rubber cushions 8 at front face of engine (Fig. 9) and the
two buffers 9 at the splitterbox side (Fig. 10) must be checked and
replaced at regular intervals.
For maintenance intervals, see maintenance schedule.

Fig. 11

6.6
BELTS

Belt for the 24 V alternator of the diesel engine (Fig. 12).

Please refers to the enclosed CUMMINS Operation and
Maintenance Manual.

Fig. 12

6.7
 THE TRACK COMPONENTS
The track chains are maintenance free, until the track does need to be reconditioned or have to be
replaced.
Track rollers, carrier rollers and idlers are lifetime lubricated. The lifetime sealings prevent the bearing
from dust, sand, mud, stones and earth contamination.
Sprocket is maintenance free.
TRACK TENSIONING
The track tension is hydraulically actuated and is correct when the slack between the sprocket 1 (or the
idler 2) and the nearest carrier roller is max 1,2” (30 mm): see Fig. 13.
To tighten the track: Remove the cover 14. Attach a special fitting 2 to grease gun 1 (). Connect the
grease gun to cylinder 3. Pump grease into cylinder 3 until the track chain is properly tensioned.
To release the track tension: carefully release some grease from the grease cylinder by loosening and
turning the grease fitting counterclockwise.

DANGER

When adjusting the chain tension, keep your head clear of the access hole. The grease cylinder
is under high pressure and the chain will sag. Grease is under high pressure and might squirt
out. Also make sure that the track tension cylinder is out!
To move the levers CVTL (left) and CVTR (right) () allows to release the track tension pressure for the
side you are working on. To tighten the track, replace the lever CVTL or CVTR.

7 Screw M 30×2 1940

MOUNTING SCREWS
Nm
The tightening torque of the 8 Screw M 30×2 1940
mounting screws must Nm
regularly be checked (see 9 Screw M 20 560 Nm
maintenance schedule) 10 Screw M 24 960 Nm
11 Screw M 20 560 Nm
1 Side frame
2 Travel gear
3 Sprocket
4 Travel motor
5 Travel motor protection
6 Travel motor cover

6.8
 Fig. 13
1 Track drive 10 Rotary connection
sprocket and final 11 Ladder
drive 12 Hex. Screw
2 Idler 13 Cover
3 Track roller 14 Cover
4 Carrier roller 15 Cover
5 Track linck 16 Cover
6 Track pad 17 Hex. Screw
7 Pin 18 Hex. Screw
8 Chain guide front 19 Locking screw
9 Chain guide back 20 Protection screw

Tightening torque:

13 Fixing side frame/Central M 42 4810 Nm

part
18 fixing track roller M33 2600 Nm
19 fixing carrier roller M24 960 Nm
fixing sprocket/gear M30×2 1940 Nm
fixing gear/support M30×2 1940 Nm
20 Fixing pad / link M39×2 5890 Nm
Fixing ladder M24 960 Nm
Screws of the locking key of LH1346 1500 Nm
the idler axis

CLEANING THE TRACK COMPONENTS

At the end of a workday, the complete undercarriage should be checked and cleaned.

CAUTION

Do not operate machine if large rocks or pieces of wood, steel, wires or cable are wedged into
the track components. Do not allow mud, rocks, etc. to collect on track components.

6.9
 THE HYDRAULIC SYSTEM

Maintenance of the hydraulic system is generally limited to the

hydraulic tank.
All other components in the system require no special maintenance.
However, hydraulic lines and hoses and fittings must be checked for
leaks at regular intervals.
Cleanliness in the hydraulic lines and hoses and fittings must be
checked for leaks at regular intervals.
for this reason, the given maintenance intervals to replace the return
Fig. 14 oil filters (Fig. 14, pos. 1) and leak oil filters (pos. 11), to clean the
hydraulic oil cooler and to change the hydraulic oil must be strictly
observed.

DANGER

At or near operating temperature, the hydraulic oil is very hot

and can be under pressure. Do not allow your skin to come
into contact with hot oil or components containing hot oil!

Always relieve the pressure in the hydraulic system before working on

Fig. 15 the hydraulic system.
Lower the attachment to the ground, actuate all servo control valves to
relieve servo pressure (with ignition key in contact position) and open
the tank pressure release (Fig. 15) valve located at the back of the
cabin. In that way, the air pressure in the hydraulic tank will be
relieved.

OIL COOLING SYSTEM

Clean hydraulic oil coolers are necessary to achieve optimum

hydraulic oil cooling.
Clean the hydraulic oil coolers with compressed air or a steam cleaner
at the intervals specified in the maintenance schedule, and more often,
if working conditions make it necessary.

TANK RETURN FILTER (Fig. 16)

The magnetic rods in the return filter of the hydraulic tank (pos.
2) should be cleaned at the intervals specified in the maintenance
schedule.
Change the filter insert 5 at the intervals specified in the
maintenance schedule and after every failure in the hydraulic system,
which could have contaminated the hydraulic system.

Fig. 16

6.10
To check and clean the magnetic rods to replace a filter
element:
Remove screws 3 (Fig. 16) and pull off the cover 1 with the
magnetic rod 2.
Carefully clean the magnetic rod 2.
remove the old filter element 5 and replace it with the new element.

CAUTION

Make sure that the lower section of the element touches the
bottom of the canister.

When inserting the element 5, make sure that the o-ring 8 is not
damaged.
Install the cover 1, making sure that the o-ring 6 is seated correctly.
Reinstall and tighten screw 3 evenly.

LEAK OIL FILTER (Fig. 17)

Clean the magnetic rod of the leak oil filter (pos. 2) at the
intervals specified in the maintenance schedule.
Change the filter insert 5 at the intervals specified in the
maintenance schedule.
To clean the magnetic rod and to replace the filter element:
Remove screws 3 on the filter cover and remove the cover 1 with
magnetic rod 2. carefully remove any dirt adhering to the magnetic
rod. Remove the old filter element 5 and insert the new element.

CAUTION

Make sure that the lower section of the element touches the
bottom of the canister.

When inserting the element 5, make sure that the o-ring 8 is not
damaged.
Install the cover 1, reinstall and tighten nuts 3 evenly.

Fig. 17

6.11
 REPLENISHING OIL AND SERVO OIL FILTER

Three hydraulic filters ensure filtration of the auxiliary circuits:

Two replenishing oil filters
One servo oil filter
The two replenishing oil filters for the closed swing circuit (Fig. 18) are
located on the splitterbox.
The servo oil filter (Fig. 19) is installed on the frame above the
hydraulic pumps.
For the filter change interval, see the maintenance schedule.

To replace a filter element

Before cleaning the filter, relieve the air pressure in the hydraulic tank
().
Remove the filter housing 5, take out the filter element 4, clean the
filter head 6 and the filter housing 5.
Insert a new filter element 4, lightly lubricate the threads of the
housing, reinstall the filter housing, making sure the o-ring 7 is
positioned correctly, tighten the filter housing by hand.
Pressurise the hydraulic tank.

Fig. 18

Fig. 19

6.12
HIGH PRESSURE FILTERS IN WORKING CIRCUITS

These filters (Fig. 20) are installed on the inlet port of the control
valves.
The filters are maintenance free.
The elements should be checked, cleaned or replaced after
replacing or repairing a working pump.
To clean the filter element:
- Relieve hydraulic tank pressure(),
- Remove the filter housing 1 (Fig. 21),
- Remove the filter element 2 and clean it with non
flammable cleaning fluid, or replace it with a new element, Fig. 20
- Clean the filter housing 1 and the filter head 3 and reinstall,
making sure the o-rings 4 and 5 are seated properly,
- Pressurise the hydraulic tank.

Important: Any time the filter element is cleaned or replaced,

check for leaks.
To check for leaks, start the engine, operate the machine for a
short period, and check for leaks between the filter housing 1
and the filter head 3.

Fig. 21

THE SUCTION PIPE TO THE MAIN PUMPS

If an expansion joint on an hydraulic pump or on the main

collector must be exchanged, close the shut off valve located
under the grid (Fig. 23) and release the tank pressure (Fig. Fig. 22
22).
In addition, remove the cover of the leak oil filter, so to prevent
the oil return via these filter and hydraulic pumps.
After repair, reinstall the leak oil filter cover, pressurise the
hydraulic tank and return the shut off valve in opened position.

Fig. 23
6.13
 REPAIR ON THE HYDRAULIC SYSTEM
The hydraulic system must be checked regularly for leaks.

DANGER

Never check for leaks with your bare hands.

Fluid escaping from a small hole can have enough force to
penetrate the skin.
Never loosen or remove lines or fittings before the
attachment is lowered to the ground, the engine is turned
off, both joysticks are moved, with the ignition key in
contact position, and the air pressure in the hydraulic tank
Fig. 24
is relieved.
NW 20, NW 25, NW 32, NW 40 and NW 60 high pressure hoses with
SAE fittings are installed on this machine (Fig. 24and Fig. 25).

DANGER

Any time a high pressure hose is defective (bubles,

moisture, damage on the surface, etc.) it must be replaced.
When installing replacement hoses, avoid any stress and
strain on the hose. Do not turn or twist the hose during
installation.
Fig. 25 The following o-rings are needed for hydraulic hoses:
NW 20 – 25 3,5 Id. No. 7367610
NW 25 – 32,9 3,5 Id. No. 7367611
NW 32 – 37,7 3,5 Id. No. 7367612
NW 40 – 47,2 3,5 Id. No. 7367613
NW 60 – 69,5 3,5 Id. No. 7360656
The mounting screws on the SAE fittings must be tightened to the
following torque value:
Torque value in Nm (ft. lbs) – Quality 10.9
Screw 4
Conical flange
Size Half flange 5a Flat flange 5b
5C
M8 31 (23) / /
M10 62 (45) 45 (33) 65 (48)
M12 108 (80) 70 (51) 110 (81)
M14 172 (127) 120 (88) 180 (133)
Fig. 26 M16 264 (195) 170 (125) 250 (184)
M20 350 (258) 250 (184) 450 (332)
Note: Tighten evenly and crosswise

TO BLEED THE HYDRAULIC PUMPS

Bleed the hydraulic pumps after every repair on the pumps and / or
after every hydraulic oil change.
To bleed a pump, loosen the hose on top of the leak oil connection on
the pump housing (do not remove) and allow air to escape. As soon as
hydraulic oil without air bubbles emerges, tighten the leak oil hose
(see Fig. 26 for working pump or Fig. 27 for swing pump). Before
initial pump start up, after pump repair or replacement, fill the pump
housings via the same connections with hydraulic oil.

Fig. 27

6.14
 THE SERVO CIRCUIT
check the complete servo circuit, tubes, connections, hoses as
well as all component connections (accumulator, pressure
relief valve, filters, etc.) regularly for leaks.

DANGER

Due to an accumulator (Fig. 28), the servo circuit remains

under pressure to actuate several attachment functions
(boom down) even after the engine is turned off.
Before any repair in the servo circuit, the pressure must be
relieve as follows:
Lower the attachment to the ground, turn the engine off Fig. 28
(turn starter key switch to the on position), and actuate both
joysticks several times.

HYDRAULIC CYLINDERS

Before attempting to repair, replace or reseal a hydraulic cylinder

(Fig. 29), contact your LIEBHERR dealer. Leaks at the cylinder
rod bearing should always be repaired by the LIEBHERR dealer.

Piston rod preservation:

If the machine is not used for more than 4 weeks or before
transporting the machine by ship, the following preservation
guidelines should be carried out:
Park and / or transport the machine in such a way that the
piston rods are fully retracted in the cylinders.
Apply anti-corrosive grease (for example: LIEBHERR CTK grease, Fig. 29
Id. 861331301) to all exposed sections of the piston rods (for ex.:
Fig. 30).
If the machine is transported by ship (salt water), or in the winter
(road salt), recheck the preservation of the piston rods after the
machine has been loaded, since the anti-corrosive grease may
have been removed by the wiper ring.
In addition, apply anti-corrosive grease if the machine is used in
certain applications with short cylinder strokes, where the piston
rods are not regularly lubricated with hydraulic oil (example:
cylinder on basic boom, when working above ground level).

Fig. 30

6.15
 THE AIR FILTERS

Maximum engine protection against premature wear due to dust is

only possible if the air intake system and filters are checked and
serviced at regular intervals (Fig. 31).
The air cleaner with multi cyclone precleaner 14 and fine filter 9 with
primary and safety element are designed to give maximum protection
at long maintenance intervals.
Maintenance also includes replacing the filter elements.
For safety reasons, we do not recommend to clean the filter elements.
Fig. 31 The vaccum indicator (Fig. 32, Fig. 34,pos. 16) stores the maximum
recorded vaccum pressure on the filter outlet, during the diesel engine
operation.
When the red stripe (Fig. 34, pos. 17) appears in the window 18, the
maximum permissible vaccum of 50 mbar has been reached.
At that time, the corresponding primary filter element must be
replaced.
To reset the vaccum indicator, press the „Reset“ button 19.
We recommend to change the primary filter elements 3 only,
when the maximum vaccum pressure has been reached, or at
intervals specified in maintenance schedule.
If the elements 3 are removed and installed too often, the seals
between the filter elements and the filter housing may be damaged.

Fig. 32 The safety elements 6 should be replaced after the primary elements
have been changed three times, or at intervals specified in
maintenance schedule.
Before installing a new element, carefully clean the seal and the
sealing surface of the filter housing.
The dust in the cyclone precleaner 14 is constantly drawn in by the
exhaust system and discharged.

TO CHANGE THE PRIMARY FILTER ELEMENT

Turn the engine off, remove nuts 2 and remove the dirty primary filter
elements 3 (Fig. 33).
Clean the inside of the air filter housing 9 and wipe off the sealing
surface in the filter housing with a damp rag.
Do not blow out the housing with pressurised air.
Insert the new primary filter elements, make sure they are seated
correctly, tighten nuts 2.

Fig. 33

6.16
TO REPLACE THE SAFETY ELEMENTS

The safety elements 6 are installed with a special wing nut with
built in maintenance indicator (Fig. 35, pos.5).
Check the wing nut for tightness.
However, if a visual inspection shows that the green dot 5a on the
wing nut has turned red, the safety elements should be replaced
immediately.
We recommend that the safety elements are replaced by a
qualified maintenance or LIEBHERR service technician.
To remove the safety elements, proceed as follows:
Remove the primary elements 3 as outlined before. Remove the Fig. 34
special wing nut and take out the safety element 6.
Carefully clean the inside of the air filter housing 9 with a damp
rag.
Clean the sealing surfaces in the housing and check for damage.
Carefully insert the new safety elements and secure with the
special wing nuts.
Install the primary filter element 3, as outlined before.

TO CLEAN THE AIR CHANNELS FOR THE PRECLEANER (Fig.

36)

Check the condition of the air channels in the precleaner 14 at the

intervals specified in the maintenance schedule. Fig. 35
Open the filter cover 1 and check the channels. If the channels are
plugged with dust, use compressed air to blow the channels out
from the inside of the filter towards the outside.

CAUTION

Do not use steam.

The safety elements 6 must remain in place.
Do not direct the air flow towards the filter elements

CHECK THE AIR INTAKE SYSTEM, HOSES, ELBOWS, Fig. 36

CLAMPS

The rubber hoses and elbows between filter housing end engine
(Fig. 32, pos. 7) must be checked for damage, wear, tightness and
leaks whenever the filter elements are replaced.
If necessary, retighten the screws on the clamps 8.
The connection to the air intake side of the air compressor must
also be checked for leaks (Fig. 37). If necessary, include the visual
inspection of the air intake system in the daily maintenance.

Fig. 37
6.17
 THE ELECTRICAL SYSTEM

To insure trouble free operation of your excavator, the electrical

system must be in good condition. The gauges, indicators and
components of the electrical system should be checked regularly for
proper function (see maintenance schedule).
Always replace burnt out fuses and bulbs. Do not repair fuses.
Check for bare and damaged wires, which could cause damage to the
electrical system or a fire. Check for loose, dirty or corroded
connections.
IMPORTANT
Before repairs on the electrical system, or before using an arc
welder on the machine, always disconnect the 2 cut off switches
S9.1 and S9.2, which are located on the left catwalk above the
door that leads to the cab.
Cover the electrical components (especially the alternator) when
washing the excavator to protect it from water.

BATTERY MAINTENANCE

The four main batteries and the two safety batteries are located in a
compartment box (Fig. 38) on the floor at the top of the access ladder.
In order for the batteries to function properly, it is important to keep
them clean at all times.
The battery poles and cable clamps in particular should be cleaned
Fig. 38 regularly and then coated with acid resistant grease (Fig. 38).
To check the electrolyte level open battery compartment door, lift up
rubber cover and remove caps.
The electrolyte level should be ½“ (10 – 15 mm) above the plates.
If the electrolyte level is low, add distilled water.
Regularly check the specific gravity with a hydrometer. A fully charged
battery should have a value of 1,28 kg/l (31,5°).
Batteries with a lower value should be recharged. Reinstall caps,
check if battery is mounted securely and close the battery
compartment door.

DANGER

Wear protective gloves and safety glasses when handling

batteries!
Keep sparks and open flame away from battery. Battery
fumes are highly flammable and explosive.
Batteries contain acid which should not be touched. In case
of contact, flush with water and get medical attention.

6.18
E1003 Power connection box E1031 Greasing control unit
E1005 Cabin connection box H1 Monitoring display
E1006 Cabin connection box / air conditioner S2 Control unit
E1010 Cabin connection box / greasing S9-1 Engine battery switch
E1022-1 Connection box / ladder control S9-2 Switch quantum
E1022-2 Connection box / trap control S100-1, 2, 3, 4 and 5 Emergeny stop

6.19
LOCATION OF SAFETY SWITCHES AND FUSES

Safety switches in control box E1003 under the cab (…)

ln
Fused circuits and components
(A)
F12.1 25 Attachment floodlight E3, E5
F12.2 25 Attachment floodlight E2, E4
F12.3 25 Fuel tank flood light, E1-1, E1-2, top of cabin floodlight E58-1
F12.4 25 Hydraulic tank floodlight E6-1, E6-2, top of cabin floodlight E58-2
F12.5 25 Counterweight floodlight E18-1, E18-2
F12.6 25 Optional counterweight floodlight E8-1, E8-2,E23-1, E23-2
F20.1 100 Supply cabin kl15
F20.2 100 Supply E1005 kl15
F20.3 100 Service battery charging current
F20.4 100 Kl30 floodlight
F20.5 100 Kl30 counterweight floodlight
F20.6 100 Engine
F37 25 Ether control
F119 8 Starting switch S1/kl30 prelub
F120 50 Air conditioning
F121 50 Air conditioning
F122 15 Optional windshield wiper
F123 50 Supply printplate A1020
F137 8 Quantum
F138 100 Service circuit supply
F139 100 Electro-hydraulic motor ladder and trap M10 supply
F140 15 Board
F141 15 Cigar lighter
F142 15 Lighting
F143 25 Lighting
F144 15 Ladder / trap
F147 100 Electro-hydraulic motor ladder and trap M11 supply / reserve
F152 25 Quantum
F164 7,5 Power connection box E1003
F167 25 Elevation pressure fan M15
F169 15 Charging

6.20
In control box E 1005 in the cab are safety switches for :
F30 8A Attenuation plate supply reserve
F31 15A A1020 boom / shovel tilt
F32 15A A1020 stick / swing
F33 15A A1020 travel / trap
F34 15A A1020 FSG
F35 15A A1020 FSG controller
F124 15A Safety switch servo cut off S7 ESP01 plate
A1001
F125 15A Regulation plate A1019 Electronic box
BST U16
F126 15A ESP01 plate A1001
F127 15A Greasing
F128 15A Board
F129 15A Cabin
F130 8A ESP01 plate A1001
F148 15A Regulation plate A1019
F161 15A Connection box pump transmitters E1036

6.21
 The safety switches for the air conditioner are in control box E1006 in
the ceiling of the cab (Fig. 39).

F131 15A Evaporator motor 1

F132 15A Evaporator motor 2
F133 15A Evaporator motor 3
F134 25A Reserve E1006
F135 25A Reserve E1006
F136 8A Reserve E1006

Fig. 39

To clean the air filters for electrical box and cab pressurisation, press
to open the dust discharge valve 5.

Fig. 40

6.22
 THE HEATER AND AIR CONDITIONER

HEATING SYSTEM

The following maintenance should be performed at the intervals

specified in the maintenance schedule:
- Check the heater water circuit for leaks, check and
retighten all connections, hose clamps and the seals on
the water valves.
- If dirty, the heat exchanger has to be cleaned immediately
(Fig. 42, pos. 2).
Fig. 41
- Remove and clean the fresh air filter of the heater (Fig.
42, pos. 3).
The heater should only be used with an antifreeze and
anticorrosive mixture.
When changing the engine coolant, close the heater valves on
the engine (Fig. 41). Otherwise the heater core must be
vented correctly after refilling.

Fig. 42

AIR CONDITIONER

Operate the air conditioner every second week for about 10

minutes regardless of the season.
During the warm season, perform following checks or
maintenance works:
- Check the heat exchanger of the condenser located on the
engine radiator (Fig. 43, pos 30) and if necessary blow it
out with pressurised air or steam, from the inner (fan side)
to outside.
- Clean the recirculating air filter on the evaporator in the Fig. 43
cab (Fig. 44).

Fig. 44
6.23
 - Check the V-belts of the compressor (Fig. 45) for correct
tension and good condition.

In addition, the refrigerant charge of the system must be checked at

regular intervals (see maintenance schedule), by observing the sight
glass of the receiver drier while the air conditioner is operated.
Bubbles or foam in the sight glass indicate an insufficient refrigerant
charge.
In this case, the system should be checked and refilled by a trained
specialist.
The condition of the refrigerant receiver 5 must be checked visually for
corrosion and mechanical damage. Should rust formation be observed
Fig. 45 on the receiver (on mounting consoles, connecting parts,…), so it must
be replaced immediately.
The filter / drier 6 must be exchanged at regular intervals, since it may
be obturated due to excessive absorption of humidity.
If the indicator becomes yellow, it means that there is too much
humidity in the circuit. The filter / drier 6 must be exchanged
immediatly by a trained specialist.
For maintenance intervals, see maintenance schedule.

Fig. 46

Fig. 47

6.24
 CHECK MOUNTING BOLTS FOR TIGHTNESS
The mounting bolts listed below must regularly be checked and
retighten if necessary. See maintenance schedule for check intervals.
Notice: When installing bolts of size bigger then M40 the thread
of the screw must be slightly coated with a MoS2 based grease.
Also grease the bolt head supporting surface, unless hereafter
otherwise specified.

DANGER
Due to their size, most of the below listed mounting bolts
require, to be tensioned to the prescribed torque, the use of a
special, hydraulic or electric actuated tensioning device.
These high torque tensioning devices are power tools, which
must be operated by trained mechanics, knowing the safety
precautions edicted by the tool manufacturer and that must be Fig. 48
observed to avoid accidents or personal injury.
In particular, pay attention to chose a solid and secure reaction
point for the tool and position the reaction arm during
operation. Keep clear of the reaction arm during operation; if it
must be held or steadied during operation, use alternative
means of securing the tool during operation.
MOUNTING BOLTS OF THE COUNTERWEIGHT
The eight mounting bolts M42 (Fig. 48, pos. 1) must be torqued to
5400 Nm (3982 ft.lbs).
MOUNTING BOLTS OF THE SWING RING
The stud bolts M36 (Fig. 49, pos. 4) for the mounting of the swing ring
10 to the uppercarriage 11 must be tensioned to 570 kN. The stud
bolts M36 (pos. 3) for the mounting of the swing ring 10 to the
undercarriage 12 must be tensioned to 570 kN. Tighten the protection Fig. 49
nuts 5 on the bolts 3 and 4 between 500 and 1000 Nm.
The use of special tensioning procedure and tool is necessary to
obtain the correct bolt tension (LIEBHERR recommends the employ of
the special bolt tensioning cylinder ident. Nb. 5617448, at the required
hydraulic pressure of 1350 bar).

DANGER
The special tool may only be operated by qualified personnel,
especially trained for the use of this high pressure tensioning
device and aware of the operating instructions as well of the
recommendations for accident and damage prevention
concerning this tool.
Use appropriate working platforms and lifting devices to install
and hold in position the special tool while tensioning the bolts.
MOUNTING BOLTS OF TANKS AND POWERPACK Fig. 50
The mounting bolts M30 of the hydraulic tank and the fuel tank must
be torqued to 1900 Nm (1400 ft.lbs). the six mounting bolts M36 of the
powerpack must be torqued to 3300 Nm (2434 ft.lbs) the thread of the
screws must be greased under its head and both sides of the washer
with Mobiltalc 81’s grease (ident. 8503279).
For the excavators equipped with the Centinel system, the tightening
of the mounting bolts of the Centinel tank is described page 8.1.
MOUNTING BOLTS OF THE SWING GEAR AND MOTOR
The mounting bolts M30 of the swing gear (Fig. 51, pos. 7) must be
torqued to 1900 Nm (1400 ft.lbs).
The mounting bolts M24 of the swing motor (pos. 8) must be torqued
to 960 Nm (708 ft.lbs).

Fig. 51
6.25
 MOUNTING BOLTS OF HYDRAULIC PUMPS

The mounting bolts M20 of the main working pumps (Fig. 52, P1, P2,
P3 and P4) must be torqued to 425 Nm (315 ft.lbs).
The mounting bolts M20 of the swing pumps (Fig. 52, PS1 and PS2)
must be torqued to 425 Nm (315 ft.lbs).Nm.
The mounting bolts M16 of the water cooler fan pump (P6.1) and the
oil cooler fan pump (P6.2) must be torqued to 210 Nm (155 ft.lbs).
The mounting bolts M12 of the splitterbox lube oil pump (P8), of the
control oil pump (P9) and of the replenishing oil pumps (P10.1 and
P10.2) must be torqued to 85 Nm (63 ft.lbs).

Fig. 52

CONNECTION OF CENTRAL PIECE AND SIDE FRAMES

These bolts must be checked regularly, and if necessary retightened.

The lower bolts M42 (Fig. 53, pos. 1) must be torqued to 5400 Nm
(3982 ft.lbs).
The upper bolts M42 (Fig. 53, pos. 2) must be torqued to 5400 Nm
(3982 ft.lbs).

Fig. 53

MOUNTING BOLTS OF THE DRIVER’S CAB

These bolts must be checked regularly, and if necessary retightened.

This screw (Fig. 54, pos. 16 and 25) are of size M16 and must be
torqued to 280 Nm (206 ft.lbs).

Fig. 54

6.26
REPLACING WEAR AND TEAR ITEMS

The regular maintenance described in this manual may be performed

by the operator or maintenance personnel.
All other repairs should only be done by trained LIEBHERR service
Personnel.
Always consult your LIEBHERR dealer, especially when removing
counterweight.

Fig. 55

WELDING
Any welding on structural parts may only be done by LIEBHERR
service personnel. If this rule is neglected, the warranty is voided.
Before welding repairs on other parts, always disconnect the 2 cut off
switches S9.1 and S9.2 to protect the electrical components.
S9.1: switch battery / ground isolator
S9.2: switch QUANTUM.
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.

CAUTION

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.

6.27
 DAILY / WEEKLY MAINTENANCE SCHEDULE R 994B
WORK TO BE PERFORMED
Adjustment, For description
repeat interval Values, refer to:
Quantities OM: Operation
first and only interval and
i t
DIESEL ENGINE & SPLITTERBOX
Check oil level OM 5.13
Check coolant level OM 5.14
Check speed on Rpm gauge OM 3.8
Check running noises
Check exhaust gas colour
Check engine and external pipework for leaks
Check exhaust connections for leaks. Check oil supply / return pipework for leaks
Empty water separator at fuel filter OM 6.4
Check for air filters clogging at the restriction indicators OM 6.16
Check oil pressure and coolant temperature during operation OM 3.8
Check coupling for leaks OM 5.19
Check oil level in splitterbox OM 5.16
Check condition of the cyclone tubes of the precleaner, clean if necessary OM 6.17
Check air intake hose for condition and leaks OM 6.17
Check and clean radiator core and fan OM 6.6
Check radiator cap for leaks, replace if necessary OM 6.6
Drain fuel tank OM 6.4
Daily: perform a complete “Daily” Maintenance Echelon, as stated in CUMMINS
Operating and Maintenance Manual

HYDRAULIC SYSTEM
Check oil level in hydraulic tank OM 5.22
Check hydraulic system for leaks OM 6.14
Inspect the fastening and the good condition of pipes and hoses for damage and
OM 6.14
leakage
Clean magnetic rods in one of the return filters (each week another one) (daily
OM 6.11
during the first 300 hrs.)
Clean magnetic rods in leak oil filter (daily during the first 300 hrs.) OM 6.11
Check hydraulic cylinder rods for leaks and good condition OM 6.15
Inspect, and if necessary clean oil coolers OM 6.10

ELECTRICAL SYSTEM
Clean and check LCD screen of the display for proper function when starting OM 4.4
Check indicator lights and gauges on control panel when starting OM 4.4
Press to open dust discharge valve on air cleaner for cab and electrical boxes OM 6.22
Check head and floodlights, clean if necessary OM 3.8
Visual inspection of wiring system damage

AIR SYSTEM
Check cut in and cut out pressure of air pressure regulator 6,2 – 7,25 bar OM 6.4
Check hydraulic tank pressurisation 0,2 – 0,4 bar
Drain air tanks OM 6.5

6.28
 DAILY / WEEKLY MAINTENANCE SCHEDULE R 994B
WORK TO BE PERFORMED
Adjustment, For description
repeat interval Values, refer to:
Quantities OM: Operation
first and only interval and
i t
SWING RING
Check function of swing ring bearing lubrication system during operation OM 5.24
Check function of swing ring teeth lubrication system during operation OM 5.24
Check visually the grease delivery (outlet of new grease around the swing ring)

SWING GEAR
Check function and operation of swing brake OM 4.13
Visually check mounting bolts of gear and oil motor OM 6.25
Check for leaks on swing gears, check oil level in expansion tanks OM 5.21

TRAVEL GEARS
Check for leaks, if gear is leaking, check oil level OM 5.20
Check function and operation of travel brakes

TRACKS
Clean track chain (after working) OM 6.9
Visually check and tighten if necessary mounting screws of side frames OM 6.26
Check tensioning cylinders, idler, carrier and track rollers for leaks OM 6.8
Visually check and if necessary tighten screws of sprocket, rollers, idlers and chain
OM 6.8
guides
Check track chain tension visually OM 6.8

CAB, HEATER AND AIR CONDITIONER

Operate air conditioner every week for 10 minutes (during winter) OM 6.23
Visual check condenser unit and evaporator filter OM 6.23
Check refrigerant level, if necessary refill circuit OM 6.24
Check tension of V-belt for air conditioner (on the engine) OM 6.24

UNDER / UPPERCARRIAGE, & ATTACHMENTS

Check function of working attachment lubrication system during operation OM 5.24
Check visually the grease delivery at each lube point OM 5.24
Check bucket teeth visually for wear
The daily maintenance work must include the check of the proper function of
hydraulic, electric, pneumatic and brakes systems before starting operation.
Visually check and if necessary tighten mounting screws of counterweight, tanks,
OM 6.25
powerpack, control valve console, cab, catwalks, grease box, ladder
Check fastening of pin covers
Check fastening of hoses and pipe clips
Check level in reservoir for windshield washer, refill if necessary 75 l. (19,8 Gal.)

CENTRALIZED LUBRICATION SYSTEM

Daily: perform a complete daily maintenance as stated on page 994B_1001a.4a OM 5.24
Weekly: perform a complete weekly maintenance as stated on page
OM 5.24
994B_1001a.4a

6.29
 MAINTENANCE SCHEDULE R 994B
WORK TO BE PERFORMED
Adjustment, For
repeat interval Values, description
Quantities in refer to:
first and only interval liters (US OM:
Gal.) O ti
Perform all checks and works in the daily / weekly maintenance schedule

DIESEL ENGINE & SPLITTERBOX

Check the tightness of all screws and bolts on splitterbox OM 5.16
Check the oil quality in splitterbox, change if necessary 75 (19,8) OM 5.16
Check mounting screws of engine and splitterbox for tightness OM 6.6
Check the engine rubber buffers (replace if necessary and at least every
OM 6.7
10000 hours)
Replace oil in elastic coupling OM 5.19
Replace primary element of air cleaner (if necessary or once a year) OM 6.17
Replace safety element of air cleaner (if necessary or once a year) OM 6.17

Every 250 hours or 6 months, perform a complete “250 hrs” Maintenance

Echelon, as stated in CUMMINS Operation and Maintenance Manual
To extend the oil change interval, it is advised to use the chart method (see
CUMMINS Manual page 19 (QSK45 with 75 US Gallon sump)). This method
allows to extend the oil change interval.
Every 10000 hours or 2 years, perform a complete “10000 hrs”
Maintenance Echelon, as stated in CUMMINS Operation and Maintenance
Manual
See CUMMINS Operatin and Maintenance Manual for other maintenance
(Eliminator, Centinel, Fleetguard, valves and injectors adjustment)
Every 20000 hours, perform a complete “20000 hrs” Maintenance Echelon,
as stated in Geislinger (coupling manufacturer) Manual

HYDRAULIC SYSTEM
Change servo filter elements (first after 500 hrs) OM 6.12
Change swing pumps replenishing oil filter elements (first after 500 hrs) OM 6.12
Change filter element of leakage oil filters (first after 500 hrs) OM 6.11
Change filter element of return filters (first after 500 hrs) OM 6.10
Check mounting of components (pumps, motors, clamps,…) OM 6.24
Check and adjust primary and secondary pressure relief valves
Replace hydraulic oil 2500 (794) OM 5.23
Visually check the cooling fan blades, replace if necessary
Bleed servo system and hydraulic pumps (as necessary) OM 6.14
Clean high pressure filters (as necessary) OM 6.13

CENTRALIZED LUBRICATION SYSTEM

Every 1000 hours, perform a complete 1000 hrs Maintenance Echelon as
OM 5.24
stated on page 994B_1001a.4a
Every 7500 hours, perform a complete 7500 hrs Maintenance Echelon as
OM 5.24
stated on page 994B_1001a.4a

6.30
 MAINTENANCE SCHEDULE R 994B
WORK TO BE PERFORMED
Adjustment, For
repeat interval Values, description
Quantities in refer to:
first and only interval liters (US OM:
Gal.) O ti
ELECTRICAL SYSTEM
Check level and specific gravity of the electrolyte in the batteries OM 6.18
Check and clean battery terminals OM 6.18

AIR SYSTEM
Replace filter cartridge of air dryers OM 6.5

SWING RING
Check and if necessary tighten mounting screws OM 6.25
Check pinion gear mesh
Check axial play of swing ring

SWING GEAR
Replace gear oil (first at 500 hrs) 2 37 (9,8) OM 5.21
Check mounting screws of gear and oil motor OM 6.25

TRAVEL GEARS
Check mounting screws of gears, sprocket wheels and oil motors OM 6.9
Replace gear oil (first at 1000 hrs) 2 52 (13,8) OM 5.20

TRACKS
Check tightening torque of screws of the locking keys of the idler axis OM 6.9
Check tightening torque of screws of rollers, pin locking screws and chain
OM 6.8
guides
Check tightening torque of side frames screws OM 6.26

CAB, HEATER AND AIR CONDITIONER

Check locks and hinges on doors and windows (lubricate if necessary)
Check heater for leaks, heat exchanger and heater filter OM 6.23
Replace the filter / drier (at least every two years) OM 6.24
Yearly check condition of the refrigerant receiver, if necessary replace it OM 6.24
Replace main element on air cleaners (at least once a year) OM 6.22
Replace safety element on air cleaners after 3 services of main element OM 6.22
Lubricate all door seals with silicone or talc (before cold season)

UNDER / UPPERCARRIAGE, & ATTACHMENTS

Check all parts for cracks
Check and lubricate cover hinges and locks
Check tightening of mounting screws for counterweight, tanks, powerpack,
OM 6.25
control valve console, cab, catwalks, grease box, ladder
Explain proper use and maintenance to the operator

6.31
 7. 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 I or travelling on uneven ground and I
or abrasive 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. Minimise travelling with
turning through a narrow turning circle and long distance travel.

To minimise the travel ratio, professional mine planning with long front winning sections is preferred. If
digging operations at various spots are necessary, a proper short term and long term plan of winning
operations has to be employed to guarantee long term use of the excavator at one place before
moving to another location.

However, if frequent machine movement is necessary, the following set of procedures defined by
LIEBHERR to minimise 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.
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 the direction of the drive
sprockets.

Moving the machine during loading operations

Moving the machine during loading operations means adjustment of excavator digging and l 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 l 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 left and vice versa.

7.1
Walking the machine over distance

Walking the machine distances means any movement of the machine of more than 100m 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.
- If temperature of any moving part is growing up about 20°C above ambient temperature, 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, to hose the heating components during travelling or cooling break.
- Move with idler and attachment forwards. Whenever possible, and 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 the machine down grades 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 motors 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, making it no more than a 30° slope
(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 ramp never use attachment to assist the
movement by pushing with the hydraulic power of the bucket, stick or boom.

Travelling the machine first time

The slide bearing (friction bearing) of the track rollers needs some time for running-in. 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 recognise and comply with the recommended travel
operating procedures, as outlined in this document, is noted.

7.2
 8. OPTIONAL ATTACHMENTS

CENTINEL SYSTEM

The Centinel system allow to increase the engine oil change

interval. This system is described in the Operation and Maintenance
Manual CUMMINS.

TO REFILL THE CENTINEL TANK

Refill via the quick change coupling 6 (Fig. 1), until the level
reaches the upper sight glass on the tank (Fig. 1). For oil quantities,
oil specifications, see lubrication and maintenance charts.
Fig. 1

TO ADD OIL IN THE ENGINE SUMP VIA THE CENTINEL VALVE

By opening the valve (Fig. 2), it is possible to refill the engine sump with oil
of the centinel tank.

DANGER
This valve must be opened only to refill the engine sump. In others
cases, it must always remain closed.

TO CHECK MOUNTING BOLTS OF THE CENTINEL TANK

The mounting bolts M20 of the centinel tank (Fig. 3) must be torqued to
560Nm.

Fig. 2

Fig. 3
8.1
 USE OF ENVIRONMENTALLY FRIENDLY HYDRAULIC FLUIDS
General
If specific applications require that even in the case of accidents or leakage there may be no damage
caused to the environment, hydraulic excavators using environmentally friendly hydraulic fluids can be
operated.
These lubricants are free of mineral oils, they are water-soluble in every proportion and meet the
requirements for biodegradability.
Never mix them together or with lubricants based on mineral oils.
The following recommendations state how to proceed when using these biodegradable hydraulic fluids
in LIEBHERR earthmoving machines.

Prescriptions for biodegradable hydraulic fluids

When using environmentally friendly hydraulic fluids, we exclusively recommend synthetic

ester oils with a viscosity according to ISO VG46.
Note
Due to their limited high temperature stability, vegetable oils cannot be used.
Polyglycols decompose various machine paints and should only be used in special cases. In this
instance, the material compatibility in regard to seals, paints, etc .... has to be observed.
Due to the lack of experience with the various products, a "Warranty Declaration" has to be
inquired from the Oil Supplier if LIEBHERR earthmoving machines are to be operated with
environmentally friendly hydraulic fluids based on synthetic ester upon "customer's demand". The
declaration applies for hydraulic components in the case of damage caused by the hydraulic fluid.
This "warranty declaration" together with the completely filled out confirmation has to be sent to
LIEBHERR.

Fundamentally, the supplier is responsible to maintain the standard of quality, standards and
specifications of his product when environmentally friendly products are being used.
In order to avoid misunderstandings, a distinct reference must be made on the hydraulic tank,
stating the fluid which the machine is operating with.

Attention
Mixing various "environmentally friendly hydraulic fluids" together is prohibited.
The name "synthetic ester" for example does not mean, that all products carrying this name have
the same contents. The lack of experience with biodegradable products does not allow a general
statement.

Oil change intervals

The oil changes in pre-set intervals are not allowed for environmentally friendly hydraulic fluids.
The time for oil change must be determined by oil sample analysis and according to the laboratory
reports. See page 5.8.
To take the oil samples, LIEBHERR offers its customers a complete Analysis-Set for Wear Check
Lubrication-Analysis (Id. No. 7018368), which consists of 6 coded sample containers, 6 sample
cover letters, 6 envelopes as well as a 3 mtr. silicon hose. Oil analysis and laboratory report are
already included in the price for the set! Furthermore, only with the first command, a hand pump
(Id.No. 8145666) or, as an alternative, an extraction valve (Id.No. 7019068) and a high pressure hose
for pressure test-point (Id.No. 7002437), will be necessary only once.
Further oil analysis or oil change intervals have to be carried out according to the sample analysis in
the laboratory report from Wear Check. The evaluation result has to be sent to LIEBHERR and the
customer.

8.2
Oil filters change intervals
The filters change intervals as stated by LIEBHERR must be adhered to.
Use only Original LIEBHERR Filters. We recommend the use of special "bio oil filters" to reduce the
percentage of zinc in the system (see also chart of return filters).

Water Condensation
Water Condensation must be drained from the hydraulic tank in regular intervals (drain plug on the
tank). It is recommended to do this after the machine was stopped for a longer period of time, for exp.
Monday morning.
The percentage of condense water is not allowed to exceed 0,1 wgt.%.

Changing to environmentally friendly hydraulic fluid

If machines, which used to operate with mineral oils or other hydraulic fluids, are modified to operate
with environmentally friendly hydraulic fluids, it is imperative to observe all LIEBHERR guidelines for
modifications. Flushing the system is absolutely necessary to ensure trouble-free operation.

Never install attachments from other machines without strictly adhering to all guidelines for
modifications with regards to the interior coating of components (e.g. the hydraulic tank), and the
procedure for flushing with flusher oil (to drain the mineral oil, ...).

The percentage of mineral oil, resulting from changing or mixing with other mineral oil based fluids,
remaining within the system is not allowed to exceed 2 wgt.%.
If the changing guidelines stated by LIEBHERR are not adhered to, warranty will be refused in
case of damage. In case of a doubt, first obtain these guidelines from your LIEBHERR
representative.
Having changed to environmentally friendly hydraulic fluid or when initially filling the system a
reference fresh oil sample must be taken after initial warm-up and sent to the laboratory for analysis.
The sample must be taken while the machine is running using pressure test-point valve (Id.No.
7019068) or right after stopping the engine via the breather valve using the vacuum pump.

Particular precautions
- When disposing of these fluids make sure that this medium is not treated as a mineral oil, i.e.
there are special regulations for the disposal of these fluids in individual countries.
In case you have any questions please contact your representative waste oil recycler.
- When handling the medium simply use gloves and, in case there is a risk of spraying, use safety
goggles as well.
Wash your hands before taking a break and at the end of your shift. In case the fluids come into
contact with skin, rinse with lots of water; in case of eye contact, rinse with water for 10 to 15 minutes.
- After any fluid is spilled or runs out, wash away any smaller amounts with lots of water; larger
amounts must be properly collected and disposed of.
- In case of fire, the usual fire extinguishers may be used (like water vapor, CO2, foam, dry ice
extinguishers, ...).
Never aim a stream of water directly at hot, burning material (risk of splattering). Thermal
decomposition generates CO and/or CO2.

8.3
 PREHEATING OF THE HYDRAULIC EXCAVATOR

The hydraulic excavator can be preheated with an external electric power supply (73 kW, 400 V, 50
Hz).

The preheating must be activated every time the excavator is still standing with external temperature
between –40°C and 0°C (week end or service and reparation day).
The excavator must be preheated minimum 6 hours before the start and the utilization of the engine.
The electric power supply must be connected to the excavator through a connector situated on the
cab elevation. At this time and if the principal switch on the electric box E1049 is activated, all
preheating units are starting.
A light H103 on the control unit alert the operator that the preheating is activated.
When the preheating is activated the excavator can be started but no movement is possible.
After the preheating, cut off the principal switch on the electric box E1049 and disconnect the electric
power supply.

PREHEATING CONTROL
Connect the generator on the 125 A socket situated on the cab elevation. The E1049 box is then
supplied in 400 V for the preheating phase.
The engine starting is available during the preheating but the movements from the excavator
are forbidden.
The 2 water engine preheaters will be cutting off at engine running.

The following heating equipments are installed on the excavator:

Hydraulic tank: 7 resistors from 2 kW / 400 V

Automatic control with internal thermostat: ON 15°C / OFF 27°C
Blower: 6 blowers from 3 kW / 230 V
Separate control with switches S186, S187, S188
Water engine: 2 preheaters from 4kW / 230 V
Automatic control with internal thermostat: ON: 37,7°C / OFF: 48,8 °C
Oil engine: 4 resistors from 500 W / 230 V
Control with an external temperature transmitter: OFF 85°C
Batteries: 7 heating covers from 100W / 230 V
Automatic control with internal thermostat: ON: 18°C / OFF: 27°C
Splitterbox: 2 resistors from 500 W / 230 V
Control with an external temperature transmitter: OFF: 85°C
Cabin: Heating filaments 2 X 500 W / 230 V + 2,5kW / 230 V
Separate control with switches S189_1, S189_2
Cabin: 1 preheater from 3kW / 400 V
Regulated with a thermostat
Greasing: 2 heating covers 0,8kW + 1,35kW / 230 V
Electrical boxes: Resistors from 20W and 150W / 24 V in the boxes from the excavator. At
engine running, boxes (without boxes from cabin) are supplied through the
service batteries.
Hydraulic components: 2 preheaters from 9kW / 400 V
The control is depending on the temperature and on the engine running.

8.4
COMPONENTS LOCATION

R30 Resistor 150 W E1003 R75_1 Hydraulic tank heating resistor 2 kW

R32 Resistor 150 W E1005 R75_2 Hydraulic tank heating resistor 2 kW
R35 Resistor 150 W control board R75_3 Hydraulic tank heating resistor 2 kW
R36 Resistor 20 W arm rest left R75_4 Hydraulic tank heating resistor 2 kW
R37 Resistor 20 W E1006 R75_5 Hydraulic tank heating resistor 2 kW
R39 Resistor 150 W arm rest right R75_6 Hydraulic tank heating resistor 2 kW
R44_1 Resistor 20 W E1035_1 R75_7 Hydraulic tank heating resistor 2 kW
R44_2 Resistor 20 W E1035_2 R76_1 Splitterbox resistor 500 W
R44_3 Resistor 20 W E1035_3 R76_2 Splitterbox resistor 500 W

8.5
R44_4 Resistor 20 W E1035_4 R77 Grease heating covers 800 W
R46 Resistor 20 W E1038 R78 Grease heating covers 1,35 kW
R47 Resistor 20 W E1036 E5 Cab windshield filaments 2,5 kW
R49 Resistor 20 W E1016 E6_1 Cab side window filaments 500 W
R64 Cabin heating 3 kW E6_2 Cab side window filaments 500 W
M28_1 Blower control valves 3 kW
R66_1 Water heating resistor 4kW M28_2 Blower control valves 3 kW
R66_2 Water heating resistor 4 kW M29_1 Blower pumps 3 kW
R67_1 Engine oil heating resistor 500 W M29_2 Blower pumps 3 kW
R67_2 Engine oil heating resistor 500 W M30 Blower engine room 3 kW
R67_3 Engine oil heating resistor 500 W M31 Blower cab elevation 3 kW
R67_4 Engine oil heating resistor 500 W U42_1 Hydraulic components preheater 9 kW
R68_1 Battery heating wrap 100 W U42_2 Hydraulic components preheater 9 kW
R68_2 Battery heating wrap 100 W B136 Splitterbox temperature transmitter
R68_3 Battery heating wrap 100 W B176_1
R68_4 Battery heating wrap 100 W B176_2
R68_5 Battery heating wrap 100 W
R68_6 Battery heating wrap 100 W
R68_7 Battery heating wrap 100 W

Fig. 4

8.6
Fig. 5 Socket 400V and switch on 1049

8.7
 WINTER POSITION OF AIR FILTER

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.

Summer position A:

The cover 25 is on bottom position, fresh air comes exclusively from outside.

Winter position B:

Unscrew the screws pos 26.

Move up cover 25 and install the screws 26 on top position.
The air is a mixture between outside air and powerpack compartment air (warmed up).

8.8
 LUBRICANTS SPECIFICATIONS FOR –40°C

Engine oil
See Cummins Operation and Maintenance Manual.

First filling: BP Vanellus Ultima 5W30, Ident-Nr. 10287072 (20L), Ident-Nr. 10287073 (60L) from -
40°C until +30°C (with preheating for -50° C excavator able).

Hydraulic oil Avia Synthofluid PE-B 30 from -50°C until +40°C

Ident-Nr. 10115282 drum 210 Liter.

Gear oil: SAE 75W90 API GL5 : Purpoint < -54°C

Like BP gear oil SHXM 75W90

- Ident-Nr. 8503299, drum 60 Liter
- Ident-Nr. 10033025, drum 208 Liter
from -50 °C until +40°C

Like AVIA Gear oil Synthogear FE 75W90 EP from -50°C until +40°C

Grease: general lubepoint

- Grease BP Energrease SY-HT2 from -40°c until +60 °C

- Ident-Nr. 10013544 container 45 Kg
- Ident-Nr. 10013547 drum 165 Kg

- Grease BP Energrease SY PM Drum 165 Kg from -30°C until +30°C,

Ident-Nr. 850373l
- Grease BP Energrease SY PM Drum 45 Kg from -30°C until +30°C,
Ident-Nr. 10279983
- Grease Avia Avilub Synthogrease PE-T1 from -50°C until +20°C
- Grease Avia Avilub Synthogrease PE-T2 from -40 °C until +60 °C,
Ident-Nr. 10286656, Drum 180 Kg
- Grease Liebherr Spezialfett 1026 LS,
Ident-Nr. 10113698, Drum 180 Kg from -30°C until +60°C.

- Grease Petro-Canada Multiflex Moly EP1 from -50°C until +20°C

- Fuchs Urethym HGO from -55°C until 0°C

Grease for swing ring teeth

Grease Avia : AVILUB PE-FK 50 VKA 5500N :

- Ident-Nr. 10113703 container 50 Kg
- Ident-Nr. 10113706 Drum 180 Kg
from -50°C until +20 °C

Grease Petro-Canada Vulcan Synthetic Arctic from -55°C until -20°C

8.9