MA en Liebherr R9200

en
Operating manual
Hydraulic excavator
R9200
from serial number 40001
Document identification
ORIGINAL MANUAL
Order number: 11695477
Edition: 04 / 2017
Valid for: R9200 from serial number 40001
Author: LEC - Technical documentation department
Product identification
Manufacturer: Liebherr-Mining Equipment Colmar SAS
Type: R9200
Type no.: 410
Conformity:
LEC/en/Edition: 04 / 2017
Address
Liebherr-Mining Equipment Colmar SAS
49 rue Frédéric Hartmann
CS 50038, F-68025 Colmar Cedex
copyright © Liebherr-Mining Equipment Colmar SAS 2017
MJFCIFSS
Operating manual
Machine data
Please fill in the following data when you receive your machine.
This will also be of use to you when ordering replacement parts.
Vehicle ident. number:

WLHZ . . . . . . . . . . . . .
Construction year:
. . . .
First start-up date:
. . / . . / . .

R9200 / 11695477
MJFCIFSS
Operating manual
Preface
These operating instructions have been written for the machine operator and for the
maintenance personnel of the machine.
They contain:
– the technical data.
– the safety requirements.
– the operating instructions.
– the maintenance instructions.
The operating instructions are to be read and used carefully by all persons
who carry out work with or on the machine before putting the machine into ser-
vice for the first time and later, at regular intervals.
Work with or on the machine includes, for example:
– Operation including setting up and equipping, rectifying malfunctions during the
course of work, resolving production dropouts, care, disposal of operating and
process materials.
– Maintenance, including maintenance, inspection and repair work.
– Transportation or loading the machine.
The operating instructions allow the machine operator to familiarize himself with the
machine more easily and prevent malfunctions occurring due to improper operation.
The observance of the operating and maintenance instructions by maintenance per-
sonnel:
– increases reliability in use.
– extends the service life of your machine.
– reduces repair costs and downtime.
The operating instructions belong with the machine for the entire lifetime of
the machine. Place a copy in an easily reached position on the cab storage
shelf. This copy must be replaced immediately if lost, damaged or unreadable.
The operating and maintenance instructions must be completed by information on
current national regulations for accident prevention and protection. In addition to the
operating instructions and legally binding regulations on accident prevention which
apply in the user country and at point of use, authorized specialist rules for safe and
correct working procedures are also to be observed.
These operating and maintenance instructions contain all the information required
for operating and maintaining your machine.
– Some illustrations in these operating instructions may depict details and working
devices which differ to your machine.
– In some illustrations, protective devices and covers have been removed in the in-
terests of better presentation.
– Improvements, which are always being incorporated into our machines, may re-
sult in changes to your machine which are not yet indicated in these operating in-
structions.
However, should you require any further explanations or information, LIEBHERR's
MJFCIFSS
Operating manual
technical documentation, sales school and customer service departments are avail-
able for your convenience.
You will appreciate that LIEBHERR warranty claims made on the basis of improper
operation, unsatisfactory maintenance, use of unauthorized operating materials or
non-adherence to safety regulations cannot be recognized.
LIEBHERR will annul any and all obligations incurred by LIEBHERR and / or its deal-
erships, such as guarantee commitments, service contracts etc. without prior notice
in the event that replacement parts other than original LIEBHERR parts or parts pur-
chased from LIEBHERR are used for maintenance or repair work.
Modifications, conditions, copyright

We reserve the right to make modifications without prior notice in the course of tech-
nical developments.
The information and illustrations contained in these operating instructions may nei-
ther be copied and distributed, nor used for the purposes of competition. All rights
are expressly reserved in accordance with copyright laws.
The warranty and liability conditions of LIEBHERR’s general business conditions will
not be enlarged upon through the above information.
MJFCIFSS
Table of contents
1 Product description ....................................................................................................................................... 1-1
1.1 Assembly - overview.............................................................................................................................. 1-1
1.1.1 Machine and construction equipment....................................................................................... 1-1
1.1.2 Uppercarriage........................................................................................................................... 1-2
1.1.3 Undercarriage........................................................................................................................... 1-3
1.2 Vibration emissions................................................................................................................................ 1-3
1.3 EC Declaration of Conformity ................................................................................................................ 1-5
1.4 Technical data ....................................................................................................................................... 1-6
1.4.1 Working technical data ............................................................................................................. 1-6
1.4.2 Technical description................................................................................................................ 1-6
2 Safety instructions......................................................................................................................................... 2-1

2.1 Meaning of the symbols in this manual.................................................................................................. 2-1
2.2 Use in accordance with the regulations ................................................................................................. 2-2
2.3 Safety Instructions ................................................................................................................................. 2-2
2.4 Servicing the machine safely ............................................................................................................... 2-14
2.5 Signs on the machine .......................................................................................................................... 2-21
2.5.1 Introduction............................................................................................................................. 2-21
2.5.2 Arrangement of signs ............................................................................................................. 2-22
2.5.3 Explanation of signs ............................................................................................................... 2-24
3 Control and operation ................................................................................................................................... 3-1

3.1 Operating and control elements............................................................................................................. 3-1
3.1.1 Overview of the control cab ...................................................................................................... 3-1
3.1.2 Arrangement of joysticks .......................................................................................................... 3-4
3.1.3 Keyboard .................................................................................................................................. 3-5
3.1.4 Cab control board ................................................................................................................... 3-12
3.1.5 Monitoring display .................................................................................................................. 3-14
3.1.6 Menus and functions of the display ........................................................................................ 3-14
3.2 The access and the outfit of the cab.................................................................................................... 3-38
3.2.1 Enter or leave the cab ............................................................................................................ 3-39
3.2.2 Safety lever ............................................................................................................................ 3-44
3.2.3 Operator’s seat ....................................................................................................................... 3-45
3.2.4 Auxiliary seat .......................................................................................................................... 3-52
3.2.5 Sunshade ............................................................................................................................... 3-53
3.2.6 Emergency exit....................................................................................................................... 3-54
3.2.7 Internal lighting ....................................................................................................................... 3-55
3.2.8 Fire extinguisher ..................................................................................................................... 3-55
3.2.9 Windscreen ............................................................................................................................ 3-57
3.2.10 Field of view ........................................................................................................................... 3-60
3.2.11 Lighting ................................................................................................................................... 3-61
3.2.12 Heating/air conditioning system ............................................................................................. 3-63
3.3 Setting the machine into operation ...................................................................................................... 3-69
3.3.1 Starting / stopping the machine .............................................................................................. 3-70
3.3.2 Starting aids (optional) ........................................................................................................... 3-78

3.3.3 Warm-up procedure for Diesel engine and hydraulic circuit................................................... 3-91
3.3.4 Jump start procedure ............................................................................................................. 3-93
3.3.5 Emergency and safety operations .......................................................................................... 3-94
3.3.6 Driving .................................................................................................................................. 3-103
3.4 Working with the machine.................................................................................................................. 3-106
3.4.1 Operating the swing gear ..................................................................................................... 3-111
3.4.2 Working position ................................................................................................................... 3-114
3.4.3 Joystick functions when setting up the machine .................................................................. 3-114
3.4.4 Lowering the work equipment when the engine is not running ............................................ 3-121

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Operating manual
3.5 General working methods .................................................................................................................. 3-122

3.5.1 Minimum impact working methods for your machine............................................................ 3-122
3.5.2 Preparatory activities ............................................................................................................ 3-123
3.5.3 Positioning of the machine ................................................................................................... 3-124
3.5.4 Working with the backhoe bucket ......................................................................................... 3-124
3.5.5 Working with the Shovel bucket ........................................................................................... 3-127
3.6 Transport............................................................................................................................................ 3-130
3.6.1 Travelling procedures for mining machine............................................................................ 3-130
3.6.2 Excavator lifting and lashing operations ............................................................................... 3-132
4 Malfunctions ................................................................................................................................................... 4-1

4.1 Error code charts ................................................................................................................................... 4-2
4.1.1 Heating/air conditioning system................................................................................................ 4-2
4.2 Faults and remedies .............................................................................................................................. 4-3
4.2.1 Diesel engine and fuel system.................................................................................................. 4-3
4.2.2 Hydraulic system ...................................................................................................................... 4-4
4.2.3 Transmission ............................................................................................................................ 4-4
4.2.4 Electrical system....................................................................................................................... 4-5
4.2.5 Heating/air-conditioning system ............................................................................................... 4-5
4.2.6 Work equipment ....................................................................................................................... 4-5
4.3 Fuses and relays.................................................................................................................................... 4-6
4.3.1 Power electrical box E1003 ...................................................................................................... 4-6
4.3.2 Cab connection box E1005 ...................................................................................................... 4-9
5 Maintenance ................................................................................................................................................... 5-1

5.1 Servicing the machine safely ................................................................................................................. 5-1
5.2 Maintenance access doors .................................................................................................................... 5-7
5.2.1 Overview of access doors ........................................................................................................ 5-7
5.3 Lubricants and operating fluids .............................................................................................................. 5-9
5.3.1 General information on changing lubricants and operating fluids............................................. 5-9
5.3.2 Lubricating chart ..................................................................................................................... 5-10
5.3.3 Service trap ............................................................................................................................ 5-11
5.3.4 Lubricant chart ........................................................................................................................ 5-13
5.3.5 Operating material chart ......................................................................................................... 5-14
5.3.6 Service trap ............................................................................................................................ 5-15
5.4 Lubricating and operating material specifications ................................................................................ 5-17
5.4.1 Lubricating oil for the Diesel engine ....................................................................................... 5-17
5.4.2 Fuel......................................................................................................................................... 5-17
5.4.3 Coolant ................................................................................................................................... 5-18
5.4.4 Hydraulic oil specifications for LIEBHERR Mining excavators ............................................... 5-18
5.4.5 Swing and travel gear oils ...................................................................................................... 5-23
5.4.6 Splitterbox oil .......................................................................................................................... 5-25
5.4.7 Lubricating grease and other lubricants ................................................................................. 5-26
5.4.8 Lubricants specifications for -40°C ......................................................................................... 5-28
5.5 Condition monitoring with oil analysis .................................................................................................. 5-28
5.5.1 General information ................................................................................................................ 5-28
5.5.2 Oil sampling ............................................................................................................................ 5-29
5.5.3 Sample processing ................................................................................................................. 5-35
5.6 Diesel engine ....................................................................................................................................... 5-39

5.6.1 Check the engine oil level....................................................................................................... 5-39
5.6.2 Change the engine oil............................................................................................................. 5-40
5.6.3 Replace the oil filter elements ................................................................................................ 5-42
5.6.4 Mounting screws..................................................................................................................... 5-43
5.6.5 Elastic bedding ....................................................................................................................... 5-45
5.6.6 Alternator belt ......................................................................................................................... 5-45
5.7 Splitterbox ............................................................................................................................................ 5-45
5.7.1 Splitterbox mounting screws................................................................................................... 5-45

R9200 / 11695477
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Operating manual
5.7.2 Elastic bedding ....................................................................................................................... 5-48

5.7.3 Breather filter .......................................................................................................................... 5-49
5.8 Cooling system .................................................................................................................................... 5-49
5.8.1 Check and clean the cooling system ...................................................................................... 5-49
5.8.2 Check the coolant level .......................................................................................................... 5-50
5.8.3 Coolant antifreeze and anti-corrosion fluid ............................................................................. 5-51
5.8.4 Change the coolant ................................................................................................................ 5-51
5.8.5 Replace the coolant filters ...................................................................................................... 5-52
5.9 Fuel system ......................................................................................................................................... 5-53
5.9.1 Refuel ..................................................................................................................................... 5-53
5.9.2 Drain the fuel tank .................................................................................................................. 5-55
5.9.3 Clean the fuel tank ................................................................................................................. 5-56
5.9.4 Fuel filtering system ............................................................................................................... 5-56
5.9.5 Replace the dust filter for the vent valve ................................................................................ 5-60
5.10 Dry air filter .......................................................................................................................................... 5-61
5.10.1 Replace the primary filter element.......................................................................................... 5-62
5.10.2 Replace the safety element .................................................................................................... 5-63
5.10.3 Clean the housing of the air filter elements ............................................................................ 5-64
5.10.4 Check the air intake system, hoses, elbow tubes, clamps ..................................................... 5-65
5.11 Hydraulic system ................................................................................................................................. 5-66
5.11.1 Preparatory activities .............................................................................................................. 5-66
5.11.2 Check the oil level in the hydraulic tank ................................................................................. 5-67
5.11.3 Release the pressure from the hydraulic system ................................................................... 5-68
5.11.4 Drain and fill the hydraulic tank .............................................................................................. 5-69
5.11.5 Hydraulic oil coolers ............................................................................................................... 5-73
5.11.6 Leak oil filter and return-line filter ........................................................................................... 5-73
5.11.7 Piloting and replenishing oil filters .......................................................................................... 5-75
5.11.8 High pressure filters in working circuit .................................................................................... 5-77
5.11.9 Control circuit ......................................................................................................................... 5-78
5.11.10 Remove the intake hoses from the pumps ............................................................................. 5-80
5.11.11 Bleeding of hydraulic pumps .................................................................................................. 5-81
5.11.12 Bleeding the hydraulic cylinders ............................................................................................. 5-84
5.11.13 Servicing the hydraulic cylinder .............................................................................................. 5-85
5.11.14 Replacement of the hydraulic hoses ...................................................................................... 5-86
5.11.15 Progressive criss-cross tightening procedure......................................................................... 5-89
5.12 Oil changes on components ................................................................................................................ 5-90
5.12.1 General information ................................................................................................................ 5-90
5.12.2 Swing gear – Oil change ........................................................................................................ 5-90
5.12.3 Travel gear and Lifetime travel gear (optional) – Oil change.................................................. 5-92
5.12.4 Swing gears and travel gears flushing ................................................................................... 5-97
5.12.5 Splitterbox – Oil change ......................................................................................................... 5-98
5.13 Track components ............................................................................................................................... 5-99
5.13.1 Check the track components mounting .................................................................................. 5-99
5.13.2 Check the track tension ........................................................................................................ 5-105
5.13.3 Increase the track tension .................................................................................................... 5-106
5.13.4 Decrease the track tension................................................................................................... 5-107
5.13.5 Clean the travel gear ............................................................................................................ 5-108
5.14 Electrical system................................................................................................................................ 5-108
5.14.1 Notes on the electrical system ............................................................................................. 5-108

5.14.2 Principal batteries switches and ECM connectors................................................................ 5-108
5.14.3 Battery care .......................................................................................................................... 5-111
5.14.4 Electrical components location ............................................................................................. 5-112
5.14.5 Cab pressurization ............................................................................................................... 5-114
5.15 Heating/air-conditioning system......................................................................................................... 5-114
5.15.1 Heating system..................................................................................................................... 5-115
5.15.2 Air-conditioning system ........................................................................................................ 5-116
5.15.3 Dual air-conditioning system (optional) ................................................................................ 5-120
5.15.4 Additional maintenance work ............................................................................................... 5-121

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Operating manual
5.15.5 Additional cab heater (optional) ............................................................................................ 5-122

5.16 Greasing the machine........................................................................................................................ 5-122
5.16.1 Lubrication of attachment bearing points.............................................................................. 5-122
5.17 Check mounting bolts for tightness.................................................................................................... 5-123
5.17.1 Counterweight mounting bolts .............................................................................................. 5-124
5.17.2 Mounting bolts of the swing ring ........................................................................................... 5-125
5.17.3 Mounting bolts of the fuel tank.............................................................................................. 5-127
5.17.4 Mounting bolts of the hydraulic tank ..................................................................................... 5-128
5.17.5 Mounting bolts of the engine cooler box ............................................................................... 5-129
5.17.6 Mounting bolts of the oil cooler box ...................................................................................... 5-129
5.17.7 Mounting bolts of the pumps box.......................................................................................... 5-130
5.17.8 Mounting bolts of swing gear and swing motor .................................................................... 5-131
5.17.9 Mounting bolts of hydraulic pumps ....................................................................................... 5-132
5.17.10 Mounting bolts of the cab elevation ...................................................................................... 5-133
5.17.11 Mounting bolts of the cab ..................................................................................................... 5-134
5.17.12 Mounting bolts of the service trap......................................................................................... 5-135
5.17.13 Mounting bolts of side frames............................................................................................... 5-135
5.18 Drive unit brakes and swing gear brakes........................................................................................... 5-136
5.19 Starting aids (option).......................................................................................................................... 5-136
5.19.1 Coolant heater (basic equipment) ........................................................................................ 5-136
5.19.2 Bleed the water system ........................................................................................................ 5-137
5.19.3 Starting fluid system (basic equipment)................................................................................ 5-139
5.19.4 Circulating heating system (if installed) ................................................................................ 5-140
5.20 General maintenance points .............................................................................................................. 5-141
5.20.1 Replacing working parts ....................................................................................................... 5-141
5.20.2 Welding work on the machine .............................................................................................. 5-141
5.21 Control and maintenance chart.......................................................................................................... 5-142
5.21.1 General information .............................................................................................................. 5-142
5.21.2 How to use the maintenance chart ....................................................................................... 5-143
5.21.3 Daily Maintenance Schedule - R9200 .................................................................................. 5-144
5.21.4 250 Hours Maintenance Schedule - R9200.......................................................................... 5-150
5.21.5 500 Hours Maintenance Schedule - R9200.......................................................................... 5-156
5.21.6 1000 Hours Maintenance Schedule - R9200........................................................................ 5-163
5.21.7 2000 Hours Maintenance Schedule - R9200........................................................................ 5-171
6 Appendix......................................................................................................................................................... 6-1
6.1 Visual check of the hydraulic hoses....................................................................................................... 6-1
6.1.1 Preface ..................................................................................................................................... 6-1
6.1.2 General information .................................................................................................................. 6-2
6.1.3 Components functions .............................................................................................................. 6-4
6.1.4 Recommendations for hose assembly maintenance ................................................................ 6-5
6.2 Cleaning procedure for hydraulic circuits............................................................................................... 6-9
6.2.1 Preface ..................................................................................................................................... 6-9
6.2.2 General information about hydraulic oil contamination............................................................. 6-9
6.2.3 General cleaning procedure ................................................................................................... 6-11
6.2.4 Location of the hydraulic tank filters ....................................................................................... 6-11
6.2.5 Working pumps circuit ............................................................................................................ 6-12
6.2.6 Swing circuit ........................................................................................................................... 6-16
6.2.7 Cooling pumps circuit ............................................................................................................. 6-20

6.2.8 Travel motors circuit ............................................................................................................... 6-25
6.2.9 Backhoe cylinders lines .......................................................................................................... 6-30
6.2.10 Shovel cylinders lines ............................................................................................................. 6-36
6.2.11 Clean the hydraulic tank ......................................................................................................... 6-42
6.2.12 Restart the machine ............................................................................................................... 6-42
6.2.13 Monitor the restarted machine ................................................................................................ 6-44
6.3 Centralized lubrication system ............................................................................................................. 6-44

R9200 / 11695477
MJFCIFSS
1 Product description
1.1 Assembly - overview
This section comprises an overview of the machine and descriptions of the compo-
nents shown.
1.1.1 Machine and construction equipment

Fig. 1-1 Machine and construction equipment

R9200 / 11695477 1-1
MJFCIFSS
Product description Operating manual
Assembly - overview
100 Uppercarriage 320 Hydraulic cylinder

200 Undercarriage 330 Stick
310 Boom 350 Bucket
1.1.2 Uppercarriage
Fig. 1-2 Uppercarriage

20 Swing gear installation 80 Covering

25 Swing ring installation 85 Lower covering
40 Service trap 90 Cab
50 PowerPack 95 Catwalk and handrail
60 Hydraulic tank installation 110 Fuel tank
65 Oil radiator installation 115 Counterweight installation
70 Control valve installation 120 Access ladder

1-2 R9200 / 11695477
MJFCIFSS
Operating manual Product description
Vibration emissions
75 Rotating deck 125 Emergency ladder

77 Cab elevation
1.1.3 Undercarriage
Fig. 1-3 Undercarriage
208 Idler 1000 Rotary connection

400 Track chain 4500 Travel gear with sprocket
1.2 Vibration emissions
The operator seat built into the machine by the manufacturer conforms to ISO
7096:2000, EM 6. When replacing the seat, ensure that the new seat also conforms
to this standard.
Hand-arm vibration
If the machine is operated according to the manufacturer instructions, the weighted
(frequency-rated) effective hand-arm vibration is below 2.5 m/s² according to ISO
5349-1:2001.

R9200 / 11695477 1-3
MJFCIFSS
Vibration emissions
Whole-body vibration
If the machine is operated according to the manufacturer instructions, the weighted
(frequency-rated) effective vibration shown for specific machine applications in the
table below apply. These values conform to the specifications in the technical report
ISO/TR 25398:2006 "Earth-moving machinery – Guidelines for assessment of expo-
sure to whole-body vibration of ride-on machines – Use of harmonized data meas-
ured by international institutes, organizations and manufacturers". The method of
assessment conforms to ISO 2631-1:1997. The effective values in the table for rep-
resentable machines are shown with the applicable standard deviations. These de-
viations are classified according to the operating conditions in the classes "light-
duty", "normal" and "heavy-duty". It is the responsibility of the machine owner to as-
sess the operating conditions according to the classes, taking into account the ter-
rain, site conditions, site organisation, material, machine equipment, working
procedure and training of the operator.
As the quoted values are effective values for specific, common applications, the
whole-body vibration to which the operator is exposed can only be estimated. For a
more detailed assessment of the daily exposure of the operator across an 8-hour
shift, please refer to the LIEBHERR brochure on whole-body vibration and the soft-
ware designed for the assessment. This document and software are available from
the LIEBHERR dealer and are included as standard on the documentation CD (Li-
part) shipped with new machines.
For instructions how to reduce whole-body vibration during operation of mobile con-
struction machinery, please refer to chapter "Control, operation / working with ma-
chine / safety instructions / vibration protection".
Weighted effective vibration in m/s²

at operating conditions "light-duty" (1), "normal" (2) and "heavy-duty" (3)
Machine type Typical working cycles

x-axis y-axis z-axis
1 2 3 1 2 3 1 2 3
Crawler excavator Excavator 0.14 0.31 0.49 0.08 0.19 0.31 0.13 0.30 0.47
with hydraulic hammer 0.16 0.38 0.59 0.09 0.22 0.35 0.27 0.55 0.83
Use for mining 0.31 0.46 0.61 0.19 0.30 0.41 0.29 0.61 0.93
Transfer travel 0.21 0.34 0.48 0.09 0.23 0.37 0.56 0.79 1.02
Mobile excavator Excavator 0.19 0.37 0.56 0.09 0.25 0.41 0.16 0.29 0.42
Transfer travel 0.21 0.29 0.38 0.24 0.38 0.52 0.42 0.61 0.80
The measurement uncertainty is defined in standard EN 12096:1997.


1-4 R9200 / 11695477
MJFCIFSS
Operating manual Product description
EC Declaration of Conformity
1.3 EC Declaration of Conformity
Fig. 1-4 Sample EC Declaration of Conformity


R9200 / 11695477 1-5
MJFCIFSS
Technical data
1.4 Technical data
1.4.1 Working technical data
Backhoe Shovel
Maximum working slope (12,5 m3)* 5,0° - 8,7% 5,0° - 8,7%
Maximum travelling angle (200 t) 27° - 50,9% 27° - 50,9%
Maximum tilt angle of Diesel engine - -
Working ambient temperature range -12°C to +55°C -12°C to +55°C
Noise emission**
LpA (inside cab) 74 dB(A) -
Tab. 1-1 Working technical data
* The maximum working slope has been determined for a hydraulic excavator in
standard configuration (with bucket volume as given in the table above) with a mate-
rial density of 1,8 t/m3.
Changing the excavator configuration or the material density has an impact on the
maximum working slope. In this case, LEC recommends contacting Customer Ser-
vice in order to determine specific working conditions and the maximum working
slope in particular.
The machine stability has been defined relative to a horizontal surface and taking into
account a safety factor. Operating the excavator with a different configuration will re-
duce this safety factor. When working on slopes, it is not permitted to overload the
bucket and to work with a material density different from that intended for the bucket
provided by LEC.
In order to use the excavator in material handling operations, LEC recommends also
contacting the Customer Service.
** The sound pressure level (LpA) is determined according to ISO 6396. The meas-
urement uncertainty is defined in the above standard.
1.4.2 Technical description

This should be taken from the accompanying technical description.

1-6 R9200 / 11695477
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Mining Excavator
R 9200
Operating Weight with

Backhoe Attachment:
205 tonnes / 225 tons
Shovel Attachment:
Engine:
810 kW / 1,086 HP
Bucket Capacity:
12.5 m³ / 16.3 yd³
Shovel Capacity:
12.5 m³ / 16.3 yd³
R 9200 Productivity Efficiency
Operating Weight with Backhoe Attachment: Working Harder and Faster Moving More for Less
Shovel Attachment:
Engine:
810 kW / 1,086 HP
Bucket Capacity:
12.5 m³ / 16.3 yd³
Shovel Capacity:
12.5 m³ / 16.3 yd³
2 R 9200
Reliability Customer Service Safety Environment
Ready to Work World-Class Support, Protecting Your Most Mining Responsibly
When You Need It Everywhere, Every Day Important Assets
R 9200 3
Productivity
Working Harder
and Faster
The R 9200 is the optimal loading tool to pair with 100 t and 140 t off-highway trucks. The
R 9200 is a world-class loading tool to meet mining customer’s expectations with leading-
edge technology. R 9200 delivers this in three ways: high productivity, exceptional reliability,
and true 200 t class performance.
4 R 9200
Fast and Cab Optimized
Precise Movement for Performance
Proven Mining Engine Accessibility, comfort and safety define the standard of
The R 9200 is powered by a single Cummins QSK38 diesel the new Liebherr cab for the R 9200. A panoramic view
engine which is US / EPA Tier 2 / Tier 4i compliant. Renowned combined with cameras system allow the operator to have in
for its reliability, the engine delivers durable and superior any case the control of the working environment. The seat,
performance contributing to achieve production goals. joysticks and pedals are designed and located to increase
Liebherr’s deliberate choice of the proven Cummins engine the result of the operator while reducing fatigue.
is due to the efficient proactive service on-site and continued
collaboration with Cummins.
Easy Machine Control

The R 9200 is designed with user friendly controls featuring Highest Digging
an advanced electronic piloting system, which promotes an
intuitive and versatile control resulting in increased productivity. and Breakout Force
Fast Cycle Time
Like all other Liebherr mining excavators, the R 9200 uses a As a result of the highest digging and breakout forces in its
closed-loop swing circuit. The main hydraulic circuit comprises class, the R 9200 provides fast and efficient filling of the bucket,
a combination of four independent main valves fed by four even in extreme digging conditions.
working pumps, providing unrivaled flexibility of attachment
control and force distribution, while allowing full oil flow
integration for fast movement and lowest cycle times.
Single Exclusive Ergonomic

Driveline Concept Bucket Solution Cab Design
• Cummins QSK38 US / EPA Tier 2 / • Innovative Liebherr bucket design • Elevated and armored cab installation
Tier 4i compliant to maximize bucket fill factor • User-friendly piloting station
• Automatic idling system and • Optimized Liebherr GET and wear package • Screen located for convenient operator
engine shutdown according to customer application viewing
• Fuel pre-filter with water separator • Ensure optimal penetration efficiency • Passenger seat for trainer, mechanical
• Max. altitude without deration: 3,600 m • Single GET hammerless locking system engineer or geologist
• Fuel consumption optimized setting (option) for safe and easy maintenance • Additional protection offered
• Fully patented GET system design
for optimal penetration / lifetime
• Four tooth profiles available
for various range of applications
R 9200 5
Efficiency
Moving More
for Less
The R 9200 follows the Liebherr philosophy of maximizing performance by improving the
efficiency of all individual subsystems. The advanced regulation system allows a well-
balanced energy consumption reducing operating costs per ton. In addition, all components
work in optimal performance range that contributes to extend their life for the highest machine
availability.
6 R 9200
Advanced Top-Class
Energy Optimization Components Access
Closed Loop Swing Circuit The R 9200 was developed to facilitate the maintenance of the
The R 9200 is the only 200 t class mining excavator using a components of the machine. For example, the hydraulic valve
closed loop swing circuit. The kinematic energy can be saved blocks are located on the uppercarriage and easily accessible
when the swing motion is used during deceleration, to drive from the service platform, and numerous filters are centrally
the main and auxiliary pumps, reducing fuel consumption and located to allow faster access. With a wide area of maintenance
allowing faster boom lift motion. around the engine and the pumps, the R 9200 offers a great
environment to the service staff to reduce at the minimum the
Litronic Plus service time of the machine.
The Liebherr-patented Litronic Plus system consists of an
intelligent power management system specially developed to
optimize electrical, mechanical and hydraulic power distribution.
This system encourages fuel efficiency and energy savings Extended
while ensuring peak subsystem performance according to
immediate working requirements. Components Lifetime
Independent Cooling System
Oil and water cooling fans are independent and electronically The hydraulic oil filtration systems remove fluid contaminants
managed. The on-demand cooling control enables to maximize to offer the highest rate of hydraulic components durability. To
available power for the working process. This technology maintain oil quality and extended oil lifetime, all return hydraulic
contributes to maintain sustainable temperature of all the oil flow goes through a fine filtration system (15 / 5 μm) and oil
hydraulic components extending their life. tank is sized to considerably extend the time between service
intervals.
Advanced Central High Performance

Machine Monitoring Service Station Less Losses
• 10.5 inch LCD color 8-key screen • Fuel, engine oil, grease system, • Pressure less boom down function
• On-board diagnostics data for service staff hydraulic oil, etc. • High pressure hydraulic circuits
• Permanent rear and side vision • Manually actuated service flap • Newest energy optimized
• Information interface to operator • Fitted with Wiggins couplings attachment controls
(engine, steering, attachment, hydraulic, etc.) • Banlaw available as option • High diameter hydraulic lines
• Non-pressurised refueling system in option • Fuel efficiency
R 9200 7
Reliability
Ready to Work
When You Need It
With over 50 years of innovative thinking, engineering and manufacturing excellence, Liebherr
sets the industry standard for advanced equipment design and technology tools to provide
the most up-to-date product responding to the requirements of the mining customers.
8 R 9200
Quality: Suit Customer
the Liebherr Trademark Requirements
Structure Made Exclusively for Mining Liebherr sales engineer support during the decision-making
Liebherr mining excavators are conceptualised, designed and stage guarantees that the customised product choice perfectly
dedicated to the mining industry. The engineering department matches customer requirements. To ensure customer
uses specific 3D solution in order to meet possible requirements, satisfaction, the Liebherr products are available in a range of
such as Finite Element and Fatigue Life Analysis. In combination, specific configurations. For example, to upgrade the machine
the manufacturing department uses advanced welding techniques for the cold climate environment, to adapt the undercarriage for
to strategically reinforce the structure. The synergy of our skills an specific application or to increase safety and comfort of the
allows to obtain maximal machine availability. operator. With more than 150 engineers dedicated to develop
mining excavators, Liebherr offers tailored-made solution to
Reinforced Undercarriage Structure meet the clients requirements.
Specifically designed for extreme mining conditions, the rugged
R 9200 undercarriage represents the basis for the stability of
the machine. Using specific anti-collision track chain guide and
heavy duty track rollers, the chains are maintained in the perfect
alignment in any condition. The access to the travel motors and Simplified Design
brakes has been designed to provide maximum protection to
the components, while providing easy and fast service access.
All through the R 9200 meets all the entire market requirements
Liebherr Components Integration concerning life cycle cost and productivity, all system and
As an OEM, Liebherr has built a solid reputation for development design solutions have been simplified to the straight minimum.
and production of high quality strategic mining components. The This increases reliability and facilitates significantly maintenance
R 9200 integrates robust and reliable mining components that are and troubleshooting. The result is less downtime and reliable
developed, manufactured and controlled by Liebherr, ensuring availability.
reliability and high performance for the entire machine.
Quality Liebherr Strengthened

Commitment Component Integration Attachment Design
• Liebherr-Mining Equipment Colmar, France, • Hydraulic pumps and motors • Designed for maximum structure life
ISO 9001 certified • Electronic and control technology • Use of advanced welding techniques
• Compliance of materials tested in laboratory • Swing and travel drives • Hard rock protections as options
• Quality control during the stages • Hydraulic cylinders
of production • Splitter box
• Vertical integration practice • Swing ring
R 9200 9
Customer Service
World-Class Support,
Everywhere, Every Day
By partnering with our customers, Liebherr implements tailored solutions from technical
support, spare parts and logistics solutions to global maintenance for all types of equipment,
all over the world.
10 R 9200
Customer Support Remanufacturing Genuine Parts
International Service Organization Reduced Costs and Investment Performance

The Liebherr Service Support has always Over the course of a mining machine’s Using genuine Liebherr components
been an important focus for the company. lifetime, major components must be ensures the best interaction within
Complete service during all operating replaced to ensure continued safety, your machine, encouraging optimal
phases from machinery installation to productivity and reliability. The Liebherr performance and most effective machine
problem solving, spare parts inventory Mining Remanufacturing Program operation and you can be sure that you
and technical service. Our service team offers customers an OEM alternative are in line with the latest improvements
is close to our customers, delivering the to purchasing brand new replacement and updates on parts providing peace-
best specific maintenance solution to components. Enabling customers to ofmind as all major components are
reduce both equipment downtime and achieve lowest possible equipment tracked in the Liebherr Maintenance
repair costs. lifecycle costs without compromising Management System.
quality, performance or reliability.
Complete Training Program Partnership
From fully trained technicians to a full Fast Availability Liebherr regularly reviews requirements
team of certified field service engineers, With an international service network for parts and components for individual
Liebherr commits to provide you with and component facilities world-wide, machines, based on operating hours,
world class training. Dedicated to mining, component repair services and exchange consumption and planned maintenance,
the Liebherr training team provides components are available to customers resulting in minimized down time for
maintenance staff training programs to regardless of their location. customers. With access to the global
allow cost-efficient and safe operations. stock via all Liebherr Mining warehouses,
you will improve productivity by having
the part you need, when you need it.
Troubleshoot Repair and Easy Access

Advisor Platform Remanufacturing Programs Parts Online
• Unique maintenance system • Liebherr certified quality • Available any time anywhere
to help you identify problems • As-new warranty • User friendly interface
• Easy and friendly-user interface • OEM expertise • Online ordering
• Compatible with mobile, tablet or laptop • Reduced costs and investment • Save time and money
• Regular updating of the database • Fast availability
• Procedures described by specialist
with images and videos
R 9200 11
Safety
Protecting Your Most

Important Assets
The Liebherr R 9200 provides uncompromising safety for operators and maintenance crews.
Equipped with the service flap accessible from the ground level and integrating wide open
accesses, the R 9200 allows quick and safe maintenance. The R 9200 cab provides
numerous features for operator safety.
12 R 9200
Safety-First Efficient
Working Conditions Machine Protection
Safety-First Cab Design Protection Against Fire Ignition

Operator safety is one of the main concerns in designing and The engine compartment has a bulkhead wall to separates
developing the new R 9200. A panoramic view, low noise level, the engine from the hydraulic pumps. This reduces the
strong structure and safety glass are elements that ensure risk of hydraulic oil entering the engine compartment. The
compliance with international safety standards. In addition, turbochargers and exhaust systems are heat shielded, and all
Liebherr provides supplementary options allowing the cab to be hydraulic hoses are made from a highly resistant material to
adapted to your specific safety standards. prevent the risk of fires.
Secure Maintenance Automatic Fire Suppression System

All components are designed to allow effortless inspection and The R 9200 can be equipped with a fully integrated fire
replacement. Numerous service lights are strategically located suppression, employing a dual agent solution to prevent and
in service areas to maintain suitable maintenance conditions, protect the machine. The fire suppression system has both
day or night. Emergency stops have been strategically placed automatic and manual release capabilities, emergency stop
in the cab, engine compartment and at ground level. The devices are strategically located on the machine to be easily
R 9200 eliminates hazards to ensure a safe environment for the accessible in any case by the operator.
service staff during maintenance.
Improved Accessibility Working Commitment to

Ease of Maintenance Environment Control Employees Safety
• 45° stairway • Rear and side camera system • Safe and protected access
• All walkways with slip-resistant surfaces • LCD color screen display to the components
• Emergency ladder available near the cab • 4 Long-range working halogen lights • Major components centralized
• Wide open service access (LED optional) to be easily accessible
• 8 service / access LED / halogen headlights • Maintenance fluids reachable
(full LED optional) at ground level
• E-stops located for the operator
and maintenance staff
R 9200 13
Environment
Mining
Responsibly
Liebherr considers the conservation and preservation of the environment as a major challenge
for the present and future. Liebherr are considerate of environmental issues in designing,
manufacturing and managing machine structures, providing solutions that allow customers to
balance performance with environmental consciousness.
14 R 9200
Reduce and Sustainable Design and
Control Emissions Manufacturing Process
Optimized Energy Consumption, Fewer Emissions Certified Environment Management Systems

The intelligent energy management system coordinates Subject to the stringent European program for the regulation of
optimal interaction between the hydraulic system and engine the use of chemical substances in the manufacturing process
output with the goal of maximum performance with minimum REACH*, Liebherr undertakes a global evaluation to minimize
fuel consumption. “Eco-Mode”, the machine is set up to the impacts of hazardous material, pollution control, water
reduce engine load, improve significantly fuel consumption and conservation, energy and environmental campaigns.
optimize emissions.
Extended Components and Fluids Lifetime
Controlled Emission Rejection Liebherr is constantly working on ways to extend component
The R 9200 is powered by a high horsepower diesel engine life. Through the Remanufacturing Program, superior lubrication
which complies with the US / EPA Tier 2 or Tier 4i compliant systems and the reinforcement of parts under stress, Liebherr
emission limits. This power drive makes the R 9200 cost can reduce frequency of part replacement. The result minimizes
effective without compromising productivity and also reduces environmental impact and lowers the overall cost of ownership.
impact on the environment.
*REACH is the European Community Regulation on chemicals and their safe use (EC 1907 / 2006)
It deals with the Registration, Evaluation, Authorization and Restriction of Chemical Substances.
Remanufacturing Sustainable
Program Eco-Mode Manufacturing Process
• Reduced environmental impact • Improved fuel efficiency • Promoted recovery-waste management
• Second life for your components • Less noise pollution • Controlled non-recyclable waste elimination
• Alternative to purchase brand-new • Less carbon dioxide emissions • Eco-friendly material selection
replacement components (95 % of material used
on machine is recyclable)
• European certifications
R 9200 15
Technical Data
Engine Swing Drive

Rating per SAE J1995 810 kW (1,086 HP) at 1,800 rpm Hydraulic motor 2 Liebherr axial piston motors
Model Cummins QSK38 Swing gear 2 Liebherr planetary reduction gears
(US / EPA Tier 2, Tier 4i compliant or fuel consumption Swing ring Liebherr, sealed triple roller swing ring, internal teeth
optimized setting) Swing speed 0 – 5.0 rpm
Type 12 cylinder V-engine Swing-holding brake hydraulically actuated, maintenance-free, multi-disc
Bore / Stroke 159 / 159 mm / 6.26 / 6.26 in brakes integrated in each swing gear
Displacement 37.8 l / 2,307 in3
Aspiration turbocharged after cooled
Fuel tank 4,500 l / 1,189 gal
Electrical system
Voltage 24 V, 25 V additional Hydraulic System
Batteries 4 x 180 Ah / 12 V Hydraulic pump
Alternator 24 V / 260 Amp for attachment 4 variable flow axial piston pumps
Engine idling automatic engine idling and travel drive
Automatic engine shut off engine self-controlled shut off 3 min. Max. flow 4 x 512 l/min. / 4 x 135 gpm
protection Max. pressure 350 bar / 5,076 psi
Water cooler cooler with temperature controlled fans driven via for swing drive 1 reversible swashplate pump, closed-loop circuit
hydraulic piston motor Max. flow 1 x 640 l/min. / 1 x 169 gpm
Max. pressure 350 bar / 5,076 psi
Pump management electronically controlled pressure, flow and power
management with oil flow optimisation
Hydraulic tank capacity 1,800 l / 475 gal
Electric Motor (optional) Hydraulic system capacity 3,400 l / 900 gal
1 electric motor Hydraulic oil filter 1 high pressure safety filter after each high pressure
Power output 850 kW / 1,139 HP pump + extra-fine filtration of entire return flow with
Type 3 phase AC squirrel cage motor integrated by-pass filtration (15 / 5 μm) + dedicated
Voltage 6,000 V, other voltage on request leak-oil filtration
Frequency 50 Hz (or 60 Hz) Hydraulic oil cooler cooler with temperature controlled fans driven via
Revolutions 1,500 rpm or 1,800 rpm hydraulic piston motor
Motor cooling integrated air-to-air heat exchanger
Starting method inrush current limited to 2,2 full load current
Electric System
Electric isolation easy accessible battery isolations
Electro-Hydraulic Controls Working lights high brightness halogen lights:
Servo circuit independent, electric over hydraulic proportional – 2 on working attachment with grid protection
controls of each function – 1 on RHS of uppercarriage with grid protection
Emergency control via accumulator for all attachment functions with – 1 on LHS of uppercarriage
stopped engine – LED lights as option
Power distribution via monoblock control valves with integrated primary other:
relief valves and flanged on secondary valves for – 4 pieces 24 V outlets
travel, 4 independent circuits – halogen access lights with timer 5 min.
Flow summation attachment and travel drive (LED as option)
Control functions – LED service lights with timer 20 min.
Attachment and swing proportional via joystick levers Emergency stop switches at ground level, in hydraulic compartment, in engine
Travel proportional via foot pedals compartment and in operator cab
Electrical wiring heavy duty execution in IP 65 standard for operating
conditions of – 50 °C to 100 °C / – 58 °F to 212 °F
16 R 9200
Uppercarriage Service Flap
Design torque resistant designed upper frame in box-type Design manually actuated service flap, easily accessible from
construction for superior strength and durability ground level to allow:
Attachment mounting parallel longitudinal main girders in box section – fuel fast refill
construction – engine oil quick change
Machine access hydraulically operated 45° access stair, full controlled – attachment / swing ring bearing grease barrel
descent, in case of emergency stop additional emer- refilling via grease filter
gency ladder fitted near the cab – 2 x swing gear oil refill
– 2 x swing gear oil draining
– splitterbox oil change
other coupler type on request
Operator’s Cab
Design resiliently mounted, sound insulated, large windows
for all around visibility, integrated falling object protec-
tion FOPS Central Lubrication System
Operator’s seat suspended pneumatic seat, body-contoured with shock Type single-line lubrication system, for the entire attach-
absorber, adjustable to operator’s weight, seat heating, ment / swing ring bearing and teeth
additional “retractable passenger / trainer seat” Grease pumps hydraulic grease pump for the attachment / swing ring
Cabin windows tinted armored glass for front window and right-hand bearing, electric grease pump for the swing ring teeth
side windows, all other windows in tinted safety glass, Capacity 200 l / 53 gal bulk container for attachment / swing
windshield-washer system 30 l / 8 gal watertank, sun ring bearing, separated 15 l / 4.0 gal bulk container
louvers on all windows in heavy duty design optional for swing ring teeth
and frontguard optional Refill via the service flap for both containers, fill line with
Heating system / heavy duty, fully automatic, high output air conditioner grease filters
Air conditioning and heater unit, contains fluorinated greenhouse Monitoring via a specific Liebherr control module with data
gases HFC 134a with a Global Warming Potential memory
(GWP) of 1430, the AC circuit contains 3.6 kg / 7.9 lb
of HFC-134 representing an equivalent of 5.1 tonnes /
5.6 tons of CO2, the 2nd AC circuit (optional) contains
2.2 kg / 4.8 lb of HFC-134 representing an equivalent
of 3.1 tonnes / 3.4 tons of CO 2 Attachment
Cabin pressurization ventilation with filter Design box-type structure with large steel castings in all high-
Controls joystick levers integrated into armrest of seat stress areas
Monitoring via LCD-display, data memory Stick wear protection underneath lower beam plate
Rear vision system camera installation on counterweight and right-hand Hydraulic cylinder Liebherr design,
side of the uppercarriage, displayed on the monitoring electronically controlled end-cushioning
display Hydraulic connections pipes and hoses equipped with SAE split-flange
Noise level (ISO 6396) 74 dB(A) connections
Pivots bucket-to-stick O-ring sealed and completely enclosed
Pivots bucket-to-link
Kinematics Liebherr parallel face shovel attachment geometry,
electronic controlled end-cushioning
Undercarriage
Design 3-piece undercarriage, box-type structures for center
piece and side frames, stress relieved
Hydraulic motor 1 axial piston motor per side frame
Travel gear Liebherr planetery reduction gear
Travel speed 0 – 2.8 km/h / 0 – 1.7 mph
Parking brake hydraulically actuated, maintenance-free, multi-disc
brakes for each travel motor
Track components B 11, maintenance-free, forged double grouser pad
Track rollers / Carrier rollers 8 / 2 per side frame
Track tensioner hydraulic and grease tensioner
Transport undercarriage side frames are removable
R 9200 17
Dimensions
A1
A F D
P W H
C K
Q
R0280
N L
S U
B Z
G V
X
mm / ft in mm / ft in
A 5,508 / 18'1" N 800 / 2' 7"
A1 6,622 / 21'9" P 6,930 / 22' 9"
B 5,502 / 18' Q 832 / 2' 9"
C 2,031 / 6'8" S 4,702 / 15' 5"
D 5,800 / 19' U 7,600 / 24'11"
F 2,158 / 7'1" V 12,600 / 41' 4"
G 5,922 / 19'5" W 7,035 / 23' 1"
H 6,930 / 22'9" X 16,775 / 55'
K 2,180 / 7'2" Z 9,599 / 31' 6"
L 5,862 / 19'3" OEL Operator’s eye level 5,980 / 19' 7"
A1
A F D
P H
W
C K
Q
R0281
N L
S U
B Z
G V
X
mm / ft in mm / ft in
A 5,508 / 18'1" N 800 / 2' 7"
A1 6,622 / 21'9" P 6,930 / 22' 9"
B 5,502 / 18' Q 832 / 2' 9"
C 2,031 / 6'8" S 4,702 / 15' 5"
D 5,800 / 19' U 7,600 / 24'11"
F 2,158 / 7'1" V 16,420 / 53'10"
G 5,922 / 19'5" W 6,460 / 21' 2"
H 6,930 / 22'9" X 18,600 / 61'
K 2,180 / 7'2" Z 9,599 / 31' 6"
L 5,862 / 19'3" OEL Operator’s eye level 5,980 / 19' 7"
18 R 9200
Backhoe Attachment
with Mono Boom 8.50 m / 27'9"
ft m
16
R0282 Digging Envelope
50 Stick length 3.80 m / 12' 5"
45 14 Max. digging depth 8.29 m / 27' 2"
Max. reach at ground level 14.82 m / 48' 7"
40 12 Max. dumping height 9.71 m / 31'10"
R 3000
35 Max. teeth height 14.03 m / 46'
10
30
Max. digging force (ISO 6015) 650 kN / 146,126 lbf
25 8
Max. breakout force (ISO 6015) 740 kN / 166,359 lbf
20 6
15
4
10 Operating Weight and Ground Pressure
2
5 The operating weight includes the basic machine with backhoe attachment and backhoe
0 0 bucket 12.50 m3 / 16.35 yd3.
-5 Pad width mm / ft in 800 / 2’6”
-2
-10 Weight tonnes/tons 205 / 225
-4 Ground pressure* kg/cm2 / psi 1.98 / 28.16
-15
* according to ISO 16754
-20 -6
-25 -8
-30
18 16 14 12 10 8 6 4 2 0m
60 55 50 45 40 35 30 25 20 15 10 5 0 ft
Backhoe Buckets
For materials class according to VOB, Section C, DIN 18300 <5 <5 <5 5–6 5–6 5–6 7–8 7–8 7–8
Typical operation according to VOB Section C, DIN 18300 GP GP GP HD HD HD XHD XHD XHD
Capacity ISO 7451 m3 15.50 14.60 13.70 13.70 12.50 11.40 11.80 10.50 10.00
yd3 20.30 19.10 17.90 17.90 16.40 14.90 15.40 13.70 13.08
Suitable for material up to a specific weight of t/m3 1.45 1.55 1.65 1.60 1.80 2.00 1.80 2.10 2.25
lb/yd3 2,445 2,614 2,782 2,698 3,035 3,373 3,035 3,541 3,794
Cutting width mm 3,450 3,250 3,100 3,100 2,800 2,550 2,650 2,350 2,250
ft in 11'3" 10'7" 10'2" 10'2" 9'2" 8'4" 8'8" 7'8" 7'4"
Weight kg 11,900 11,700 11,500 12,500 12,000 11,400 13,000 12,450 12,000
lb 26,235 25,794 25,353 27,558 26,455 25,133 28,660 27,448 26,455
GP: Loading bucket with Liebherr Z110 teeth
HD: Heavy-duty bucket with Liebherr Z120 teeth
XHD: Heavy-duty rock bucket with Liebherr Z120 teeth
R 9200 19
Face Shovel Attachment
with Shovel Boom 6.00 m / 19'7"
ft m R0283 Digging Envelope

14 Stick length 4.37 m / 14'4"
45
Max. reach at ground level 12.60 m / 41'4"
R 3245 Max. dumping height 8.37 m / 27'5"
40 12
Max. crowd length 4.18 m / 13'8"
35 Bucket opening width T 2.17 m / 7'1"
10
30
Crowd force at ground level (ISO 6015) 868 kN / 195,134 lbf
8 2175
25 Max. crowd force (ISO 6015) 924 kN / 207,723 lbf
Max. breakout force (ISO 6015) 750 kN / 168,606 lbf
20 6
15
4
10 Operating Weight and Ground Pressure
2
5 The operating weight includes the basic machine with shovel attachment and bucket
12.50 m3 / 16.35 yd3.
0 0
4180 Pad width mm / ft in 800 / 2’6”
-5 Weight tonnes / tons 210 / 231
-2
-10
Ground pressure* kg/cm2 / psi 2.02 / 28.73
-4
* according to ISO 16754
14 12 10 8 6 4 2 0m
45 40 35 30 25 20 15 10 5 0 ft
Face Shovel Buckets

For materials class according to VOB, Section C, DIN 18300 <5 <5 5–6 5–6 5–6 7–8 7–8 7–8
Typical operation according to VOB Section C, DIN 18300 GP GP HD HD HD XHD XHD XHD
Capacity ISO 7451 m3 14.00 13.50 13.50 12.50 11.50 12.50 11.50 10.00
yd3 18.30 17.70 17.70 16.40 15.00 16.40 15.00 13.10
Suitable for material up to a specific weight of t/m3 1.6 1.7 1.6 1.8 2.0 1.7 1.9 2.2
lb/yd3 2,698 2,867 2,698 3,035 3,373 2,867 3,204 3,710
Cutting width mm 3,050 3,050 3,050 3,050 3,050 3,050 3,050 3,050
ft in 10' 10' 10' 10' 10' 10' 10' 10'
Weight kg 17,600 17,000 18,400 17,500 17,000 18,750 18,150 17,500
lb 38,801 37,479 40,565 38,581 37,479 41,337 40,014 38,581
GP: Loading bucket with Liebherr Z110 teeth
HD: Heavy-duty bucket with Liebherr Z120 teeth
XHD: Heavy-duty rock bucket with Liebherr Z120 teeth
20 R 9200
Optional Equipment
Undercarriage Operator’s Cab

HD travel gear seal for muddy application Front protective grid
Undercarriage bottom cover Double A/C system
External louvers on back and side cab windows
Operator comfort package
Sliding hatch window on door
Uppercarriage
LED lighting
Multiflo Hydrau-Flo® for fast fueling system
Wiggins / Banlaw counter plugs for fuel / lube trucks Attachment
Rock protection for swing gear Piston rod guard for the bucket cylinders
Steel grease lines on swing ring Piston rod guard for hoist cylinders
Semi-automatic swing brake with joystick control
Swing ring scrapers
Hydraulic-powered grease refill station
Specific Solutions
Arctic package (– 20 °C / – 4 °F, – 35 °C / – 31 °F, – 50 °C / – 58 °F)
Sound attenuation package
Hydraulic System High altitude kit
Bio-degradable hydraulic oil Hammer / shear / grapple attachments
Oil cooler inlet screens Arrangement for object handling operation
Fine filtration bypass (2 μm)
Safety
Engine Automatic fire suppression system
Fuel consumption optimized engine version
Cold application start aid
R 9200 21
The Liebherr Group of Companies
All illustrations and data may differ from standard equipment. Subject to change without notice. All indicated loads are based in accordance with ISO 9248.
Wide Product Range State-of-the-art Technology
The Liebherr Group is one of the largest construction equipment To provide consistent, top quality products, Liebherr attaches
manufacturers in the world. Liebherr’s high-value products and great importance to each product area, its components and
services enjoy a high reputation in many other fields. The wide core technologies. Important modules and components are
range includes domestic appliances, aerospace and trans- developed and manufactured in-house, for instance the entire
portation systems, machine tools and maritime cranes. drive and control technology for construction equipment.
Exceptional Customer Benefit Worldwide and Independent

Every product line provides a complete range of models in many Hans Liebherr founded the Liebherr family company in 1949.
different versions. With both their technical excellence and Since that time, the enterprise has steadily grown to a group of
acknowledged quality, Liebherr products offer a maximum of more than 130 companies with over 41,000 employees located
customer benefits in practical applications. on all continents. The corporate headquarters of the Group is
Liebherr-International AG in Bulle, Switzerland. The Liebherr
family is the sole owner of the company.
www.liebherr.com
Printed in Germany by Eberl RG-BK LEC/SP 11657947-1-02.17_enGB-US
Liebherr-Mining Equipment Colmar SAS

49 rue Frédéric Hartmann, FR-68025 Colmar Cedex
S +33 369 49 20 00, Fax +33 369 49 23 18
www.liebherr.com, E-Mail: [email protected]
www.facebook.com/LiebherrMining
2 Safety instructions
Working with the machine holds dangers to which you as the owner, machine oper-
ator or maintenance expert could be exposed. If you regularly read and note the safe-
ty information, however, you can prevent danger and accidents. This is particularly
true for those who are only occasionally in contact with the machine, eg. for mainte-
nance work. The following information comprises safety regulations which, if fol-
lowed conscientiously, will contribute to your safety and that of other persons, as well
as avoiding damage to the machine.
Following these precautions does not release you from the responsibility to take note
of safety regulations which apply on site or of guidelines given by legal bodies or pro-
fessional associations.
For EU countries, guideline 2009 / 104 / EC contains the minimum required safety
information applicable to the owner.
2.1 Meaning of the symbols in this manual
Work processes and actions that could cause danger are accompanied by safety in-
formations in these operating instructions. These safety informations describe vari-
ous dangers which are emphasized by the terms Danger, Caution and Note.
These terms are identified by symbols in the operating instructions and have the fol-
lowing meaning:
Danger!
Warning relating to a danger that carries with it a high risk of death or serious injury
if the appropriate preventative measures are not taken.
Caution!
Warning relating to dangers that could result in physical injury and/or damage to the
machine if the appropriate preventative measures are not taken.
Note!
This symbol identifies user tips and operating and maintenance procedures whose
use will guarantee a high degree of user-friendliness and longevity to the machine
or which will considerably simplify working procedures.
– This symbol identifies a listing.

• This symbol identifies a sub-listing.

 This symbol signifies the following: “The precondition must be fulfilled”.
The machine operator or the maintenance personnel must first fulfil the precondi-
tion described, i e. the machine must be brought into a particular work position in
order to be able to carry out the actions subsequently described.
 This symbol identifies an action.
The machine operator or the maintenance personnel should be active at this lo-
cation and carry out the action described.
 This symbol means “Carry out an activity".

R9200 / 11695477 2-1
MJFCIFSS
Safety instructions Operating manual
Use in accordance with the regulations
If the machine operator or maintenance personnel have carried out the activities
described in an action, the result of this action will be described here.
Following these notes does not relieve you of responsibility for following ad-
ditional rules and guidelines!
Additional points that should be noted are:
– the safety regulations which apply on site,
– statutory road traffic regulations,
– the guidelines provided by professional associations.
2.2 Use in accordance with the regulations
– The hydraulic excavator is a machine with work equipment (eg. hoe type bucket,
grab, bucket attachment) designed to detach, lift, transport and shake off earth,
stones and other materials, while the transportation of the load itself usually takes
place without moving the machine. Moving the machine when it is carrying a load
must be carried out while observing the appropriate safety measures (see section
"Notes for safe working").
– Machines used for hoisting are subject to specific conditions and must be fitted
with the stipulated safety devices (see section “Hoisting work”).
– Machines used underground (deep mining and tunnel construction) must be
equipped with exhaust gas reducing equipment (e.g. diesel particle filter). Always
comply with the statutory regulations applicable at the location of operation.
– Special tasks require special attachments and possibly also special safety devic-
es. This equipment may only be attached to the machine and used with the ex-
plicit consent of and according to the instructions of the manufacturer of the basic
machine.
– Any other use, in particular transporting persons or working in explosive atmos-
pheres or contaminated environments is not deemed to be in accordance with
regulations. The manufacturer is not liable for any damage resulting from this ac-
tion. The user is solely responsible for the risk incurred.
– Observing the operating instructions and the inspection / maintenance instruc-
tions is also deemed to be appropriate use in accordance with regulations.
2.3 Safety Instructions
General safety instructions

– Please familiarize yourself with the operating instructions before starting up the
machine.
– Ensure that you have obtained, read and understood any additional instructions
relating to special accessories for the machine.
– Only specifically authorized persons may operate, maintain or repair the machine.
The legal minimum age is to be adhered to.
– Only employ trained or appropriately instructed personnel. Clearly establish
which personnel are responsible for operating, setting up, maintaining and repair-
ing the machine. Give personnel the power to refuse to carry out unsafe instruc-

2-2 R9200 / 11695477
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Operating manual Safety instructions
Safety Instructions
tions. This also applies in relation to traffic regulations.

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

R9200 / 11695477 2-3
MJFCIFSS
Safety Instructions
Avoidance of crushing and burns

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

– Switch off the engine when refuelling.
– Do not smoke or use a naked flame when refilling tanks and working near or
charging the batteries.
– Always start the engine in accordance with the operating instructions.
– Check the electrical system regularly.
– Have all faults, such as loose connections, blown fuses and lamps and clogged
or abraded cables rectified by authorized personnel.
– Do not transport any combustible liquids anywhere on the machine other than in
the tanks provided for this purpose.
– Check all lines, hoses and screwed joints regularly for leakage and damage.
– Rectify leakages immediately and replace damaged components.
– Oil spraying out of leaking areas can easily cause a fire.
– Ensure that all holds and shields are correctly installed to guard against vibration,
abrasion and heat accumulation.
– Do not use cold start materials (ether) in the vicinity of heat sources, naked flames
or in inadequately ventilated areas.
– Do not use any starting aids containing flammable material to start diesel engines
with preheating or flame glow systems. There is a risk of EXPLOSION.
– Familiarize yourself with the location and operation of fire extinguishers on the
machine and with local fire warning and fire abatement options.
– It is possible to install an extinguisher into the driver’s cab.
– All doors, covers and boxes locks have to be unlocked before operation in order
to facilitate firefighting in case of fire. Only electrical boxes from and over 50V

2-4 R9200 / 11695477
MJFCIFSS
Safety Instructions
must remain locked during operation.
Bringing the machine safely into service

– Carry out a careful inspection tour around the machine each time before starting
it.
– Ensure that no one, except an authorized person, is in the work and movement
area of the machine.
– Check the machine for loose bolts, cracks, wear, leakage and damage.
– Never attempt to operate a damaged machine.
– Ensure that any damage is immediately rectified.
– Ensure that all hoods and covers are closed, but that locks are unlocked, to facil-
itate the fight against fire in case of.
– Ensure that all warning signs are present.
– Keep windows and interior and exterior mirrors clean. Secure doors and windows
against unintended movement.
– Ensure that no one is working on or under the machine and warn personnel in the
vicinity of the machine that it is about to start by sounding the horn.
Safely getting up
– Proceed with the same precautions to climb up or down onto the machine, as to
install yourself at the operator’s seat.
– When getting up or down, position the machine on even, horizontal ground. The
upper structure should be positioned with the undercarriage in such a way that
the steps and ladders are aligned with each other.
– Ensure that steps, ladders and hand-rails (grips) are in good condition. In particu-
lar, you should ensure that they are free of dirt, oil, ice and snow.
NOTE: To ensure that the doors open properly in all weather conditions, the door
seals must be dusted with talc or silicon at least every two months or more often
if required. The door hinges and locks should be greased regularly.
– If you are able to reach the door handle with your free hand, open the doors be-
fore you climb any higher. External influences, such as wind, can make it more
difficult to open doors. Because of this, always use your hand for control when
opening doors. Ensure that the door is latched open to prevent it slamming open
and shut.
– In case of bad weather conditions, be particularly vigilant to realise the climbing
and descent from the cab with the best safety conditions, and do or give the in-
structions to the execution of prior preparations to be accomplished, as enunciat-
ed above, in order to displace yourself safely.
– Be particularly vigilant with those prerequisites conditions.
– For cab with a side door:

• Now continue to climb up, still using the three-point support and sit down in the
operator’s seat as soon as you enter the cab.
• Fasten the safety belt (if available), unlock the door, using the planned lever,
and close it immediately using the door handle, before tilting down the safety
lever, and start the machine.
• If you wish to work with the door open, it is necessary to fasten your safety belt.
If unavailable, let it be installed before working with the door open.
– For cab with a rear door:

R9200 / 11695477 2-5
MJFCIFSS
Safety Instructions
• Now continue to climb up, still using the three-point support and close the door
as soon as you enter the cab.
• Sit down in the operator’s seat and fasten the safety belt (if available) before tilt-
ing down the safety lever, and start the machine.
Adjusting the operator’s standing position

– Before starting the machine, adjust the seat, mirrors, armrests and operator’s
controls in such a way that you are able to work comfortably and safely.
– Acoustic insulation devices on the machine must be set to the insulation position
throughout operation.
Protection from vibration - seat adjusting

– Keep the seat in good condition and adjust it as follows:
• The seat and its damping action should be adjusted depending on the weight
and height of the operator.
• Check the seat’s damping action and adjustment mechanisms regularly and en-
sure that these seat characteristics remain as per the seat manufacturer’s in-
structions.
Utilisation in confined spaces

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

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

– Only stop the machine on level, firm ground.

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

2-6 R9200 / 11695477
MJFCIFSS
Safety Instructions
– Lower the attachment and anchor the grab lightly in the ground.
– Position every control lever into neutral position and apply the travel and swing
brakes.
– Stop the engine in accordance with the operating instructions and tilt the safety
lever up before leaving the cab.
– Lock the machine, included hoods and compartments, remove every keys and
secure the machine against unpermitted use and vandalism.
Safely getting down

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

– Before you start working, acquaint yourself with the special features of the job site
and any special precautions and warning signals. Examples of particular work en-
vironments would be on-site or traffic obstructions, the load-carrying capacity of
the ground and any requirements to make the job site safe from public use.
– Always maintain a safe distance from overhangs, edges, slopes and unsafe
ground.
– Be particularly careful in conditions of reduced visibility and changeable ground
conditions.
– Familiarize yourself with the location of power lines on the job site and take par-
ticular care when working near them. If necessary, inform the responsible author-
ities.
– Maintain a safe distance from electrical aerial lines. Do not allow the attachment
to come near cables when working near electrical aerial lines. Risk of fatality! In-
form yourself about required safety distances.
– The following actions must be carried out in the event of any transfer of electricity:
• do not move the machine or its attachment,
• do not leave the driver’s cab,
• warn any personnel in the vicinity not to come close to the excavator and
not to touch it,
• instruct or initiate that someone turns off the voltage.

• move the machine, if possible, from the danger zone to a sufficient distance,
• Do not leave the machine until you are absolutely sure that voltage in the line,
which had been touched or damaged, has been turned off !
– Before moving the machine, always ensure that any attachments are safely se-
cured.
– When driving onto public roads, paths and squares, observe current traffic regu-
lations and if necessary, ensure that the machine has been made safe as per reg-
ulations beforehand.

R9200 / 11695477 2-7
MJFCIFSS
Safety Instructions
– Always turn on the lights in conditions of poor visibility or darkness.

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

2-8 R9200 / 11695477
MJFCIFSS
Safety Instructions
If necessary remove the lift ring.

– In case of a thunderstorm:
• lower the attachment to the ground and if possible anchor the digging tool into
the soil.
• leave the cab and move away from the machine before the storm breaks out.
Otherwise, you must stop the excavator, turn off the radio and keep inside the
closed cab until the end of the storm.
– Auxiliary control units can have various functions. Always check their functions
when starting up the machine.
– Stop the swinging motion of the uppercarriage when lowering the attachment into
a ditch without striking the attachment on the ditch walls.
– Inspect the machine for damage if the attachment has been swung into a wall or
any other obstacles.
– Applications in which the attachment is to be used to strike the material being ex-
tracted are not permitted, even when working in a longitudinal direction.
– Repeated strikes against an object leads to damage to the steel structures and
machine components.
– Please refer to your Liebherr dealer if special teeth for heavy-duty or special ap-
plications are required.
– Do not attach too large bucket or bucket with side cutters or that are during oper-
ations with rocky material. This would prolong the work cycles and may lead to
damage to the bucket as well as further machine components.
– With the 2x45° offset articulation, the offset position may only be employed if the
working tool or the attachment does not touch the material.
– Operation of the offset articulation to drill into the material is not permitted.
– Do not lift the machine during operation. Should this happen, lower the machine
slowly back to the ground.
– Do not let the machine fall heavily on the ground and do not hold it back with the
hydraulics. This would damage the machine.
– During operation with the attachment it is forbidden to raise the machine with the
dozing blade (e.g. carving at the ceiling when tunnelling).
– Do not dig under the undercarriage. Take all necessary measures to prevent
ground collapse under the machine.
– The operation of Liebherr Mining machines in the following Mining applications is
not approved or condoned by Liebherr:
• Batter pulling (also known as Scaling), without exception.
• Double benching (also known as Split benching or Double flitching) when the
material is un-blasted and non-fragmented material which requires the boom
down (rod side) pressure to exceed 50 bar.
The use of these Mining methods will result in increased fatigue levels to steel
structures and components of the respective Liebherr Mining Machine and
therefore will significantly reduce the expected lifetime of structures and/or com-
ponents.
Safe use of a hydraulic hammer or a hydraulic ripper

– According to the severity of the application, the use of a hydraulic hammer or a
hydraulic ripper can result in vibrations, shocks or stresses which are higher than
in normal use. It may reduce the expected lifetime of structures and/or compo-
nents.
– The hydraulic hammer or the hydraulic ripper must be selected with particular
care. When using a hydraulic hammer or a hydraulic ripper not permitted by Lieb-
herr, warranty for steel structures and machine components will be ceased.

R9200 / 11695477 2-9
MJFCIFSS
Safety Instructions
– Before beginning breaking tasks, position the machine on firm and level ground.
– Use a hydraulic hammer or a hydraulic ripper designed exclusively for breaking
stone, concrete and other breakable materials.
– Only operate the hydraulic hammer or the hydraulic ripper in the longitudinal di-
rection of the machine and with the windshield closed or with a front protective
grid.
– Ensure during hammer or ripper operation that no cylinder is entirely extended or
retracted and that the stick is not in the vertical position.
– In order to avoid damages to the machine, try not to break stone or concrete while
performing retraction and extension motions of the hydraulic hammer.
– Do not apply the hydraulic hammer uninterrupted for more than 15 seconds at a
time to the same place. Change the breaking point. Too long uninterrupted oper-
ation of the hydraulic hammer leads to an unnecessary overheating of the hydrau-
lic oil.
– Do not use the drop force of the hydraulic hammer or of the hydraulic ripper to
break stone or other materials. Do not move obstacles with the hydraulic hammer.
Misuse of this nature would damage both the hammer and the machine.
– Do not use the hydraulic hammer or the hydraulic ripper to lift objects.
– Before beginning breaking tasks, the pressure of the dampening accumulator of
the hydraulic ripper must be adjusted depending on the nature of the ground and
the excavator model.
Safe use of a ripper

– Rippers are generally used in applications where the use of a bucket is not effi-
cient to break out rocks. Thus, these applications are more severe than in normal
use.
– According to the severity of the application, the use of a ripper can result in vibra-
tions, shocks or stresses which are higher than in normal use. It may reduce the
expected lifetime of structures and/or components.
– Special hydraulic devices can be necessary. Contact the Liebherr customer ser-
vice.
– The ripper must be selected with particular care. When using a ripper not permit-
ted by Liebherr, warranty for steel structures and machine components will be
ceased.
– Do not use the ripper to lift objects.
Safe use when loading and unloading (particularly when

loading and unloading wood)
– According to use, it can be necessary when working with a grab to move with the
attachment raised and the load lifted up; this applies, for example, when loading
and unloading wood.
– Here, the centre of gravity of the machine will be displaced upwards in the vertical
direction. The driving characteristics of the machine will thus be influenced per-
sistently, e.g. through reduction of the dynamic stability.
The following instructions are therefore to be observed at all times:
• Adjust vehicle handling to suit the altered machine characteristics and environ-
mental conditions.
• Reduce your speed to prevent the need for sudden braking and steering ma-
noeuvres.
• Avoid sudden speed changes, such as braking, accelerating and changing di-

2 - 10 R9200 / 11695477
MJFCIFSS
Safety Instructions
rection.
• Only rotate the uppercarriage when the undercarriage is stationary.
• Only rotate the uppercarriage after you have picked up the load.
• Only move the machine when you have picked up and lifted the load and rotat-
ed the upper structure to the driving position.
• There is a danger of possible swinging movement and dropping of the load
when the attachment is raised.
• A protective grid (FOPS) in accordance with ISO 10262 must be attached to the
cab.
• A protective roof (FOPS) in accordance with ISO 10262 must be attached if
there is a risk of objects falling from above.
• Only the maximum permissible load may be taken up using the grab.
– NOTE: The weight of absorbent materials, such as logs, is dependent on length,
diameter and specific weight. The influencing variables present in a natural prod-
uct, such as moisture, must be noted.
– Working procedures when using machines with grabs require the machine oper-
ator to receive special instruction and training.
– Use as part of the work process is only permitted when the machine operator has
sufficient training and practical experience.
Safe use of machines with tower elevation

– Due to the tower elevation, the centre of gravity of the machine will be displaced
upwards in the vertical direction. The driving and work characteristics of the ma-
chine will thus be influenced persistently, e.g. through reduction of the dynamic
stability.
– Due to the heightened centre of gravity, the machine must be aligned horizontally
before use. In horizontal alignment, the centre of gravity of the uppercarriage is
over the centre of the undercarriage, which reduces the risk of tilting.
– The machine can still sway and tilt despite being aligned!
When moving the machine:
• Rotate the uppercarriage parallel to the undercarriage (transport position).
• Draw the attachment as close as possible to the machine.
• Only at this point may the support feet be retracted and the machine moved.
• Moving with loads is not permitted.
• Check the terrain to be covered to ensure that the ground is solid and even. Pot-
holes and uneven surfaces jeopardize the stability of the machine.
• Adjust vehicle handling to suit the altered machine characteristics (high centre
of gravity) and environmental conditions.
noeuvres.
rection.
• Ascending gradients and obstacles may only be approached in the longitudinal
direction in order to prevent unacceptable banking of the machine.
• Special care should be taken when driving through narrow passages - drive
slowly!
When loading and unloading:
• The machine must be supported and aligned horizontally before moving (swing)
the uppercarriage out of the transport position.
• It is imperative that you check the contact surface of the support (load carrying
capacity of the substrate). A support subsiding would have disastrous conse-
quences!
• Carry out all movements with increased care.

R9200 / 11695477 2 - 11
MJFCIFSS
Safety Instructions
• To slew the load, move the attachment as close as possible to the machine
(Caution! swinging grab) and hold the load close to the undercarriage and
above the substrate.
• Avoid braking or accelerating the attachment or uppercarriage abruptly.
• Do not lift any loads which are heavier than those given in the load chart.
Protection from vibration

– Vibrational loads on mobile building machinery are mainly the result of the type
and method of use. The following parameters in particular are decisive influences:
• Terrain conditions: Uneven areas and potholes;
• Operational techniques: Speed, steering, brakes, controlling the machine’s
control elements when driving and working.
– To a large extent, the machine operator determines the vibrational loads since he
selects the speed, gearbox ratio, working method and route himself.
This means that there is a wide range of different vibrational loads for the same
machine type.
Whole-body vibrational load for the machine operator can be reduced if the following
recommendations are observed:
– Select suitable machines, attachment parts and auxiliary devices for each part of
the job.
– Use a machine that has a suitable seat (i.e. for earth-moving machinery such as
hydraulic excavators, this should be a seat which corresponds with EN ISO
7096).
structions.
– Check the maintenance status of the machine, particularly with respect to: tyre
pressure, brakes, steering, mechanical connections etc.
– Do not steer, brake, accelerate, shift gears, move or load the machine’s attach-
ment jerkily.
– To reduce vibrational load, adjust the machine speed to suit the route as follows:
• Reduce speed when driving on difficult terrain;
• Drive around obstacles and avoid driving on very difficult terrain.
– Keep the terrain on which the machine is working and driving in good condition:
• Remove large stones and obstacles;
• Fill in ruts and holes;
• Have machines ready to prepare and maintain suitable ground conditions and
calculate in sufficient time to carry out any work required.
– Drive longer distances (e.g. on public roads) at an appropriate (medium) speed.
– Use special auxiliary systems (if available) which reduce vibration for machines
that are driven frequently.
If such auxiliary systems are not available, regulate speed to avoid "oscillating"
the machine.
Towing the machine safely

– Always follow the correct procedure if applicable.
– The machine may only be towed in exceptional circumstances, e.g. in order to
move the machine away from an area where it is at risk.
– Before towing, check all attachments and towing devices for safety and stability.

2 - 12 R9200 / 11695477
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Safety Instructions
– Towing devices such as bars, cables or ropes must have adequate tensile
strength and should be secured around the undercarriage tower or the towing
hook provided on the undercarriage.
Any damage or accidents which occur while towing the machine are not covered
by the manufacturer’s guarantee.
– Ensure that there is no one in the vicinity of the towing devices when towing.
– Stretch safely and hold the towing devices. Avoid kinks on cables or ropes.
– When towing, maintain the correct transport position, permitted speed and route,
and avoid lurching.
– After towing, return the machine to correct operational status.
– When restarting the machine, be sure only to proceed in accordance with the op-
erating instructions.
Attaching and removing attachment parts safely

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

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

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Servicing the machine safely
Transporting the machine safely

– Due to transport restrictions, use only suitable means of transport and lifting de-
vices with sufficient load-carrying capacity.
– Park the machine on a flat surface and wedge the crawler or wheels securely.
– If required, detach a part of the machine’s working attachment during transporta-
tion.
– The ramp used to drive the machine up onto the flatbed trailer should not exceed
an inclination of the angle value indicated in the "Technical data" section of this
manual (machine must be able to walk up unaided) and should have a wooden
cover to prevent sliding back.
– The undercarriage should be swept clean, i.e. before driving up the ramp, clean
any snow, ice and mud from the crawler / wheels of the machine.
– Align the machine precisely with the loading ramp.
– Attach the hand levers for fine-tune driving (crawler excavator) onto the travel
pedals.
– Ensure that a spotter gives the machine operator the required signal.
– Prepare the placing block to ensure against rolling back when the machine is driv-
ing up onto the flatbed.
– Tilt the equipment up and drive up the loading ramp. While doing this, always hold
the equipment securely over the loading area, drive very carefully up the ramp
and onto the transportation vehicle.
– Rotate the upper structure carefully to the rear and lower the equipment. Due to
restrictions during transport on hoe equipment, tilt the arm in and dismantle the
bucket during transportation.
– After loading the machine onto the flatbed trailer, the upper structure must be se-
cured facing the undercarriage using the stop bolts (only A devices).
– Secure the undercarriage and the remaining individual parts using chains and
blocks to prevent slipping.
– Before you leave the machine, reduce pressure on all pressure lines, remove the
ignition key and tilt up the safety lever.
– Lock all cab and panel doors.
– Before transportation, find out all details about the route to be travelled, particu-
larly as they relate to width, height and weight restrictions.
– Pay particular attention when driving under electrical lines and bridges and
through tunnels.
– When unloading the machine, take the same amount of care as was taken when
it was loaded. Remove all chains and blocks. Start the engine as per the operating
instructions. Drive carefully off the trailer’s loading area and down the ramp. Hold
the working equipment as securely as possible over the ground while doing this.
Have a spotter guide you.
2.4 Servicing the machine safely

– Maintenance and repair work may only be carried out by specially trained person-
nel.
– Observe statutory timetables or intervals given in the operating instructions for re-
peat tests / inspections. It is imperative that a suitably equipped workshop is avail-
able in order to carry out maintenance work.

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– The inspection and maintenance schedule given at the end of these operating in-
structions defines precisely who is required / permitted to carry out what work.
Jobs listed as daily / weekly work may be carried out by the machine's driver or
maintenance personnel when they have received appropriate instruction.
The remaining work may only be carried out by specialist personnel with appro-
priate training.
– Replacement parts must correspond to the technical requirements determined by
the manufacturer. Original replacement parts are always guaranteed to meet
these criteria.
– Always wear safe work clothes when carrying out maintenance work. Avoid the
wearing of rings, wrist watches, ties, scarves, open jackets, baggy clothing etc...
There is a risk of injury from, for example, getting caught up or being drawn in.
Protective goggles, safety helmets, safety shoes and gloves, reflective vests and
ear protection etc. are required for specific jobs.
– Do not remain in direct proximity of the diesel engine while the diesel engine is
running.
Persons with pacemakers should not approach within 20 cm of the running diesel
engine.
Do not touch voltage-carrying parts on the electrical connection of the individual
solenoid injection pumps (Unit Pumps UP) while the diesel engine is running.
– Do not permit unauthorised persons to approach the machine during mainte-
nance work.
– Cordon off a wide maintenance area if required.
– Inform operational personnel before starting to carry out any special work and re-
pair work. Designate persons in charge of supervision.
– In the absence of any other information in the operating instructions, carry out all
maintenance work on the machine on level, firm ground with the working equip-
ment set aside and the engine switched off.
– For some machines, the only one position which enables a secured access to
every maintenance locations on the uppercarriage, is when the uppercarriage is
aligned with the undercarriage so that the sprockets locate at the back-end.
The ladder situated on the undercarriage only corresponds with the uppercar-
riage’s access when the excavator is in this configuration.
– Pull out the ignition key and shut off the main battery switch.
– Always tighten any loose screw connections during maintenance and repair work.
– The mounting bolts of the main components, of the hydraulic hoses and of the
counterweight must be replaced after every removal.
– If safety devices have to be dismantled during set-up, maintenance and repair
work, they must be immediately reinstalled and checked at the end of the work.
– When carrying out repair work, particularly when working under the machine,
hang a “Do not start” warning sign in a clearly visible position on the control panel.
Pull out the start key and shut off the main battery switch.
– Operate combustion motors and fuel operated heaters only in well ventilated ar-
eas. Before operating these units, check ventilation.
– In addition, always follow applicable local regulations.
Cleaning
– Clean oil, fuel or care products off the machine before starting maintenance or re-
pair work and pay particular attention to connections and screw fittings.
Do not use aggressive cleaning products and use lint-free cleaning cloths.
– Do not use aggressive cleaning products or steam jet devices to clean the ma-
chine for the first two months after initial set-up of the machine (or after repaint-
ing).

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– Do not use combustible liquids to clean the machine.

– Before cleaning the machine with water or steam jets (high pressure cleaner) or
other cleaning materials:
• lubricate all bearing points, bolt connections and the rim bearing to prevent wa-
ter or steam entering the bearing points.
• cover or glue shut all openings into which for safety or functional reasons water
or steam may not be permitted to enter.
Electric motors, electrical components, control boxes, plug connections and air
filters are particularly at risk.
– Ensure that the fire warning systems and fire extinguishers of the engine compart-
ment’s temperature sensor do not come into contact with hot cleaning products
during cleaning work.
The fire extinguisher could start.
– If you use a high pressure cleaner with steam or hot water to clean the machine,
observe following recommendations :
• the distance between the nozzle and the surface to be cleaned must be no low-
er than 20 inches
• the water temperature should not exceed 60°c (140°F)
• limit the water pressure to 80 bar maximum (1160 PSI)
• if you employ cleaning fluid, only use neutral cleaning agents such as custom-
ary car shampoos diluted to 2 or 3 percent maximum
– After cleaning:
• remove all covers completely.
• check all fuel, engine oil and hydraulic lines for leakage, loosened connections,
chafing and damage.
• rectify any defects found immediately.
• lubricate all bearing points, bolt connections and the rim bearing to displace any
water or cleaning products that may have entered.
Corrosion protection
– The corrosion protection of the machine must be inspected and renewed at reg-
ular intervals. For further information, refer to the Maintenance manual for corro-
sion protection.
Field of view
– Mirrors and cameras, which were possibly removed for the transport, must be in-
evitably reinstalled and correctly adjusted before the initial set-up of the machine.
– Regularly check that the interior and exterior mirrors as well as the cameras are
correctly adjusted.
– Control the surroundings, and particularly the nearness area of the machine, dur-
ing operation or when travelling.
– Mirrors are installed on the machine:
• on the left to check the left side of the machine.
• on the front to check the front side of the machine.
• on the right to check the right side of the machine.

• above the counterweight to check the rear side of the machine.
– On some machines, some mirrors may be replaced with cameras.
– At each extension, construction or change on the machine, the sight conditions
must be maintained. These conditions must otherwise be checked according to
ISO 5006.
– Mirrors and cameras must always be clean.
– Damaged mirrors and cameras must be immediately replaced.

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– The site has to be organised so that the dangers due to a restricted field of view
are minimized, particularly for machines with an operating weight which is supe-
rior to 40 tons.
Crack testing
– Even when the machine is operated carefully, there is a possibility of individual
cases of overloading occurring, which could lead to cracks or loose connections.
The machine should therefore be checked regularly for cracks, loose connections
or other visible damage to maintain operational safety.
– In order to be able to check for cracks, it is essential that the machine is kept clean
and cleaned regularly.
– The tests should be carried out in accordance with the monitoring and mainte-
nance plan:
• every 250 operating hours by the machine owner’s maintenance personnel.
• every 500 operating hours by authorised specialist personnel.
– It is advisable to carry out these tests: supported, on firm, horizontal substrate,
with the equipment in longitudinal and cross direction for variable loads. Current
accident prevention regulations must be adhered to.
– Especially check the supporting components, in particular :
• framed construction undercarriage with axle and gearbox storage, support out-
riger, lower slewing ring support with tower and slewing ring.
• framed construction uppercarriage with bearing for boom and hoist cylinder, up-
per slewing ring support, cab suspension, mounting for slewing gear and coun-
ter weight.
• framed construction components of attachments, e.g. boom, stick, quick
change adapter, digging tool and grapple.
• hydraulic cylinders, axles, steering, pins and pin connections, ascents, ladders
and mounting elements.
– The crack test should be carried out visually. If a crack is suspected, the dye pen-
etration test should be carried out as a crack test on areas which do not have
good visibility, such as the ring bearing support, in order to increase testing safety.
– Any damage found must be rectified immediately. Welding work on load-bearing
parts of the earth-moving machinery, loading devices and transport devices may
only be carried out by trained specialist personnel and only in accordance with the
accepted rules of welding engineering. In case of doubt, contact the LIEBHERR
customer support service to discuss suitable remedies.
Welding, drilling, firing and grinding work

– Any welding on structural parts (as undercarriage, uppercarriage, equipment
parts,…) may only be done by the manufacturer, or authorized official dealer. If
this rule is neglected, the warranty is voided.
– Only carry out welding, drilling, firing and grinding work on the machine with ex-
press authorization. Clean dust and combustible materials off the machine and its
surrounding areas before welding, drilling, firing or grinding.
Ensure adequate ventilation. Risk of fire or explosion.

– Before welding repairs on other parts, always disconnect the battery. Always re-
move the negative terminal first and reconnect it last.
– Nevertheless if welding repair should be done on components which may contain
inflammable gases (welded counterweight, hydraulic tank, fuel tank, …), these
components must be previously and sufficiently ventilated with pressurized air to
avoid all fire or explosion hazard
– Before welding, connect the ground cable as close as possible to the welding
point, so the welding current will not run through parts like the swing ring, rotary

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connection, gears, bushings, bearings, hinges, joints, hydraulic hoses, sockets,

rubber parts or seals.
Process materials
– When working with oils, greases and other chemical substances, observe the ap-
propriate current safety regulations for the product.
– Ensure that process materials and replacement parts are disposed of in a safe
and environmentally acceptable manner.
– Take care when handling hot process materials
(Risk of burning and scalding).
Repair work
and which have sufficient load capacity. When replacing single parts and larger
subassemblies, carefully secure them on lifting devices so that they do not pres-
ent a risk. Only use suitable and correctly functioning lifting devices and load take-
up devices with adequate load capacity.
Do not stand or work under swinging loads.
– Do not use lifting devices which are damaged or do not have sufficient load car-
rying capacity.
Wear work gloves when working with wire cables.
crane operator. This people must be in the operator’s sight or in radio contact with
him.
– When working above body height, use safe climbing devices and working plat-
forms which are appropriate for the job.
Do not use machine parts as climbing devices if they are not designed for this pur-
pose.
When working at height, wear a harness to prevent falling.
Ensure that all grips, steps, rails, platforms and ladders are free of dirt, snow and
ice.
– Pneumatic cylinders do not have to be used as handles. Open doors and covers
carefully, so that pneumatic cylinders do not hit their stops, because this could
cause mechanical damages.
– Make sure the equipment on which you will operate is securely supported before
working (e.g. replacing teeth). Prevent metal touching metal when doing this.
– For safety reasons, never open and remove a track chain unless having previous-
ly totally released the pretension of the chain tensioning unit.
– Never lay under the machine if it is raised with work equipment and has not been
securely supported with appropriate supports.
– Always jack the machine up in such a way that any weight displacement does not
jeopardize stability and prevent metal touching metal while doing this.
– Work on the suspension, brake and steering systems may only be carried out by
trained specialist personnel.

– If the machine has to be repaired on a slope, secure the crawler with chocks and
connect the upper structure to the chassis using stop bolts.
– Only personnel with special training and experience may work on hydraulic equip-
ment.
– When searching for leakage, wear protective gloves. A fine jet of liquid under
pressure can penetrate the skin.
– Do not unscrew any lines or connections before you have set aside the equip-

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ment, switched off the engine and depressurized the hydraulic system. After
switching off the engine, with the start key in contact position and with the safety
lever down into its lowest position, you must operate all pilot control devices (joy-
stick and pedals) in all directions in order to reduce the actuating and dynamic
pressures in the work circuits. You must then reduce the internal tank pressure
as described in these operating instructions.
Electrical system
Have all faults, such as loose connections, blown fuses and lamps and clogged
or abraded cables rectified by personnel.
– Only use original fuses with approved current strength.
– For machines with electrical neutral and high tension leads:
• switch the machine off immediately in the event of malfunctions in the power
supply.
– Work on the machine’s electrical equipment may only be carried out by skilled
electrical personnel or by trained personnel under the supervision of an electri-
cian in accordance with electrical regulations.
– When working on live parts, ensure that a second person is available to operate
the emergency-off or the main switch and overvoltage release. Cordon off the
working area with a red and white safety chain and a warning sign. Only use in-
sulated tools.
– When working on neutral and high tension subassemblies, after releasing the
voltage, briefly disconnect the supply cable at earth and electronic devices such
as capacitors using an earthing rod.
– First test the released parts to make sure that they are off circuit, earth them and
then disconnect them briefly. Insulate adjacent live parts.
– Disconnect the battery before working on the electrical system or carrying out any
electric arc welding on the machine.
First disconnect the negative, then the positive pole. When reconnecting, proceed
in the reverse order.
Hydraulic accumulator
– All work on the hydraulic accumulators must be carried out by trained specialist
personnel.
– Inexpert assembly and handling of hydraulic accumulators can cause serious ac-
cidents.
– Do not operate damaged hydraulic accumulators.
– Before working on a hydraulic accumulator, you must reduce the pressure in the
hydraulic system (hydraulic system including hydraulic tank), as described in
these operating instructions.
– Do not carry out welding or soldering or do any mechanical work on the hydraulic
accumulator.
The hydraulic accumulator can be damaged by heat penetration and can be

made to rupture by mechanical working. RISK OF EXPLOSION!
– Only charge the hydraulic accumulator with nitrogen. There is a RISK OF EXPLO-
SION if oxygen or air is used.
– The accumulator body can become hot during operation; there is a risk of burning.
– New hydraulic accumulators must be charged with the pressure required for the
purpose of use before installation.
– The operating data (minimum and maximum pressure) are marked permanently

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on hydraulic accumulators. Ensure that this marking remains visible.
Hydraulic lines and hoses

– It is forbidden to carry out repair work on hydraulic lines and hoses!
– All lines, hoses and bolt connections must be checked regularly for externally vis-
ible damage and any possible damage must be immediately checked for leakage.
– Never check for leaks with your bare hands, use a sheet of paper or something
else.
– Any damaged parts must be removed immediately! Spurting oil can lead to injury
and burns.
– Even with correct storage and permitted load, lines and hoses are subject to the
natural aging process. This restricts their duration of use.
• Incorrect storage, mechanical damage and unauthorized load are the most
common causes of failure.
• In relation to duration of use, current norms, regulations and guidelines pertain-
ing to lines and hoses at place of use must be adhered to.
• Use at the limit range of permissible load can shorten duration of use (e.g. high
temperatures, frequent movement cycles, extremely high pulse frequencies,
multiple shift usage).
– Lines and hoses should be replaced if the following are found during inspection:
• Damage to the outer sheath as far as the liner (e.g. chafing, cuts and cracks);
• Brittleness of the outer sheath (fracture formation in hose material);
• Deformations which do not correspond to the natural form of the line or hose,
whether in a unpressurized or pressurized state or on bends e.g. sheath sepa-
ration, blistering;
• Unsealed areas;
• Non-adherence to requirements during installation;
• Damage or deformations to the hose fittings which reduce the tightness of the
fittings or the hose / fitting connection;
• Hoses working themselves out of the fittings;
• Corrosion of the fittings which reduces function and tightness;
– When replacing lines and hoses, use only original replacement parts.
– Install and mount lines and hoses correctly. Do not mix up the connections.
– The following is to be noted when replacing lines and hoses:
• Always ensure that the lines and hoses are installed free of torsion. For high-
pressure hoses, the screws from the half-clamps or full flange must always be
attached to both hose ends and should only be tightened afterwards.
• When tightening the flange on high-pressure lines and hoses with bent fittings,
the side with the bent fitting must always be tightened first and then the side with
the straight fitting tightened afterwards.
• Any mounting clamps which are located in the centre of the hose may only be
attached and tightened subsequently.
• Check daily to ensure that all clamps, covers and protective devices are prop-
erly fastened. Doing this will prevent vibration and damage during operation.
• Install the lines and hoses in such a way that they cannot chafe on other lines,
hoses or parts.
• A minimum distance from other parts of approx. half the exterior diameter of the
hose is recommended. The distance should not, however, be less than 10 to
15 mm.
• When replacing the lines or hoses on moving parts (e.g. from the boom to the
stay), check before initial start-up that there are no chafing areas in the entire
area of movement.

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Signs on the machine
2.5 Signs on the machine
2.5.1 Introduction
The excavator comprises several types of signs:
– the safety plates provide warnings relating to dangers of accidents which could
result in serious injury or death.
– the information plates indicate specific points relating to the operation, mainte-
nance and characteristics of the machine.
– the nameplates are attached to components for which the machine serial num-
ber must be provided when ordering spare parts.
Danger!
Non-observance of safety plates can result in serious injury or death.
 Check warning plates regularly to ensure that they are complete and clearly leg-
ible.
 Replace missing or illegible safety and information plates immediately. You will
find the ordering numbers of these plates in the spare parts book of the excava-
tor.

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2.5.2 Arrangement of signs

2 - 22 R9200 / 11695477
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Fig. 2-1 Arrangement of signs on the machine
2 Typeplate LEC "CE" / "EAC" 24 Warning label

3 Typeplate LEC 25 External starting label
4 Typeplate LAM 26 Controls adhesive label
5 Typeplate LBR "CE" / "EAC" 35 Hoist fixing points
6 Typeplate LBR 36 Emergency exit label
10 Typeplate restricted area label 40 Warning label
11 Typeplate maximum charge label 44 Warning label
12 Typeplate emergency stop label 48 Warning label
20 Danger signal 54 Door-closing label
21 Label safety belt 56 Warning label
22 Label safety lever 70 Emergency ladder label
23 Warning label - hydraulic valve

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2.5.3 Explanation of signs
Plate 2: Typeplate LEC (Liebherr-Mining Equipment Colmar SAS) "CE" / "EAC"

This typeplate gives the following information:
– product identification number
– type
– construction month and year
– nominal engine power
– maximum speed
– operating mass
Plate 3: Typeplate LEC (Liebherr-Mining Equipment Colmar SAS)
– type
– construction year
– maximum speed
– operating mass
Plate 4: Typeplate LAM (Liebherr America)
– type
Plate 5: Typeplate LBR (Liebherr Brazil) "CE" / "EAC"

– type
– construction month and year
– maximum speed
– operating mass
Plate 6: Typeplate LBR (Liebherr Brazil)
– type
– construction year
– maximum speed
– operating mass

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Plate 10: Restricted area label

Indicates access restriction to the related area.
Plate 11: Maximum charge label

Indicates the maximum allowable charge on the access ladder.
Plate 12: Emergency stop label

Indicates an emergency stop.
Plate 20: Danger signal label

Indicates to stay out of the surrounding operating area in order to avoid severe injury.
Plate 21: Safety belt label

Indicates to always seat belt while operating the excavator.
Plate 22: Safety lever label

Indicates precaution to be taken before leaving the driver seat.

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Plate 23: Hydraulic tank shut-off valves label

Indicates precaution to be taken before starting the excavator.
Plate 25: External starting label

Indicates precautions to be taken before removing starting cables.
Plate 40: Burn hazard label

Indicates risks due to hot surfaces and gives associated safety instructions.
Plate 44: Oil injection hazard label

Indicates risks due to oil discharge and gives associated safety instructions.
Plate 48: Explosion hazard label

Indicates explosion risk and gives associated safety instructions.

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Plate 54: Door-closing label

Indicates that the concerned door must stay closed during operation.
Plate 56: Rotation blade hazard label

Indicates risks due to rotating blades and gives associated safety instructions.
Plate 70: Emergency ladder label

Indicates the emergency ladder.

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2 - 28 R9200 / 11695477
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3 Control and operation
3.1 Operating and control elements
3.1.1 Overview of the control cab

Fig. 3-1 Control cab

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Control and operation Operating manual
Operating and control elements
1 Control board U21 Left joystick

E1005 Cab connection box U22 Right joystick
P5 Hour meter U23 Right travel pedal
S100_1 Emergency stop U24 Left travel pedal
S7 Safety lever Display
Fig. 3-2 Standing position from operator’s point of view
S100_1 Emergency stop U21 Left joystick

S7 Safety lever U22 Right joystick
U23 Right travel pedal

U24 Left travel pedal

3-2 R9200 / 11695477
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Operating manual Control and operation
Fig. 3-3 Switches on the joysticks
S5L Switch / horn S6L Switch / semi-automatic flap clos-

ing (shovel attachment only)
S5M Not used S6M Not used
S5R Not used S6R Switch / boom down with pres-
sure
S55 Rocker switch / deactivation of S57 Rocker switch / semi-automatic
the attachment damping system swing brake (option)

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3.1.2 Arrangement of joysticks
Fig. 3-4 Joysticks right (U22) and left (U21)
The left joystick (U21) controls the stick and swing movements.
– Direction of movement a and b: Stick is drawn in or out.
– Direction of movement c and d: Uppercarriage turns left or right.
The right joystick (U22) controls the boom and bucket movements.
– Direction of movement e and f: Bucket will be tilted up or down.
– Direction of movement g and h: Boom will be raised or lowered.

3-4 R9200 / 11695477
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3.1.3 Keyboard
Fig. 3-5 Keyboard
A168 – PowerPack keypad
Decrease the engine speed

 Push the "Decrease engine speed" button.
 The engine speed decreases to the previous lower step.
 Push and hold the "Decrease engine speed" button.
 The engine speed decreases continuously.
 The LED in the button flashes until you get the minimum speed.
 The LED in the button is on while the minimum speed is selected.

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Increase the engine speed

 Push and release the "Increase engine speed" button.
 The engine speed increases until the next higher step.
 Push and hold the "Increase engine speed" button.
 The engine speed increases continuously.
 The LED in the button flashes until you get the maximum speed.
 The LED in the button is on while the maximum speed is selected.
Travel brake
The travel brake is engaged by default, undercarriage is locked and first LED in the
button comes on.
 Push the button.
 Travel brake is disengaged.
 Undercarriage is unlocked.
 First LED in the button goes off.
 Push the button again.
 Travel brake is engaged.
 Undercarriage is locked.
 First LED in the button comes on.
The travel brake is engaged if the safety lever is up and the access ladder is down.
Swing brake
The swing brake is engaged by default, uppercarriage is locked, and first LED in the
button comes on.
 Swing brake is disengaged.
 Uppercarriage is unlocked.
 Swing brake is engaged.
 Uppercarriage is locked.
The swing brake is engaged if the safety lever is up and the access ladder is down.
Eco / Power modes
Use this button to switch quickly between the "Eco" mode (fuel saving mode) and the
"Power" mode (full engine speed).
 The engine speed is set to the "Eco" mode.
 The LED above "Eco" in the button comes on.
 The engine speed is set to the "Power" mode.
 The LED above "Power" in the button comes on.
Each time you push the button, the engine speed switches from one mode to the oth-
er.
You can also set the "Power" mode when you set the engine speed to the last step
with the "Increase engine speed" button.

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Start / Stop
 Make sure that the electrical system is switched to on.
 Push and hold the "Start/Stop" engine button on the keyboard.
 The engine start procedure begins and the first LED in the button comes on.
 First LED in the button goes off when you release the button.
 Push the "Start/Stop" engine button on the keyboard again.
 The engine turns at minimum speed during a specified interval.
 The right LED in the button and the related symbol on the display flash.
 Then the engine stops. The right LED and the display symbol are on.
 The right LED goes off.
 Turn the ignition key S1 to position "0" to switch to off the machine.
 Remove the ignition key S1.
A169 – Standard functions keypad 1
Windscreen wiper
 Intermittent mode is activated.
You can set the interval in the submenu "Wiper" of the monitoring display.
 Continuous mode is activated.
 Second LED in the button comes on.
 Push the button a third time.
 Windscreen wiper is switched off.
 Second LED in the button goes off.
Windshield washer
 Push and hold the button.
 Washing water is sprayed onto the windscreen through the outlet nozzles.
 Windscreen wiper runs continuously.
 Release button.
 Washing water is stopped.
 Windscreen wiper finish its cycle.

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Front working lights / Attachment headlights

 Front working lights on the uppercarriage are activated.
 Front working lights and attachment headlights are activated.
 First LED and second LED in the button are on.
 Front working lights are deactivated.
 Attachment headlights remain activated.
 Second LED in the button is still on.
 Push the button a fourth time.
 Attachment headlights are deactivated.
Rear working lights
 Rear top of cab working lights are activated.
 Rear counterweight working lights are activated.
 Rear top of cab working lights are deactivated.
 Push the button a fourth time.
 Rear counterweight working lights are deactivated.
A170 – Standard functions keypad 2
Automatic stick draw in (for shovel attachment only) (if installed)

 The function is on, but it is not activated.
 The LED in the button comes on.
 If necessary during the work of the machine, the function is automatically ac-
tivated and helps draw in the stick.
 The function is off.
 The LED in the button goes off.

3-8 R9200 / 11695477
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Overload warning device (optional)

If installed:
 The overload warning device is activated.
 All the LED in the button come on.
 Do the deactivation procedure.
 The overload warning device is stopped.
 All the LED in the button go off.
 Refer to the related section for detailed description of the system.
If not installed:
 This symbol is shown on the display.
 All the LED in the button are off.
 The symbol on the display goes off.
Turn of the grapple / shear (optional)
 The LED in the button comes on.
 You can turn the grapple / shear with the related operating and control ele-
ments.
 The LED in the button goes off.
 The turn function of the grapple / shear is off.
High speed gear
 Transfer from normal drive to fast drive is activated.
 Transfer from normal drive to fast drive is deactivated.

R9200 / 11695477 3-9
MJFCIFSS
Auto idle
The auto idle function reduces automatically the engine speed, e.g. when the ma-
chine is on but you do not operate it.
 Push the "Auto idle" button.
 The auto idle function is on, but it is not activated.
 The LED on the button comes on.
 If you let the joysticks and pedals in neutral position during the specified auto idle
interval:
 The auto idle function is activated.
 The engine speed is automatically reduced.
 The E / P mode and the engine speed are stored. The related symbol flash on
the display.
You can set the auto idle interval in the submenu "Auto idle control" of the monitoring
display.
 If you push on the "Increase engine speed" button while the auto idle function is
activated:
 The engine speed does not change.
 The new step is stored.
 If you push on the "Decrease engine speed" button while the auto idle function is
activated:
 If the new step is higher than the auto idle speed, the engine speed does not
change and the new step is stored.
 If the new step is lower than the auto idle speed, the auto idle function is de-
activated.
 If you operate the joysticks or the pedals:
 The auto idle function is deactivated.
 The engine speed is set to the stored value.
 Push the "Auto idle" button again.
 The auto idle function is off.
 The LED on the button goes off.

3 - 10 R9200 / 11695477
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A171 – Optional functions keypad
Dual air conditioning (optional)

When you switch the machine on, the automatic dual air conditioning system is op-
erated by default. The two air conditioning units are working alternately.
The first LED and the second LED in the "Dual air conditioning" button of the control
keyboard come on.
 Push the "Dual air conditioning" button.
 Automatic air conditioning mode is deactivated.
 First air conditioning unit is operated.
 Second air conditioning unit is deactivated.
 First air conditioning unit is deactivated.
 Second air conditioning unit is operated.
 Automatic air conditioning mode is operated again.
 First LED and second LED in the button come on.

R9200 / 11695477 3 - 11
MJFCIFSS
3.1.4 Cab control board
Fig. 3-6 Control board
Standard functions: ECM engine monitoring system:

S1 Ignition key H60 ECM STOP indicator
S8 Internal cabin lighting H61 ECM WARNING indicator
S100_1 Emergency stop H62 ECM PROTECTION indicator

3 - 12 R9200 / 11695477
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S122 Disable access ladder or trap S82_1 Diagnostic increment

control lock
S126 External cabin lighting S82_2 Diagnostic decrement
S177 Winter position for the central- S85 ECM monitoring ON/OFF
ized lubrication system (op-
tional)
S233 Manual preheating of electri-
cal boxes (if applicable)
S256 Rotary switch for control se-
lection (if installed)
H68 Access ladder or trap control Safety operation engine:
lock
H92 Fire alarm (optional) S23 Engine safety operation ON
R6 Engine RPM adjustment
Air conditioning: Greasing:

U103_1 Module air conditioning A15 Greasing module
U103_2 Optional module air condition-
ing (if installed)
Keyboard:
Radio: A168 PowerPack keypad
A2 Radio A169 Standard functions keypad 1
A170 Standard functions keypad 2
A171 Optional functions keypad
Disable access ladder or trap control lock

 For further information about correct use of this function, refer to section "Entering
or leaving the cab" or "Service Trap" of this manual.
ECM (Electronic Control Module) engine monitoring system

If an indicator H60, H61 or H62 comes on during operation, test switches S82_1 and
S82_2 will allow the engine maintenance mechanics to ask system to indicate the re-
corded default by giving a coded message via the control light.
 For further information, see Cummins Operation Manual.
Safety operation functions

 For further information about correct use of these functions, refer to section
"Emergency operations" of this manual.

R9200 / 11695477 3 - 13
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3.1.5 Monitoring display
Fig. 3-7 Monitoring display
1 Screen 3 Ambient luminosity sensor

2 Control buttons 4 Power indicator
Screen
Note!
The screen luminosity is automatically adjusted depending on the environmental lu-
minosity detected by the sensor 3.
Control buttons
The control buttons F1, F2, F3, F4, F5, F6, F7 and F8 allow to switch between the
different menus and to use the functions available on the display.
Each button is aligned with the menu or function (represented on the bottom of the
screen) it is associated with.
3.1.6 Menus and functions of the display

Main screen
The main screen comes on first when the machine is started. It shows different infor-
mation and gives access to the machine menus and functions.
 Push the "Main screen" button to go back to this menu from all others menus.

3 - 14 R9200 / 11695477
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Fig. 3-8 Main screen on cab display
The main screen is divided into four fields:

– the general information
– the dials and the error warning symbols
– the camera views
– the buzzer and the links to access the monitoring menus

R9200 / 11695477 3 - 15
MJFCIFSS
General indicator field
Fig. 3-9 General indicator field
1 General indicator field
The upper field 1 shows time information and general indicator symbols. Each sym-
bol has a specified location on the field. If two symbols must flash on the same place,
they flash alternatively.
 For symbols description, refer to the section "Indicator and error warning sym-
bols".
Dials and error warning symbols field
Fig. 3-10 Dials and error warning symbols field

3 - 16 R9200 / 11695477
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2 Dials and error warning symbols field
The central field 2 shows measured values and error warning symbols.
Dials
The measured values that follow are represented with dial indicators:
– coolant temperature
– fuel level
– oil temperature
– engine speed
The related numerical value is also shown under the dial needle.
If a measured value is out of the possible range (e.g. in case of defective sensor):
– The related dial needle goes under the minimal value.
– The numerical value is shown in its field.
 In this case, contact LIEBHERR customer service.
If the signal transmitting communication is broken:
– The related dial needle goes under the minimal value.
– The messages below are shown:
• "NO SIGNAL!"
• "-50" for standard values (e.g. temperature, pressure)
• "-1" for strictly positive values (e.g. percentage, speed)
Error warning symbols
The error warning symbols can be shown anywhere in the central field 2. If all the
symbol locations are on, the system show the most important symbols.
If the same error occurs on different elements, the error symbol is on and the different
related parameters flash alternatively.
 For errors description, refer to the section "Indicator and error warning symbols".

R9200 / 11695477 3 - 17
MJFCIFSS
Camera views
Fig. 3-11 Camera views
3 Camera views field
The main screen has two windows 3, which show the image from the monitoring
cameras.
 Push the "Main screen" button to go back to the camera views from all others
menus.
Buzzer and links field
Fig. 3-12 Links field

3 - 18 R9200 / 11695477
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4 Buzzer and links field
With the lower field 4, you can get access to different functions.
"Buzzer" function
The buzzer symbol is off (black color) until an error message occurs. When it occurs,
the buzzer symbol becomes grey and the buzzer sounds.
 When the buzzer sounds, push the "Buzzer" button to switch it to off.
Links to the monitoring menus

The available monitoring menus from the main screen are:
– menu "Diag"
– menu "Check"
– menu "Info"
– menu "Settings"
Monitoring menus
Select a monitoring menu

Fig. 3-13 Monitoring menus

R9200 / 11695477 3 - 19
MJFCIFSS
Menu "Diag"
The menu "Diag" is used to collect and save all the errors which occur during the op-
eration. With this menu, you can see the error codes list in chronological order of oc-
currence.
 Push the "Diag" button to access to this menu from all others menus.
Menu "Check"
With the menu "Check", you can see the value of different parameters and specified
inputs/outputs of the machine.
 Push the "Check" button to access to this menu from the main screen.
Menu "Info"
With the menu "Info", you can see different technical data and working times of spec-
ified parts of the machine.
 Push the "Info" button to access to this menu from the main screen.
Menu "Settings"
With the menu "Settings", you can set specified parameters of the machine.
 Push the "Settings" button to access to this menu from the main screen.
Select a submenu
From each monitoring menu:
 Push the "Up" and "Down" buttons to select the necessary submenu.
 Push the "Accept" button to access to the selected submenu.
Return to the monitoring menu

From each submenu:
 Push the "Return" button to go back to the related monitoring menu.

Menu "Diag"
When an error occurs on the machine, the symbol of the menu "Diag" flashes red on
the main screen. This symbol continues to flash until there are errors not acknowl-
edged or not rectified.

3 - 20 R9200 / 11695477
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Fig. 3-14 Menu "Diag"
 Push the safety lever up to see the error messages.

A code number and a short description are shown for each error code.
 Push the "Up" and "Down" buttons to select an error message.
 Push the "Acknowledgement" button to acknowledge the error.
Danger!
If the error shown on the display is not rectified immediately, this could cause inju-
ries to persons or damages to the machine.
 Rectify / have the error rectified immediately.

If you want to change the language of the messages:
 Refer to the menu "Settings".
Menu "Check"
This menu gives access to the submenus that follow:


R9200 / 11695477 3 - 21
MJFCIFSS
Fig. 3-15 Submenus of the menu "Check"
Submenus:
This submenu shows in real time different

Engine
parameters values of the engine.
This submenu shows the status of digital

Inputs Attachment
and analogical inputs of the machine
attachment.
This submenu shows the status of digital

Inputs / Outputs
and/or analogical:
– control inputs and/or movement inputs
of the machine
– control general outputs of the machine

3 - 22 R9200 / 11695477
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This submenu shows the inputs status of:

Steering
– the primary electronic control of the ma-
chine
– optional electronic controls
Submenu "Engine"
This submenu shows the information that follows:
Torque shown through a dial Engine load rate

indicator and a numerical
value
Engine speed shown through Intake manifolds pressure

a dial indicator and a
numerical value
Fuel rate shown through a Engine coolant temperature

dial indicator and a
numerical value
Status of mode "Safety start" Hydraulic oil temperature

(status light)
Engine speed Barometric pressure
If a measured value is out of the possible range:

– The related dial needle goes over the maximal value.
If a measured value is missing:
– The related dial needle goes over the maximal value.
– The specified values below are shown:
• "-50" for temperature values
• "-1" for strictly positive values (e.g. percentage, pressure, current)
Submenu "Inputs Attachment"

R9200 / 11695477 3 - 23
MJFCIFSS
– boom cylinder pressure

– boom angle
– rate of boom angular stroke
– stick cylinder pressure

– stick angle
– rate of stick angular stroke
– bucket cylinder pressure

– bucket angle
– rate of bucket angular stroke
If a value connected to a position is out of the possible range:

– It is replaced by dots.
If a value is missing:
– "-1" is shown.
 In these cases, contact LIEBHERR customer service.
Submenu "Inputs / Outputs"
First page
Status lights Numerical values
Status of swing lock Splitterbox temperature
Status of travel lock Splitterbox pressure
Status of the air conditioning Swing speed

Status of boom down with Control pressure

pressure

3 - 24 R9200 / 11695477
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Status lights Numerical values
Status of the safety lever
Status of the optional semi-

automatic swing brake
If a value connected to a position is out of the possible range:

– It is replaced by dots.
If a value is missing:
– "-1" is shown.
 In these cases, contact LIEBHERR customer service.
Last page
Regulating solenoid valve of Regulating solenoid valve of

hydraulic oil cooling engine cooling
Flow control valves Regulating solenoid valve of

power regulator of work-
ing pumps
Submenu "Steering"
First page
Solenoid valve of swing left Pedals left (L) and right (R)
(status light) movements in forward
and rearward directions
Solenoid valve of swing right Pedal for special and/or

(status light) optional controls (if
installed)
Adjustment solenoid valve of Joysticks left (L) and right (R)

swing left movements in all direc-
tions

R9200 / 11695477 3 - 25
MJFCIFSS
Adjustment solenoid valve of Uppercarriage swing

swing right
Last page
Analog stick for special and/

or optional controls (if
installed)
Menu "Info"
Fig. 3-16 Submenus of the menu "Info"
Submenus:

3 - 26 R9200 / 11695477
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This submenu shows the parameters of

Excavator
the machine (type, serial number, ...).
This submenu shows hour counters of:

Hours
– the machine working time
– the time during which the machine was
on specified working mode
– the working time of special and/or op-
tional tools (if installed)
This submenu shows different types of

Counter Engine
hour counters related to the engine life.
This submenu shows the different types of

Counter User
hour counters managed by the opera-
tor.
Submenu "Excavator"
Version of software Type of engine
Type of excavator Type of attachment
Serial number of the machine Type of cooling

Submenu "Hours"

R9200 / 11695477 3 - 27
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First page
Working time of the engine Working time of working

pumps
Working time of the machine Working time of the engine

with its speed lower than
1000 RPM
Working time during which Working time of the engine

the machine was in swing with its speed lower than
mode 1400 RPM
Working time during which

the machine was in travel
mode
The hour counters related to the engine (working time and RPM) are set to zero if the
engine is replaced. Thus, these values are related to one specified engine.
The other values are related to the machine.
Last page
This page is available when you can install optional special tools on the machine.
Working time of special tool (if

installed)
Working time of special rotary

tool (if installed)
Submenu "Counter Engine"

Mode of working "Eco" Hours spent in the related

mode of working
Mode of working "Power" Average engine power dur-

ing the related period

3 - 28 R9200 / 11695477
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Total of the two modes of Fuel consumption during the

working E and P related period
Submenu "Counter User"
This submenu shows the same information as the submenu "Counter Engine", but
it can be managed by the operator.
 Push the "Reset" button to set to zero all the counters of this submenu.
Menu "Settings"


R9200 / 11695477 3 - 29
MJFCIFSS
Fig. 3-17 Submenus of the menu "Settings"
Submenus:
This submenu is used to set the time.

Time
This submenu is used to set the auto idle

Auto idle control
interval of the auto idle function.
This submenu is used to set the wind-

Wiper
screen wiper interval.
This submenu is used to set the lumines-

Brightness
cence of the display.
This submenu is used to set the language

Language
in which the error codes are written.
Set a parameter
From each submenu of the menu "Settings":
 Push the safety lever up.
 Push the "Up" and "Down" buttons to select the parameter to set (time, value or
language).
 Push the "Accept" button to record the new parameter.

Submenu "Time"
You can also use this submenu to switch from summer to winter time (and back
again).
 Push the "Daylight" button.
 This symbol is transparent when the time difference of an additional hour is de-
activated.

3 - 30 R9200 / 11695477
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 This symbol is green when it is activated.

Submenu "Brightness"
To use this submenu, you must before select the manual mode.
 Push the "AUTO" button.
Automatic mode
Manual mode
 Each time you push this button, the status light related to the selected mode
comes on.
Indicator and error warning symbols

The symbols which are shown on the main screen give information about the condi-
tions, the setting and the possible malfunctions of the machine.
There are two types of symbols:
– The indicator symbols which are shown in the field 1.
– The error warning symbols which are divided into two groups:
• the engine error symbols shown in the field 5
• the other error symbols shown in the field 6
Fig. 3-18 Indicators and error warnings on the main screen

R9200 / 11695477 3 - 31
MJFCIFSS
1 General indicator symbols

5 Engine error symbols
6 Other errors symbols
 For symbols description, refer to the sections that follow.
General indicator symbols (1)

The indicator symbols give information about the conditions and the setting of the
machine. They are related to functions activated with the keyboard.
Travel brake closed

This symbol is shown if the Travel brake button has been pressed on the control key-
board.
Swing brake closed

This symbol is shown if the Swing brake button has been pressed on the control key-
board.
Brakes manu
This symbol is shown if the Safety Brake Control has been allowed through emer-
gency functions.
Power Control off

This symbol is shown if the Power Control Manu has been allowed via emergency
functions.
Flow Control off

This symbol is shown if the Flow Control Manu has been allowed via emergency
functions.
Fan Control off
Speed Control off

This symbol is shown if the Speed Control Manu has been allowed via emergency
functions.
Preheating on
This symbol is shown while preheating is occurring.
Shovel movement blocked

This symbol is shown if the shovel movement is blocked (when grease level is low or
when the track tensioning procedure is in progress).

3 - 32 R9200 / 11695477
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Pumps in Qmin
This symbol is shown when the working pumps flow rate is limited.
High Speed Gear

This symbol is shown if the High Speed Gear button has been pressed on the control
keyboard.
Hydraulic oil temperature high

This symbol is shown if the hydraulic oil temperature is more than a specified oper-
ating value.
 A buzzer is activated in the cab.
Hydraulic oil temperature low

This symbol is shown if the hydraulic oil temperature is below a specified operating
value at the excavator start.
 The working pumps are automatically limited to 50%.
 The maximum limitation time of the working pumps is set to 15 minutes.
Engine error symbols (5)
The engine error symbols show malfunctions of the engine in the field 5.
These symbols have:
– an index which gives the affected element
– a symbol related to the error
– a background color (yellow or red) which gives the severity of the problem
Fig. 3-19 Example of engine error symbol
Three symbols can be shown in the field 5. The most important symbol is shown in
higher location. The less important symbol is shown in lower location.
If the same error occurs on different indexed elements, the error symbol is on and
the different index flash alternatively.
If all the error symbol locations are on, the system show the most important symbols.
Low engine oil pressure

This symbol is shown if the engine oil pressure falls below a specified operating val-
ue.
 Perform engine power derate and motor stop procedure.
 Find and rectify the cause of the problem (see engine Operating and Maintenance
Manual).

R9200 / 11695477 3 - 33
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Intake manifold overheating

This symbol is shown if the intake manifold temperature is more than a specified op-
erating value.
Manual).
Fuel overheating
This symbol is shown if the fuel temperature is more than a specified operating value.
 Perform engine speed derate.
Manual).
Rail overpressure
This symbol is shown if the fuel rail pressure is more than a specified operating value.
 Perform engine power and/or speed derate.
Manual).
Engine start at low coolant temperature
This symbol is shown as long as the engine coolant temperature is below a specified
value.
 Avoid start the Diesel engine and operating the excavator under these conditions
if the excavator does not have an optional preheating system.
 If the excavator has an optional preheating system, operate the preheating sys-
tem first until the symbol goes off.
Water in fuel
This symbol is shown if water has accumulated in the fuel filter.
 Drain water from the fuel filter.
Engine shutdown necessary

This symbol is shown on the related dial indicator (field 2) if a engine shutdown is
required.
Coolant overheating
This symbol is shown next to the coolant temperature dial indicator (field 2) if the
coolant temperature is more than a specified operating value.
Manual).
Crankcase pressure high

This symbol is shown if the crankcase pressure exceeds a given operating value.
 Engine will undergo full derate.
Manual).

3 - 34 R9200 / 11695477
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Coolant pressure low

This symbol is shown if the coolant pressure drops below a given operating value.
 Engine will undergo power and speed derate and motor stop procedure.
Manual).
Engine oil temperature high
This symbol is shown if the engine oil temperature exceeds a given operating value.
 Engine will undergo torque derate.
Manual).
Engine oil level
This symbol is shown if it is necessary to do a check of the engine oil level.
 Stop operation.
 Find and rectify the cause of the problem.
Engine oil level differential pressure
This symbol is shown if there is a difference between the oil pressures before and
after filtration.
 Engine will undergo power derate.
Manual).
Engine oil level in Centinel system (if installed)
This symbol is shown if it is necessary to do a check of the engine oil level in the Cen-
tinel system (if installed).
 Stop operation.
Engine oil change necessary
This symbol is shown if it is necessary to change the engine oil.
 Stop operation.
Other error symbols (6)

The other error symbols show other malfunctions of the machine in the field 6.
These symbols have the same structure as above.
Three symbols can be shown in the field 6. The most important symbol is shown in
higher location. The less important symbol is shown in lower location.

If the same error occurs on different indexed elements, the error symbol is on and
the different index flash alternatively.
If all the error symbol locations are on, the system show the most important symbols.

R9200 / 11695477 3 - 35
MJFCIFSS
Splitterbox oil overheating

This symbol is shown if the splitterbox oil temperature is more than a specified oper-
ating value.
 Stop operation and turn the engine to off.
Servo oil pressure low
This symbol is shown if the servo oil pressure falls below a specified operating value.
Servo oil pressure high
This symbol is shown if the servo oil pressure is more than a specified operating val-
ue.
Coolant level low
This symbol is shown if the coolant level falls below minimal level.
 The engine stops automatically.
If the engine does not stop automatically:
 Add coolant to get the correct level.
Splitterbox oil pressure low
This symbol is shown if the splitterbox oil pressure falls below minimal level.
Battery level high
This symbol is shown if the battery level is more than a maximum level.
Battery level low
This symbol is shown if the battery level falls below a minimum level.

3 - 36 R9200 / 11695477
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Battery charging
When the excavator is operating, this symbol is shown if the V-belt alternators or the
electrical charging system are defective.
 Put the engine to low idle immediately.
 Allow the engine to idle for approximately 5 seconds.
 Switch to off the engine.
 Rectify the error.
Hydraulic oil overheating
This symbol is shown if the hydraulic oil temperature is more than a specified oper-
ating value.
 Stop operation and let the engine run at high idle until the symbol disappear.
If necessary:
 Turn the engine to off.
Hydraulic oil level low
This symbol is shown if the hydraulic oil level falls below minimal level.
 Pumps are automatically set to minimal flow.
 Add hydraulic oil to get the correct level.
Grease level low

This symbol is shown if the grease level falls below the minimal level.
 Add grease to get the correct level.
Greasing failure
This symbol is shown if a failure occurs on the lubrication system.
Greasing module not in operation
Only available with the greasing module A15, this symbol is shown if a failure occurs
on the module.
Lifetime sealing interspace oil level high (optional)

This symbol is shown if the oil level in the Lifetime sealing interspace is more than
the maximal level.

R9200 / 11695477 3 - 37
MJFCIFSS
The access and the outfit of the cab
Lifetime sealing interspace oil level low (optional)

This symbol is shown if the oil level in the Lifetime sealing interspace is below the
minimal level.
 Stop operation and turn the engine off.
 Add oil until you get the correct level.
3.2 The access and the outfit of the cab
Safely getting up
install yourself at the operator’s seat.
– When getting up or down, position the machine on even, horizontal ground. The
upper structure should be positioned with the undercarriage in such a way that
the steps and ladders are aligned with each other.
– Ensure that steps, ladders and hand-rails (grips) are in good condition. In particu-
lar, you should ensure that they are free of dirt, oil, ice and snow.
NOTE: To ensure that the doors open properly in all weather conditions, the door
seals must be dusted with talc or silicon at least every two months or more often
if required. The door hinges and locks should be greased regularly.
– If you are able to reach the door handle with your free hand, open the doors be-
fore you climb any higher. External influences, such as wind, can make it more
difficult to open doors. Because of this, always use your hand for control when
opening doors. Ensure that the door is latched open to prevent it slamming open
and shut.
– In case of bad weather conditions, be particularly vigilant to realise the climbing
and descent from the cab with the best safety conditions, and do or give the in-
structions to the execution of prior preparations to be accomplished, as enunciat-
ed above, in order to displace yourself safely.
– Be particularly vigilant with those prerequisites conditions.
– For cab with a side door:
• Now continue to climb up, still using the three-point support and sit down in the
operator’s seat as soon as you enter the cab.
• Fasten the safety belt (if available), unlock the door, using the planned lever,
and close it immediately using the door handle, before tilting down the safety
lever, and start the machine.
• If you wish to work with the door open, it is necessary to fasten your safety belt.
If unavailable, let it be installed before working with the door open.

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

3 - 38 R9200 / 11695477
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Safely getting down

install yourself.
– Stop the machine on level, horizontal ground. The upper structure should be po-
sitioned with the undercarriage in such a way that the steps and ladders are
aligned with each other.
– Open and lock the door. Be sure of it’s locking. Take care of weather conditions !
Unfasten the safety belt.
– Position yourself with your face toward the machine when getting out and use
three-point support, i.e. two hands and one foot or two feet and one hand must
always be in contact with the access system at the same time. Climb down until
you can close the doors safely. Always use your hand for control when closing the
doors. Lock the door.
– Now climb down to the ground.
3.2.1 Enter or leave the cab
Climb up
Caution!
Entering or leaving the cab incorrectly could lead to injury.
 Proceed with the same attention on exit or entry of the cab, as while climbing the
machine.
 Ensure that the safety lever is always in its highest position when entering or
leaving the cab.
 Always use the handholds provided for the purpose when entering or leaving the
machine.
 Face the machine when getting in or out and always use three-point support, i.e.
 Never use the control elements as handles.
 Never jump from the machine.

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Fig. 3-20 Access ladder
Getting in
If the access ladder is in its lowest position and the excavator is not running, you can
climb up on the machine.
 Climb in with the ladder and with your face towards the ladders and use the pro-
vided handholds.
 On the cabin catwalk, open the door.
 Go in the cabin and take place on the operator seat.
 Adjust the seat if necessary.
Getting out
 Switch to off the machine and push the safety lever up.
 Open the door fully.
 Go out of the cabin on the cabin catwalk.
 Close the door.

 Go down with your face towards the ladders, and use the appropriate handholds.
Access ladder
The access ladder can be moved into:
– lower position to permit the access to the uppercarriage
– upper position during the operation

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Before operating the excavator, the access ladder must be fully lifted to the upper-
carriage and locked in upper position.
The access ladder can be automatically extended and retracted from the uppercar-
riage with the control box E1022, which is located on the catwalk near the cab door.
Fig. 3-21 Control box E1022
H68 Warning light on E1022

S155 Push-button / access ladder up
S158 Push-button / access ladder down
Danger!
Never actuate the 45° access ladder if you or a third person are on the ladder or in
immediate proximity of the ladder.
Move the ladder into lower position

You can move the access ladder in lower position with the engine on or off.
 Push the button S158 to extend the ladder until it is at the lowest position.
Move the ladder into upper position (working position)

 Make sure that the Diesel engine is running.
 Push the button S155 until the ladder is at the top position (working position).

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Fig. 3-22 Warning light on the control board
H68 Warning light on the control board
When the ladder gets its top position, it is locked and the two warning lights H68 go
off.
Caution!
For safety reason, the excavator can only be operated if the ladder is locked in its
top position. This means that the swing and travel movements remain locked.
This safety measure can be momentarily by-passed by pushing and holding the but-
ton S122 on the control board.
Fig. 3-23 Button S122: Disable of ladder control position

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Switch to on the access ladder lighting
Fig. 3-24 Button S126
S126 Cab push-button / external cab lighting
 Inside the cab, press button S126 located on the control board.
Fig. 3-25 Button S125
E59_3 Ladder lighting 70W

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S125 External push-button / external cab lighting
 From the outside, press button S125 located on the ladder side.
Move the access ladder into lower position in case of emergency
Fig. 3-26 Emergency valve of access ladder
1 Manual valve
In case of failure (service batteries out of order, defective solenoid valve or wiring, ...)
of the access ladder moving procedure, an emergency valve is installed near the ac-
cess ladder.
 Open the valve 1 to move the ladder in lower position.
If an emergency stop is operated, the access ladder is automatically moved in lower
position.
3.2.2 Safety lever

Fig. 3-27 Safety lever

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For safety purposes, the left control panel is provided with a safety lever.
Caution!
The safety lever must always be pushed up into its highest position (see arrow)
when entering or exiting the cab.
When the safety lever is pushed up, the pilot control circuit is disconnected. This
means that:
– No work movements can be carried out when pilot control devices, e g. the joy-
stick or foot pedals, are operated.
– The swing gear brake is locked (LED in swing brake switch is on).
– It is not possible to release the swing gear brake using this switch.
When the safety lever is pushed (push up / push down) to its lowest position, the
swing gear brake and the LED in swing brake switch will return to their original states
and the pilot control devices will be active.
 Before the operator starts working, he must push the safety lever down into its
lowest position while seated in the operator’s seat.
3.2.3 Operator’s seat

Fig. 3-28 Standard operator’ seat
1 Set horizontal, upper 4 Set seat inclination

2 Set weight 5 Set height

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3 Adjust armrests 10 Set backrest
The operator’s seat must be set up before starting the machine.

 The Diesel engine is switched to off.
 The safety lever is pushed up.
 This will prevent unexpected movement of the machine.
Weight adjustment
Fig. 3-29 Setting the weight
To adjust the seat for the driver’s weight:

 Quickly pull the lever 2.
Note!
The driver must be seated during the adjustment.

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Height adjustment
Fig. 3-30 Setting the height
The seat height can be set pneumatically and is continuously adjustable.
To adjust the seat height:

 Pull the lever 5 up or down.
Caution!
Before adjusting the height, adjust shock absorbers to the position «soft».

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Setting the armrests
Fig. 3-31 Setting the armrests
To adjust the seat armrest:

 Turn the knurled head screw 3 in direction 1 to slope the armrest upwards.
 Turn the knurled head screw 3 in direction 2 to slope the armrest downwards.
Setting the seat
Fig. 3-32 Setting the seat

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To adjust the angle of the seat:

 Pull lever 4 up.
 By applying pressure on the seat, move it to the correct position.
Setting the backrest
Fig. 3-33 Setting the backrest
To set the backrests:

 Pull lever 10 up to release the backrest.
 By applying pressure on the seat, move it to the correct position.
 Release the lever 10 to lock the backrest.

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Setting the horizontal seat position
Fig. 3-34 Setting the horizontal
To adjust the horizontal position of the seat:

 Pull up the lever 1.
 Move the seat backwards or forwards to the correct position.

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Fasten / release the safety belt
Fig. 3-35 Safety belt
The safety belt is automatic.
To adjust the belt length:

 Pull the belt and buckle 2 out of the roller mount 1.
 If pulled out of the roller mount suddenly, the belt can lock.
 Push the buckle into the belt lock 3 until it fastens.
Danger!
The safety belt is designed to protect the operator.
 Before starting the machine, always fasten the safety belt.
 Ensure that the safety belt is not twisted when it is fastened.
 For safety reasons, check the condition, function and fastening of the belt regu-
larly and replace any damaged parts without delay.
 To open lock 4, push down on the belt lock using your thumbs.
 The safety belt will slide automatically back into the roller mount 1.

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3.2.4 Auxiliary seat
Fig. 3-36 Auxiliary seat
1 Auxiliary seat
2 Storage cabinet
The auxiliary seat 1 is a folding seat located near the operator. A storage cabinet 2
is installed under the auxiliary seat.
Move the folding seat

 Pull up or down the seat 1 to move it in position.
 When there is no one on the auxiliary seat, the folding seat automatically pulls up
against the cab wall.

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3.2.5 Sunshade
Fig. 3-37 Cab sunshade
1 Cab sunshade
You can pull up or down the cab sunshade(s) 1 and set it for individual use.

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3.2.6 Emergency exit
Fig. 3-38 Emergency exit and emergency hammer
1 Emergency hammer
2 Emergency exit
Only in case of emergency, you can use the rear window 2 of the cab as an emer-
gency exit.
 Break the rear window 2 with the emergency hammer 1.
You can also break with the emergency hammer 1 the window of the cab access door
and the left window next to this door.

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3.2.7 Internal lighting
Fig. 3-39 Internal lighting switch button
The internal lighting is switched to on through the S8 button on the control board.
Switch to on the internal lighting

 Push the S8 button.
Switch to off the internal lighting

 Push the S8 button again.
3.2.8 Fire extinguisher

The interior of the cab is fitted with fixing points allowing the mounting of a fire extin-
guisher. These fixing points are on the left of the rear window.

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Fig. 3-40 Fire extinguisher fixing location
1 Fire extinguisher
It is the responsibility of the owner of the machine to decide if it must be fitted with a
fire extinguisher or not, considering the operating conditions and the regulations
which apply in the country and at the point of use of the machine.
Caution!
If your machine is fitted with a fire extinguisher:
 Always comply with the operating guide on the body of the extinguisher,
 Make sure, all the inspections of the fire extinguisher which are prescribed by
the regulations applicable to the operating place of the machine are accom-
plished.

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3.2.9 Windscreen
Windscreen wiper
Operate the windscreen wiper
 Make sure that the ignition key is switched to on.

 Intermittent mode is activated.
 Continuous mode is activated.
 Press the button a third time.
 Windscreen wiper is switched off.
 LED in the button goes off.
Set the interval time for the intermittent switching

You can set the interval in the submenu "Wiper" of the monitoring display.
Windshield washer installation
Operate the windshield washer
 Make sure that the ignition key is switched to on.

 Push and hold the button.
 Washing water is sprayed onto the windscreen through the outlet nozzles.
 Windscreen wiper runs continuously.
 Release button.
 Washing water is stopped.
 Windscreen wiper finish its cycle.

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Fill the container of the windscreen washer fluid
Fig. 3-41 Container of the windscreen washer fluid
1 Cab elevation
2 Container
The container 2 for the windscreen washer fluid is located into the cab elevation 1.
You can fill it through the filler neck.
 For fluid quantity, refer to the operating material chart.
Heated windscreen (optional)

A heated windscreen is installed to remove frost from the front cab window.

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Fig. 3-42 Heated windscreen
S189 Actuator for windscreen heating
 Start the Diesel engine.

 Use actuator S189 to start the windscreen heating.
 Use actuator S189 again to stop it.

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3.2.10 Field of view
Fig. 3-43 Field of view
1 Camera 1: opposite side of the cab

2 Camera 2: counterweight
Monitoring cameras are installed on the excavator as follows in order to extend the
operator’s field of view with the operating environment:
– camera 1: on the opposite side of the cab
– camera 2: on the counterweight
The combination of the cameras and the outside mirrors allows to see a person
standing out of the hatched area illustrated on the figure above.
Danger!
Before using the excavator, make sure that the cameras and the outside mirrors are
correctly adjusted.
 Regularly check mirrors and cameras for condition. If necessary:

– Clean them with a soft, dry cloth.
– Use an external safety device to get access to them.

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 Regularly check mirrors and cameras for correct adjustment.

 For maintenance intervals, refer to the control and maintenance chart.
 Replace damaged mirrors and cameras immediately.
To cover the correct area:

 Set the cameras and adjust the outside mirrors so as to be able to see a person
standing out of the hatched area defined by the four checkpoints given on the fig.
above.
3.2.11 Lighting
 Regularly check lighting devices for condition. If necessary:
– Clean them with a soft, dry cloth.
– Use an external safety device to get access to them.

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Fig. 3-44 Configuration of lighting
E1 Front working light 70W / uppercarriage (cab elevation)

E18_1 Rear working light 35W / counterweight
E18_2 Rear working light 35W / counterweight
E2 Attachment headlight 70W / right side

E3 Attachment headlight 70W / left side
E58_1 Front working light 70W / top of cab
E58_2 Front working light 70W / top of cab
E59_1 Rear working light 70W / top of cab
E59_2 Rear working light 70W / top of cab
E60_1 Front working light 35W / fuel tank
E60_2 Front working light 35W / fuel tank

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E61_1 Camera lighting 70W / fuel tank

E61_2 Camera lighting 70W / counterweight
Front working lights and attachment headlights
 Press button.
 Front working lights on the uppercarriage are activated.
 Press button again.
 Front working lights and attachment headlights are activated.
 Press button a third time.
 Front working lights are deactivated.
 Attachment headlights remain activated.
 Second LED in the button is still on.
 Press button a fourth time.
 Attachment headlights are deactivated.
Rear working lights
 Press button.
 Rear top of cab working lights are activated.
 Rear counterweight working lights are activated.
 Press button a third time.
 Rear top of cab working lights are deactivated.
 Press button a fourth time.
 Rear counterweight working lights are deactivated.
3.2.12 Heating/air conditioning system

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 sys-
tem is integrated in the roof of the cab, and the condenser is installed on the Diesel
engine radiator.

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Control unit front panel
Fig. 3-45 Front panel of the heating/air conditioning control unit
Control keys Indication on the LCD Display
1 Air conditioning ON/OFF 9 Recirculated air mode indicator

2 Increase cabin temperature 10 Reheat mode indicator
Manual setting "upwards" 11 Air conditioning mode indicator
3 Decrease cabin temperature 12 Automatic mode indicator
Manuel setting "downwards" 13 Blower manual speed bar
4 Control unit ON/OFF 14 Manual blower mode indicator
5 Evaporator blower speed manu/auto 15 Heating mode indicator
6 Reheat ON/OFF 16 Drivers cabin indicator
7 Heating ON/OFF 17 Temperature set value / error code
8 Fresh air / recirculated air mode 18 Temperature unit
19 LCD Display
Note!
If the control unit recognizes a system error in the heating / air conditioning circuit,
a flashing error code number F0-F5 is displayed. Refer to the section "Error code
charts" further in this manual.
Operating the heating/air-conditioning control unit
Switching on the control unit

 Press button 4.
 The control unit runs a self-test for approximately 5 seconds (software version
and equipment function are displayed on field 17).

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

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Temperature setting
 Press button 2 to increase the temperature.
 Press button 3 to decrease the temperature.
 The selected temperature is displayed on field 17.

 The new set value is stored 5 seconds after last button pressure.
Switching ON/OFF the air conditioning unit

 Press button 1.
 Air conditioning mode is operated.
 Symbol 11 appears on display 19.
 Press button 1 again.
 Air conditioning mode is deactivated.
 Symbol 11 disappears from display 19.
Note!
In case of high outside temperature, and especially if the cab has been heated up
by the sun, decrease the temperature inside the cab as far as possible before turn-
ing on the air conditioner.
 Open the windows for a few minutes and adjust blower speed to maximum
speed via buttons 5 and 2.
Switching ON/OFF the reheat mode

In order to achieve a quick dehumification of the cab when setting the machine into
operation, it may be advisable to briefly turn on the air conditioning operation when
the heater is already operative.
 Press button 6.
 Reheat mode is operated.
 The blower speed is raised to 100%. If necessary the control unit switches the
heating on, to hold ambient temperature at the desired value.
 Reheat mode is deactivated.
 Symbol 10 disappears from display 19.
Note!
To avoid overloading the starter motor and the batteries, turn on the air conditioning
mode and the reheat mode only after the diesel engine is running.
Reheat mode is automatically limited on 10 minutes.

 If the machine is used for a longer period of time without using the air condition-
er, press the reheat button 6 about every 2 weeks so to turn on the compressor.

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Setting the evaporator blower speed manually

 Press button 5.
 Blower speed manual setting is operated.
 Indication bar 13 appears on display 19 and gives currently set blower speed.
 Automatic mode symbol 12 disappears from display 19.
 Manual blower mode symbol 14 flashes on display 19 for 5 seconds.
 During these 5 seconds, evaporator blower speed can be increased with button 2
or decreased with button 3 in steps of 10%.
 Press button 5 twice.
 Manual mode is deactivated.
 Symbols 13 and 14 disappear from display 19.
 Automatic mode is operated again.
 Symbol 12 reappear on display 19.
Switching ON/OFF the heating mode

 Press button 7.
 Heating mode is operated.
 Heating mode is deactivated.
 Symbol 15 disappear from display 19.
Fresh air / recirculated air mode

 Press button 8.
 Control unit switches from fresh air to recirculated air mode.
 Fresh air flap is closed.
 Control unit switches from circulated air to fresh air mode.
 Fresh air flap is open.
 Symbol 9 disappear from display 19.
Switching the temperature unit from °Celcius to °Fahrenheit

 Press and hold button 8.
 Press button 3 additionally.
 Temperature unit indication 18 switches over into °Fahrenheit.
 Repeat same procedure to switch back temperature unit indication to °Celcius.

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Dual air conditioning (optional equipment)

When you switch the excavator on, the automatic dual air conditioning system is op-
erated by default. The two air conditioning units are working alternately.
The first LED and the second LED in the "Dual air conditioning" button of the control
keyboard illuminate.
 Press "Dual air conditioning" button.
 Automatic air conditioning mode is deactivated.
 First air conditioning unit is operated.
 Second air conditioning unit is deactivated.
 Second LED in the button goes out.
 First air conditioning unit is deactivated.
 Second air conditioning unit is operated.
 First LED in the button goes out.
 Automatic air conditioning mode is operated again.
 First LED and second LED in the button come on.
Additional cab heater (optional)

An additional cab heater is installed above the operator seat. The temperature ad-
justment of this device is the same as the standard heating system.
Fig. 3-46 Additional cab heater
S234 Actuator for additional cab heater

 Use actuator S234 to start the additional cab heater.

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Foot heater (optional)

A foot heater can be installed on the foot board.
Fig. 3-47 Foot heating zones
Fig. 3-48 Foot heater
S235 Actuator for foot heater


 Use actuator S235 to start the foot heater.

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Setting the machine into operation
3.3 Setting the machine into operation
Bringing the machine safely into service

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

– Before starting the machine, adjust the seat, mirrors, armrests and operator’s
controls in such a way that you are able to work comfortably and safely.
– Acoustic insulation devices on the machine must be set to the insulation position
throughout operation.
Protection from vibration - seat adjusting

structions.
Utilisation in confined spaces

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

– Before starting, check all control lamps and instruments for correct function, place
all operator’s controls in Neutral and tilt the safety lever up.
– Before starting, sound the horn briefly to alert people in the vicinity of the machine.
– Only start the machine from the driver’s seat.

– In the absence of any other instructions, start the engine in accordance with the
regulations given in the operating instructions.
– Tilt the safety lever down and then test all display and checking devices.
– In enclosed spaces, only allow the engine to run when there is adequate ventila-
tion. If necessary, open doors and windows to ensure sufficient fresh air supplies.
– Bring the engine and hydraulic oil to operating temperature. Low oil temperatures
make the control unit react sluggishly.

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– Check that the attachment is operating correctly.

– Move the machine carefully to an open area and then check the function of the
travel and swing gear brakes, the steering and the signalling and lighting devices.
Lighting devices must always be clean.
Stopping the machine safely

– Only stop the machine on level, firm ground.
– If the machine has to be stopped on an incline, chocks should be used to secure
it from rolling away.
– Before stopping the machine, each time it is possible, align the uppercarriage with
the undercarriage so that the sprockets locate at the back-end. This is the only
one position which enables a secured access to every maintenance locations on
the uppercarriage.
– Use the stop bolts to secure the uppercarriage facing the undercarriage, if avail-
able.
– Lower the attachment and anchor the grab lightly in the ground.
– Position every control lever into neutral position and apply the travel and swing
brakes.
– Stop the engine in accordance with the operating instructions and tilt the safety
lever up before leaving the cab.
– Lock the machine, included hoods and compartments, remove every keys and
secure the machine against unpermitted use and vandalism.
3.3.1 Starting / stopping the machine
General information
Note!
When using the machine at a specific height above sea level and in connection with
certain outside temperatures, the performance and service life of the turbocharged
diesel engine may be decisively affected.
Under these conditions, there is also an increased risk of overheating of the coolant
circuit and of the oil.
To avoid damaging CUMMINS diesel engines, the engine power must be reduced
when operating in the following environmental conditions (sea level and exterior tem-
perature):
 Refer to the CUMMINS Operation and Maintenance Manual.
Activities before starting

Caution!
It is only possible to extinguish a source of fire when this one is accessible.
 Before starting, unlock all locks on the panelling of the hydraulic excavator.
 In the event of fire, doors can be opened immediately and the fire extin-
guished.
 For locks arrangement, see maintenance chapter

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Caution!
The activities referred below involve scald or burn hazards due to the high temper-
ature of the coolant or of the oil when the machine is at operating temperature.
 Please read first the maintenance chapter in order to get informations about car-
rying out these activities.
 Before starting the machine, the following activities should be carried out on a dai-
ly basis:
– Check air filters for contamination*.
– Check the oil level in the engine*.
– Check the coolant level in the diesel engine*.
– Check fuel system and fuel level.
– Check the oil in the hydraulic system.
– Check that the cameras and the outside mirrors are correctly adjusted.
– If required, remove any ice and snow from the engine hood in the area of the cool-
ing and combustion air intake.
* Refer to the maintenance chapter for further informations about the procedure to follow.
Turn on the electrical system
Ignition key switching positions

Fig. 3-49 Ignition key S1 on cab control board
S1 Ignition key 1 Contact position

P Not used 2 Contact position
0 Off 3 Contact position

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The ignition key S1 is located on the cab control board.
Switch on the electrical system
Fig. 3-50 Principal battery switches
1 Pumps box
S9_1 Principal batteries circuit breaker
The principal batteries circuit breakers S9_1 and S9_2 are located on the side of the
pumps box.

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Fig. 3-51 Engine ECM circuit breaker S9_3
S9_3 ECM circuit breaker
The engine ECM circuit breaker S9_3 is installed on the electrical box E1086 which
is located on the power pack inner side, near the engine doors.
 Make sure that the principal battery switches S9_1 and S9_2 and the engine ECM
circuit breaker S9_3 are in position "CLOSE".
 Turn the ignition key S1 to contact position 1. After a few seconds:
– The display turns on.
– On the keyboard, the first LED of the "Increase engine speed" button comes on,
because the engine is at its minimum speed on start.
– The first LED on the travel brake button comes on.
– The first LED on the swing brake button comes on.
– If the dual air conditioning optional system is installed on your excavator, the first
LED and the second LED on the related button come on because the automatic
air conditioning is operating by default.
If the display or the above listed LEDs do not come on when the ignition key is in the
contact position:
 Check that the principal batteries switches are in position "CLOSE".

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Start the engine
Note!
A wrong start can cause damages for the Diesel engine!
 Only operate the starter motor when the Diesel engine is off.
 Do not operate the starter more than 20 seconds.
 If the engine does not start after 20 seconds, wait at least 1 minute before you
try to start again.
 If the engine does not start after you have tried three times, find the problem and
correct it.
According to the exterior temperature, the starting procedure is different.

Above 0°C:
 Refer to the section "Starting procedure when the exterior temperature is above
0°C".
Between 0°C and -20°C:
 Refer to the section "Starting procedure when the exterior temperature is below
0°C".
Below -20°C:
 Refer to the section "Starting procedure when the exterior temperature is below -
20°C".
Starting procedure when the exterior temperature is above 0°C
 Make sure that the electrical system is switched to on.

 Push and hold the "Start/Stop" engine button on the keyboard.
 The engine start procedure begins and the first LED in the button comes on.
 First LED in the button goes off when you release the button.
Starting procedure when the exterior temperature is below 0°C

After starting the engine, the attachment must be moved slowly in order to gradually
increase the oil temperature in the hydraulic system.
The starting procedure is described in the section "Warm-up procedure".
Starting procedure when the exterior temperature is below -20°C

For starting at temperatures below -20°C, it is recommended to equip the machine
with a preheating system in accordance with Liebherr. If this system is installed, refer
to the section "Starting aids".
Note!
If the excavator is switched off and the ambient air temperature is above -10°C, or
if the excavator is turned off less than one hour and the ambient air temperature is
below - 10°C (e.g. for daily maintenance):
 Follow standard procedure to park the excavator.
 Start the excavator by following the starting procedure when the exterior temper-
ature is below 0°C.

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Speed adjustment
Fig. 3-52 Speed indication on the main menu of the display
You can set the engine speed in different specified steps with the "Increase engine
speed" and "Decrease engine speed" buttons, which are located on the A168 Pow-
erPack keypad. The selected speed is shown on the display with a dial indicator.
Increase the engine speed

 Push and release the "Increase engine speed" button.
 The engine speed increases until the next higher step.
 Push and hold the "Increase engine speed" button.
 The engine speed increases continuously.
 The LED in the button flashes until you get the maximum speed.
 The LED in the button is on while the maximum speed is selected.
Decrease the engine speed

 Push the "Decrease engine speed" button.
 The engine speed decreases to the previous lower step.
 Push and hold the "Decrease engine speed" button.
 The engine speed decreases continuously.
 The LED in the button flashes until you get the minimum speed.
 The LED in the button is on while the minimum speed is selected.

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Eco / Power modes

Use this button to switch quickly between the "Eco" mode (fuel saving mode) and the
"Power" mode (full engine speed).
 The engine speed is set to the "Eco" mode.
 The LED above "Eco" in the button comes on.
 The engine speed is set to the "Power" mode.
 The LED above "Power" in the button comes on.
Each time you push the button, the engine speed switches from one mode to the oth-
er.
You can also set the "Power" mode when you set the engine speed to the last step
with the "Increase engine speed" button.
Auto idle mode

The auto idle function reduces automatically the engine speed, e.g. when the ma-
chine is on but you do not operate it.
Caution!
 Make sure that the auto idle function is switched to off when:
– You start the Diesel engine.
– You travel on slopes.
 To prevent Diesel engine damages, do not let the it in auto idle mode for an ex-
tended period.

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 Push the "Auto idle" button.

 The auto idle function is on, but it is not activated.
 The LED on the button comes on.
 If you let the joysticks and pedals in neutral position during the specified auto idle
interval:
 The auto idle function is activated.
 The engine speed is automatically reduced.
 The E / P mode and the engine speed are stored. The related symbol flashes
on the display.
You can set the auto idle interval in the submenu "Auto idle control" of the monitoring
display.
 If you push on the "Increase engine speed" button while the auto idle function is
activated:
 The engine speed does not change.
 The new step is stored.
 If you push on the "Decrease engine speed" button while the auto idle function is
activated:
 If the new step is higher than the auto idle speed, the engine speed does not
change and the new step is stored.
 If the new step is lower than the auto idle speed, the auto idle function is de-
activated.
 If you operate the joysticks or the pedals:
 The auto idle function is deactivated.
 The engine speed is set to the stored value.
 Push the "Auto idle" button again.
 The auto idle function is off.
 The LED on the button goes off.
Notes after starting the engine
Danger!
Danger of suffocation.
 When operating in enclosed spaces, only run the engine in areas with sufficient
ventilation.
 Open doors and windows to ensure sufficient supplies of fresh air.
Caution!
 Bring the engine and hydraulic oil up to operating temperature. The controls op-
erate sluggishly at low oil temperatures.
 Move the machine carefully in an open space to test the function of the travel
and swing brakes.

 Check that the attachment is operating perfectly.

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Stop the Diesel engine
Caution!
The engine could be damaged.
 Do not switch off the engine suddenly from full throttle.
 Push the "Start/Stop" engine button on the keyboard.

 The engine turns at minimum speed during 180 seconds.
 The right LED in the button and the related symbol on the display flash.
 Then the engine stops. The right LED and the display symbol are on.
 The right LED goes off.
 Turn the ignition key S1 to position "0" to switch to off the machine.
 Remove the ignition key S1.
3.3.2 Starting aids (optional)

Optional starting aids devices can be installed on the machine. According to the am-
bient temperature of the work environment, these devices can have:
– A basic equipment required for the system operation:
• a coolant heater
• resistors for the heating of fuel and electrical boxes
• an additional cab heater
• a heated windscreen
• a special gear pump for the travel motors flushing
• a starting fluid system
– Additional devices which can be installed to improve the overall efficiency of the
system:
• louvers and tarpaulins
• a preheating of the hydraulic oil
• a connection for an external warm air duct
• a foot heater in the cab
 Do the preheating procedure that follows with the related devices.
This section gives the procedures to perform manually.
 For automatic functions and devices, refer to the Service Manual. LEC/en/Edition: 04 / 2017

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Measures to be taken before Diesel engine stop or before to

start the preheating procedure
Fig. 3-53 Backhoe (up) and shovel (down) attachments position
 Lay down the attachment on the ground in order to have a maximum quantity of
oil in the hydraulic tank: stick and bucket cylinders fully retracted, bucket on the
ground.
The machine can be equipped with additional tarpaulins, louvers and covers in order
to improve the thermal insulation of the coolers, the PowerPack and the pumps box.
Fig. 3-54 Additional tarpaulins and louvers (if installed)
1 Tarpaulins 3 Crank handle

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2 Louvers 4 Covers
When the crank handle 3 is not used, it is installed in the PowerPack, against the
counterweight.
 If installed, close the additional tarpaulins 1 and louvers 2 with the crank handle 3.
Notes on preheating procedure

The machine start is not recommended before the preheating procedure below is
completed with the starting aids devices.
The standard preheating procedure takes 120 minutes.
 Take this time into account for the machine start. This period can change with en-
vironmental conditions.
Preheating procedure
Turn on the preheating electrical system (basic equipment)

Special preheating batteries (24 V - 180 Ah) supply electrical power for the preheat-
ing devices.
Fig. 3-55 Circuit breakers of the special preheating batteries
1 Box of the special preheating batteries

2 Circuit breaker of the special preheating batteries
 Make sure that the circuit breakers 2 of the special preheating batteries are in po-
sition "CLOSE".
 During the machine operation, let the circuit breakers 2 in position "CLOSE" to
charge the special preheating batteries.
You can monitor the special preheating batteries with the voltmeter P8.2, which is lo-
cated on the cab control board.

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Fig. 3-56 Voltmeter of special preheating batteries
P8.2 Voltmeter of special preheating batteries
Start the coolant heater (basic equipment)

Fig. 3-57 Devices for coolant preheating

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1 Coolant heater
2 Manual valves (3x)
 Make sure that the Diesel engine of the machine and the coolant heater 1 are
switched to off.
 Make sure that all the manual valves 2 are opened.
 Start the coolant heater as given below.
Fig. 3-58 Control unit U106 of the coolant heater
U106 Control unit of the coolant heater
The coolant heater is started and set with the control unit U106 and the related but-
tons that follow:
Previous
This button is usually used to select a menu or a parameter.
Next
This button is usually used to select a menu or a parameter.
Filled
This button is usually used to confirm a selection or a setting.
Blank
This button is usually used to go back to the previous menu.

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 Refer to the sections that follow for the control unit U106 operation.
Start the control unit

When the U106 display is off:
 Push one of the buttons above for less than 2 seconds.
Set the time

 Start the control unit.
 Push the "Previous" or "Next" button to select the menu "Settings" in the upper
frame of the U106 display.
 This symbol flashes.
 Push the "Filled" button.
 The symbol "Time" flashes in the lower frame of the U106 display.
 Push the "Filled" button to go to this submenu.
 Set the time with "Previous" or "Next" button.
 Push the "Filled" button each time to confirm the settings.
 Push the "Blank" button to go back to the menu "Settings".
 Push the "Previous" or "Next" button to select the submenu "Day" in the lower
 Set the day with "Previous" or "Next" button.
 Push the "Filled" button to confirm the setting.
Start and stop the coolant heater manually

 Push the "Filled" button for more than 2 seconds.
 The heater is on.
 Push the "Blank" button for more than 2 seconds.
 The heater is off.
Record the automatic starting time

 Start the control unit.
 Push the "Previous" or "Next" button to select the menu "Program" in the upper

 Push the "Previous" or "Next" button to select a program number.

 The program number parameters are shown.

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 Push the "Previous" or "Next" button to select the submenu "Settings".

 Set the day, hours and minutes with "Previous" or "Next" button.
 Push the "Filled" button each time to confirm the settings.
Set the duration of the operating time

In the same submenu as above, you can also set the operating time of the coolant
heater.
 Set the necessary operating time with the "Previous" or "Next" button.
 Push the "Filled" button to confirm the setting.
The coolant heater will automatically stop.
Start and stop the coolant heater automatically

 Go to the menu "Program".
 Select a program number.
 Push the "Previous" or "Next" button to select "ON".
 The automatic start and stop of the coolant heater is activated, with the param-
eters set in the sections above.
 Push the "Previous" or "Next" button to select "OFF".
 The automatic start and stop of the coolant heater is deactivated.
Caution!
The coolant heater current time and the recorded data will be erased if the preheat-
ing electrical system is opened.
 Let the circuit breakers of the preheating electrical system in position "CLOSE"
to keep the data.
Thus, while the coolant heater is on or on standby, the special preheating batteries
continue to supply the resistors for the heating of the electrical boxes.
 Monitor the state of charge of the special preheating batteries.
Warning lights
After the coolant heater start, Diesel engine coolant and block warm up. Thus, differ-
ent warning lights are located on the cab control board to control this preheating.

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Fig. 3-59 Warning lights of coolant preheating
H168 Level of special fuel tank of coolant heater

H169 Temperature of Diesel engine coolant
Level of special fuel tank of coolant heater

As it will be difficult to restart the system in case of fuel exhaustion, the warning light
H168 comes on if the level in the special fuel tank is too low.
If the warning light H168 comes on:
 Stop the Diesel engine.
 Stop the coolant heater using the control unit U106.
 Refer to chapter 5 of this manual to fill the special fuel tank of the coolant heater.
Danger!
 Do not fill the special fuel tank of the coolant heater and the machine fuel tank if
the Diesel engine and the coolant heater are not switched to off.
Temperature of Diesel engine coolant

The warning light H169 is on as long as the coolant temperature is too low to start in
good conditions.
 Do not start the Diesel engine as long as the warning light H169 is on.
The preheating of Diesel engine coolant stops automatically.
 After the coolant heater switch off, wait for 5 minutes before switch to off the bat-
teries (to let the fan stop because of risk of device overheating).
 Do not disconnect the batteries if the fan and/or the pump of the coolant heater
are on.

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Preheating of hydraulic oil (if installed)

This procedure is applicable only if the optional preheating of the hydraulic oil is in-
stalled.
If not installed
 Move to the next basic equipment.
If installed
The preheating of the hydraulic oil works with:
– immersion resistors in the hydraulic tank
– a circulating heating system
It is supplied by an external electric power supply (Gen-Set) which is not provided
with the machine. According to local power supply, the Gen-Set must supply a mini-
mum of:
– 17,5 kW - 25 A - 400 V / 50 Hz
– 17,5 kW - 21 A - 480 V / 60 Hz
At this step, the preheating of the Diesel engine coolant is already in progress and
the machine is switched to off.
Fig. 3-60 Circulating heating system (if installed)

1 Circulating heating system

2 Manual valve (1x)
 Make sure that the manual valve 2 is opened.

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Fig. 3-61 Control box of the circulating heating system (if installed)
3 Control box switch

4 Circuit breaker of control box
E1090 Control box of the circulating heating system
The control box E1090 is located in the cab elevation.

 Make sure that the switch 3 on control box E1090 is in position "ON" or "LOCAL".
 Make sure that the circuit breaker 4 on control box E1090 is in position "ON".
Fig. 3-62 External socket (if installed)
5 External socket
 Connect the Gen-Set to the external socket 5.

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Fig. 3-63 Warning light H68: external Gen-Set connected
The warning light H68 located on the cab control board comes on. This function is
automatically regulated.
 Do not disconnect the Gen-Set at this step.
 Do not wind and/or attach the Gen-Set cable on the machine (e.g. on the catwalk).
Caution!
If it is necessary to start the Diesel engine during this step, travel and swing move-
ments are not allowed if the additional external Gen-Set is connected.
Additional connection for warm air duct (if installed)
Fig. 3-64 Additional connection for warm air duct (if installed)
A special interface can be installed under the uppercarriage structure to connect an

external blower heater (which is not supplied with the machine) to warm up different
environments. The warm air duct must have a diameter of approximately 250 mm.

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At this step of the preheating procedure, the preheating of the Diesel engine coolant
is already in progress and the machine is switched to off.
 Connect the external blower heater.
Caution!
If it is necessary to start the Diesel engine during this step, travel and swing move-
ments are not allowed if the additional external warm air duct is connected.
Preheating of fuel (basic equipment)

At this step of the preheating procedure, the Diesel engine coolant temperature must
be in good conditions.
 Make sure that the warning light H169 is off.
 Turn on the machine electrical system. Refer to "Starting the Diesel engine" sec-
tion.
The fuel preheating automatically starts.
 Wait for 5 minutes before going on with next step.
This function will automatically stop.
 If installed, disconnect the Gen-Set and the external warm air duct.
Start the machine

 Make sure that all the preceding steps are finished.
If installed, as long as the Gen-Set and the external warm air duct are connected,
swinging and travelling movements are not possible and not allowed, even if it is pos-
sible to start the Diesel engine.
 If installed, disconnect the Gen-Set and the external warm air duct.
 Do the warm-up procedure given below in this manual.
Diagnostic unit of the coolant heater

The on-board diagnostic unit shows the recorded error codes which occur on the
coolant heater during operation.
Start the diagnostic

 Make sure that no preheating procedure is in progress.
 Make sure that the control unit U106, which is located in the cab, is off.

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Fig. 3-65 Diagnostic unit system
1 Cab elevation
E1049 Electrical box of the starting aids
F266 Fuse 1A
U163 Diagnostic unit of the coolant heater
The diagnostic unit system is installed in the electrical box E1049, which is located
in the cab elevation.
 Set the fuse F266 to on.
 The diagnostic unit U163 starts automatically.
Then, the diagnostic unit U163 is controlled with the buttons that follow:
Previous
This button is usually used to go back in the menus.
Next
This button is usually used to access to the next menus.
OK
This button is usually used to confirm a selection.
 Wait until the two units U163 and U106 are interconnected.
 During this time, the symbol "INI" is shown on the U163 display.
 When the U163 display is blank, push the "OK" button.
 The diagnostic starts automatically.

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Get the error codes

This section is available only for the diagnostic unit U163.
For the error codes chart, you must refer to the Troubleshooting Instructions of the
coolant heater manufacturer.
– If the symbol "STOP" is shown on the display:
 There is no error code that is active at the moment.
– If the symbol "ERR" is shown on the display:

 There is an active error code.
– In the two cases:

 You can have a view of the recorded error codes.
 You can erase the error codes memory.
Get the active error code
 Push the two buttons "Previous" and "Next" at the same time.
 The active error code is shown with the label "AF".
Get the recorded error codes
 Push one of the two buttons "Previous" or "Next".
 The recorded error codes are shown with the label "F".
Erase the error codes memory

 Select the active error code or a recorded error code.
 Push the "OK" button.
 The symbol "DEL" is shown on the display.
 Push the "OK" button again.
 The error codes memory is erased.
 The symbol "STOP" is shown on the display.
If necessary, you can also unlock the control unit with this procedure.
Stop the diagnostic

This section is available only for the diagnostic unit U163.
When the symbol "STOP" is shown on the display:
 Push the "OK" button.
 Set the fuse F266 to off.
3.3.3 Warm-up procedure for Diesel engine and hydraulic circuit

If the excavator is started when the exterior temperature is below 0°C, the operator
must do the warm-up procedure:
 Make sure that the hydraulic oil temperature is sufficient (refer to lubricating sec-
tion in chapter 5) to do this procedure. If this temperature is not sufficient when a
preheating system is installed on the excavator, keep preheating.
 Let the engine idle at approximately 1/2 rated speed during the first 3 to 5 minutes
and make sure that no error symbols are shown on the monitoring display (refer
to the functions of the display in chapter 3).

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Note!
Depending on the excavators, the engine speed can be automatically limited for the
hydraulic oil warm-up. If not, use the special button installed on the keyboard.
 Refer to speed adjustment section in chapter 3.
Caution!
Idling for an extended period of time damages the engine.
 Switch off the Diesel engine if the machine is not being used.
 Step 1 - Open louvers and tarpaulins (if installed).

 Step 2 - Slowly increase the engine load until the coolant temperature reaches
40°C, on the temperature indicator of the main menu of the display.
 Step 3 - Carefully activate the working hydraulic circuits. Do not reach end posi-
tions of piston rod. Operate all movements at reduced speed:
– Smoothly lift up attachment.
– Slowly activate each cylinder of the attachment. Activate cylinder in order below
and repeat 10 times before moving to next cylinders:
• Shovel flap cylinders (in case of shovel attachment)
• Bucket tilt cylinders
• Stick cylinders
• Boom cylinders
– Slowly swing clockwise and counterclockwise on approximately 1/2 turn. Repeat
4 times in each direction.
 Step 4 - Repeat step 3 a second time.
 Step 5 - Repeat step 3, with reaching end position of piston rod.
 Step 6 - Repeat step 5 a second time.
 Step 7 - Check oil temperature in hydraulic tank. If oil temperature is under 10°C,
repeat step 5 until oil temperature reaches 10°C. If oil temperature is above 10°C,
move to step 8.
 The step 8 that follows is applicable only to crawler excavators.
 Step 8 - Start the travel hydraulic circuits very slowly forward and backward on
approximately 10 meters. Repeat 4 times.
The excavator can now be operated.

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3.3.4 Jump start procedure
Start with jump start cables
Danger!
When connecting to exterior batteries, old batteries can be subject to increased gas
formation.
 Wear protective goggles and gloves whenever jump starting, avoid naked flame
and creating any sparks in the vicinity of the flat vehicle battery. RISK OF EX-
PLOSION!
 Only use jump starting cables with a sufficient cross section. Always follow the
established jump starting procedure.
Connect the batteries

 First connect the cable to the positive terminal (+) of the flat battery and then to
the positive terminal (+) of the exterior battery.
 Connect the second cable to the negative terminal (-) of the flat battery and then
to the negative terminal (-) of the exterior battery.
 Start the engine as described above.
Caution!
 Before removing the jump start cable, be sure to place the diesel engine of the
jump started machine into low idle.
 For safety reasons, switch on large consumers such as work headlights, upper
carriage lighting etc. to avoid overvoltage. The electronics could otherwise be
damaged.
Disconnect the batteries

 First remove the cable from the negative terminal (-) of the exterior battery and
then from the negative terminal (-) of the flat battery.
 Remove the second cable from the positive terminal (+) of the exterior battery and
then from the positive terminal (+) of the flat battery.
 Check the electrical function of the machine.
For battery care and maintenance, see the chapter “Battery care”.
Start with auxiliary start receptacle

You can connect an external power supply to the machine through the auxiliary start
receptacle.

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Fig. 3-66 Auxiliary start receptacle
1 Auxiliary start receptacle (X60)

2 Protective cover
The auxiliary start receptacle (X60) 1 is located on the pumps box, near the engine
doors.
Connect an external power supply

The external power supply is not provided with the machine.
 Make sure that the ignition key of the machine is on "off" position.
 Switch the principal batteries switches of the machine to position "open".
 Remove the protective cover 2.
 Connect the external power source to the auxiliary start receptacle (X60) 1.
 Turn on the two electrical systems.
 Start the engine.
You can refer to section "Start and stop the machine" of this manual.
3.3.5 Emergency and safety operations
Emergency stop
Location of the emergency stop buttons

Different emergency stop buttons are installed on the machine.

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Fig. 3-67 Cab emergency stop S100_1
The emergency stop S100_1 is located on the cab control board.

Fig. 3-68 Electrical box E1086 emergency stop S100_2
The emergency stop S100_2 is installed on the electrical box E1086 which is located
on the power pack inner side, near the engine doors.

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Fig. 3-69 Emergency stop S100_3
The actuator of the emergency stop S100_3 is located under the counterweight.
Fig. 3-70 Actuator of emergency stop S100_4
The emergency stop S100_4 is located inside the engine box.

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Do an emergency shutdown
Caution!
Only use this method in case of emergency.
 Turn the ignition key S1 to the "off" position or push one of the emergency stop
buttons S100_1, S100_2, S100_3 or S100_4.
 This action will stop the Diesel engine and disconnect the electrical system.
 If an emergency stop is operated, the ladder is automatically lowered.
After a shutdown with an emergency stop button, you must unlock the button before
you try to start again.
Test of the Diesel engine starter (optional)

The electrical box E1086 can have test switches to do a functional test of each Diesel
engine starter.
Fig. 3-71 Starter test switches S51_1 and S51_2
 Make sure that the Diesel engine is switched to off.

 Push the starter test switches S51_1 and S51_2 on the electrical box E1086.
Safety controls for the Diesel engine

If you cannot start, monitor or operate safely the Diesel engine because a failure oc-
curs in the primary electronic circuit of the machine, you can keep it temporarily in
safety modes of operation.

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Safety start of the Diesel engine
Fig. 3-72 Safety control for the Diesel engine start
A161 Electrical plate in E1005

S1_A161 Safety switch
The electrical plate A161 is located in the cab connection box E1005. You can also
refer to chapter 4 of this manual.
 Turn the ignition key S1 until it is in its stop point.
 At the same time, push the switch S1_A161.
 The Diesel engine starts in safety operation.
 The machine stays in this mode until you turn the ignition key S1 to position
"0".

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Safety control of the Diesel engine speed
Fig. 3-73 Safety controls for the Diesel engine speed
R6 Engine RPM adjustment

S23 Engine safety operation ON
 Make sure that the safety start of the Diesel engine is on.
 Push the button S23.
 The indicator light in the button comes on.
 Turn the knob R6 clockwise to increase the engine speed.
 Turn the knob R6 counterclockwise to decrease the engine speed.
 When you use this mode, this symbol "Speed control off" is shown on the dis-
play.
Safety stop of the Diesel engine
Caution!
Do not suddenly turn the engine off when it is running at high idle.
 Decrease the Diesel engine speed to low idle with the knob R6.
 Let the Diesel engine run at low idle for 3-5 minutes to decrease the temperature.
 Then turn the ignition key S1 to the position "0" and remove it.

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Safety control for swing and travel brakes
Fig. 3-74 Safety control for swing and travel brakes

S73 Safety switch
If the swing and/or travel brake(s) does/do not operate correctly, because of the fail-
ure of the keypad A168:
 Push the switch S73.
In this mode, you can operate the brakes with the safety lever.
 Push the safety lever down.
 The brakes are disengaged.
 When you use this mode, this symbol "Brakes manu" is shown on the display.
 Push the safety lever up.

 The brakes are engaged.

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Safety controls for hydraulic pumps
Fig. 3-75 Safety controls for hydraulic pumps

S74_1 Safety switch for pumps power safety control
S74_2 Safety switch for pumps flow safety control
Pumps power safety control

During safety operation, a specified value for the power of the hydraulic pumps is ac-
tivated.
 Push the switch S74_1.
 When you use this mode, this symbol "Power control off" is shown on the dis-
play.
Pumps flow safety control

During safety operation, a specified value for the flow of the hydraulic pumps is acti-
vated.
 When you use this mode, this symbol "Flow control off" is shown on the dis-
play.

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Safety fans control
Fig. 3-76 Safety fans control

S74_3 Safety switch
If the engine cooling and/or oil cooling fan(s) does/do not operate correctly:
 The fans operate at maximum speed.
 When you use this mode, this symbol "Fan control off" is shown on the dis-
play.

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3.3.6 Driving
Driving straight ahead
Fig. 3-77 Driving straight ahead
1 Idler 5a / 5b Pedal for left drive unit

2 Sprocket wheel 6a / 6b Pedal for right drive unit
Caution!
When driving, the uppercarriage must be turned to the undercarriage in such a way
that when driving forwards, the idler 1 is in front and the sprocket wheel 2 is at the
rear.
Driving forwards:
 Push both pedals forward (5a and 6a).
Reversing:
Caution!
Before reversing, ensure that the area behind you can be safely entered.
 Push both pedals down (5b and 6b).
Turning on the spot

Fig. 3-78 Turning on the spot

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Turning left (A):

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

 Push the right pedal down (6b).
 Push the left pedal forwards at the same time (5a).
Turning with a crawler
Fig. 3-79 Turning with a crawler
Turning to the left (A):

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

 Push the left pedal forwards (5a).
Note!
If possible, avoid turning backwards in order to preserve the running gear parts.
Manual control of the travelling movements
Fig. 3-80 Hand levers for manual travel control

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 When particularly careful and progressive travel movements are required:

 Insert the hand levers 1 and 2 into the both pedals for travel movements.
 The travel movements can now be controlled manually.
Note!
When travelling the machine onto or off a low loader, the travel movements must
be controlled manually for safety reasons.
Controlling the speed

The driving speed is controlled by the "High speed gear" button of the control key-
board. The travel motors can be operated in two different positions:
– Normal drive (position 1):
Maximum tensile force of both drive units at moderate speed.
– Fast drive (position 2):
Reduced tensile force of both drive units at maximum speed.
 Press "High speed gear" button.
 Transfer from normal drive to fast drive is operated.
While driving, the machine will automatically switch from normal drive to fast drive as
the ground conditions permit. If the ground conditions become more difficult again,
the system will automatically switch from fast drive to normal drive.
 Press "High speed gear" button again.
 Transfer from normal drive to fast drive is deactivated.
When button is switched off, the travel motors remain continually in position 1.
Braking the machine
To stop the machine while driving:

 Disengage the pedals for the drive units.
 The pedals will return to the neutral position.
 The travelling mechanism will be stopped.
 The machine will stop.
When the pedals for the drive units are in the neutral position, the hydrostatic drive
prevents the machine from rolling off.
Caution!
Disengaging the pedals quickly causes the machine to stop abruptly.
 Before starting the machine, always fasten the safety belt.
To engage the travel brake:

 Operate the "Travel brake" button on the related keypad:

 Travel brake is engaged.
 Undercarriage is locked.
 Press "Travel brake" button again to release the travel brake.
The travel brake is engaged if the safety lever is up and the access ladder (if in-
stalled) or the service trap (if installed) are down.

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Working with the machine
Towing the machine safely

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

– Before you start working, acquaint yourself with the special features of the job site
and any special precautions and warning signals. Examples of particular work en-
vironments would be on-site or traffic obstructions, the load-carrying capacity of
the ground and any requirements to make the job site safe from public use.
– Always maintain a safe distance from overhangs, edges, slopes and unsafe
ground.
– Be particularly careful in conditions of reduced visibility and changeable ground
conditions.
– Familiarize yourself with the location of power lines on the job site and take par-
ticular care when working near them. If necessary, inform the responsible author-
ities.
– Maintain a safe distance from electrical aerial lines. Do not allow the attachment
to come near cables when working near electrical aerial lines. Risk of fatality! In-
form yourself about required safety distances.
– The following actions must be carried out in the event of any transfer of electricity:
• do not move the machine or its attachment,
• do not leave the driver’s cab,
• warn any personnel in the vicinity not to come close to the excavator and
not to touch it,
• instruct or initiate that someone turns off the voltage.

• move the machine, if possible, from the danger zone to a sufficient distance,
• Do not leave the machine until you are absolutely sure that voltage in the line,
which had been touched or damaged, has been turned off !
– Before moving the machine, always ensure that any attachments are safely se-
cured.
– When driving onto public roads, paths and squares, observe current traffic regu-
lations and if necessary, ensure that the machine has been made safe as per reg-
ulations beforehand.

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– Always turn on the lights in conditions of poor visibility or darkness.

– Do not permit any passengers in the machine.
– Only work when seated properly and with the safety belt securely fastened (if
available).
– Report all function faults and ensure that all necessary repairs are carried out im-
mediately.
– Assure yourself that no one is endangered when you start the machine moving.
– Before you start working, test the brake system in accordance with the regulations
given in the operating instructions.
– Never leave the driver’s seat while the machine is moving.
– Never leave the machine unattended while the engine is running.
– The machine must be positioned, moved and operated in such a way that it is sta-
ble and that there is no danger of overturning. Only known loads may be moved
with the attachment; this applies particularly when using the grab.
– Position the upper structure in the longitudinal direction when moving and hold
the load as close to the ground as possible.
EXCEPTION: excavators used for loading and unloading, see the part "Safe use
when loading and unloading (particularly when loading and unloading wood)" on
page 109.
– Adjust your driving speed to suit site conditions.
– Avoid any working movements which may tip the machine. Should the machine
start to tip or slide sideways, however, turn the upper structure to face downhill
and lower the attachment at the same time.
– As far as possible, work downhill or uphill and not side on to the slope.
– Drive safely on stony, slippery or inclined ground
– Only drive downhill at the permitted speed or you could lose control of the ma-
chine.
– Always shift down to a lower running step before a slope. When doing this, the
diesel engine must run at maximal speed and the speed may only be reduced us-
ing the foot pedals.
– Load an occupied truck only if all safety requirements are fulfilled, notably in order
to protect the truck operator.
– For demolition work, digging and crane operations etc., always use protective de-
vices specifically designed for the purpose.
– For terrain which is difficult to gain an overview of and whenever necessary, ask
for the assistance of a spotter. Only permit one person to give you signals.
machine operator. This people must be in the operator’s sight or in radio contact
with him.
work tool and the machine (uppercarriage and undercarriage). The greatest de-
gree of care must be taken to avoid damage.
work tool and the cab, the cab protection or the boom cylinders. The greatest de-
gree of care must be taken to avoid damage when the hoe teeth come within this
area.
work tool and the attachment parts. The greatest degree of care must be taken to
avoid damage.
lift ring of the attachment and the cab or the cab protection. Before operating, en-
sure that there is no risk of collision, especially on excavator with cab elevation.

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If necessary remove the lift ring.

– In case of a thunderstorm:
• lower the attachment to the ground and if possible anchor the digging tool into
the soil.
• leave the cab and move away from the machine before the storm breaks out.
Otherwise, you must stop the excavator, turn off the radio and keep inside the
closed cab until the end of the storm.
– Auxiliary control units can have various functions. Always check their functions
when starting up the machine.
– Stop the swinging motion of the uppercarriage when lowering the attachment into
a ditch without striking the attachment on the ditch walls.
– Inspect the machine for damage if the attachment has been swung into a wall or
any other obstacles.
– Applications in which the attachment is to be used to strike the material being ex-
tracted are not permitted, even when working in a longitudinal direction.
– Repeated strikes against an object leads to damage to the steel structures and
machine components.
– Please refer to your Liebherr dealer if special teeth for heavy-duty or special ap-
plications are required.
– Do not attach too large bucket or bucket with side cutters or that are during oper-
ations with rocky material. This would prolong the work cycles and may lead to
damage to the bucket as well as further machine components.
– With the 2x45° offset articulation, the offset position may only be employed if the
working tool or the attachment does not touch the material.
– Operation of the offset articulation to drill into the material is not permitted.
– Do not lift the machine during operation. Should this happen, lower the machine
slowly back to the ground.
– Do not let the machine fall heavily on the ground and do not hold it back with the
hydraulics. This would damage the machine.
– During operation with the attachment it is forbidden to raise the machine with the
dozing blade (e.g. carving at the ceiling when tunnelling).
– Do not dig under the undercarriage. Take all necessary measures to prevent
ground collapse under the machine.
– The operation of Liebherr Mining machines in the following Mining applications is
not approved or condoned by Liebherr:
• Batter pulling (also known as Scaling), without exception.
• Double benching (also known as Split benching or Double flitching) when the
material is un-blasted and non-fragmented material which requires the boom
down (rod side) pressure to exceed 50 bar.
The use of these Mining methods will result in increased fatigue levels to steel
structures and components of the respective Liebherr Mining Machine and
therefore will significantly reduce the expected lifetime of structures and/or com-
ponents.
Safe use of a hydraulic hammer or a hydraulic ripper

– According to the severity of the application, the use of a hydraulic hammer or a
hydraulic ripper can result in vibrations, shocks or stresses which are higher than
in normal use. It may reduce the expected lifetime of structures and/or compo-
nents.
– The hydraulic hammer or the hydraulic ripper must be selected with particular
care. When using a hydraulic hammer or a hydraulic ripper not permitted by Lieb-
herr, warranty for steel structures and machine components will be ceased.

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– Use a hydraulic hammer or a hydraulic ripper designed exclusively for breaking
stone, concrete and other breakable materials.
– Only operate the hydraulic hammer or the hydraulic ripper in the longitudinal di-
rection of the machine and with the windshield closed or with a front protective
grid.
– Ensure during hammer or ripper operation that no cylinder is entirely extended or
retracted and that the stick is not in the vertical position.
– In order to avoid damages to the machine, try not to break stone or concrete while
performing retraction and extension motions of the hydraulic hammer.
– Do not apply the hydraulic hammer uninterrupted for more than 15 seconds at a
time to the same place. Change the breaking point. Too long uninterrupted oper-
ation of the hydraulic hammer leads to an unnecessary overheating of the hydrau-
lic oil.
– Do not use the drop force of the hydraulic hammer or of the hydraulic ripper to
break stone or other materials. Do not move obstacles with the hydraulic hammer.
Misuse of this nature would damage both the hammer and the machine.
– Do not use the hydraulic hammer or the hydraulic ripper to lift objects.
– Before beginning breaking tasks, the pressure of the dampening accumulator of
the hydraulic ripper must be adjusted depending on the nature of the ground and
the excavator model.
Safe use of a ripper

– Rippers are generally used in applications where the use of a bucket is not effi-
cient to break out rocks. Thus, these applications are more severe than in normal
use.
– According to the severity of the application, the use of a ripper can result in vibra-
tions, shocks or stresses which are higher than in normal use. It may reduce the
expected lifetime of structures and/or components.
– Special hydraulic devices can be necessary. Contact the Liebherr customer ser-
vice.
– The ripper must be selected with particular care. When using a ripper not permit-
ted by Liebherr, warranty for steel structures and machine components will be
ceased.
– Do not use the ripper to lift objects.
Safe use when loading and unloading (particularly when

loading and unloading wood)
– According to use, it can be necessary when working with a grab to move with the
attachment raised and the load lifted up; this applies, for example, when loading
and unloading wood.
– Here, the centre of gravity of the machine will be displaced upwards in the vertical
direction. The driving characteristics of the machine will thus be influenced per-
sistently, e.g. through reduction of the dynamic stability.
• Adjust vehicle handling to suit the altered machine characteristics and environ-
mental conditions.
noeuvres.

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rection.
• Only rotate the uppercarriage when the undercarriage is stationary.
• Only rotate the uppercarriage after you have picked up the load.
• Only move the machine when you have picked up and lifted the load and rotat-
ed the upper structure to the driving position.
• There is a danger of possible swinging movement and dropping of the load
when the attachment is raised.
• A protective grid (FOPS) in accordance with ISO 10262 must be attached to the
cab.
• A protective roof (FOPS) in accordance with ISO 10262 must be attached if
there is a risk of objects falling from above.
• Only the maximum permissible load may be taken up using the grab.
– NOTE: The weight of absorbent materials, such as logs, is dependent on length,
diameter and specific weight. The influencing variables present in a natural prod-
uct, such as moisture, must be noted.
– Working procedures when using machines with grabs require the machine oper-
ator to receive special instruction and training.
– Use as part of the work process is only permitted when the machine operator has
sufficient training and practical experience.
Safe use of machines with tower elevation

– Due to the tower elevation, the centre of gravity of the machine will be displaced
upwards in the vertical direction. The driving and work characteristics of the ma-
chine will thus be influenced persistently, e.g. through reduction of the dynamic
stability.
– Due to the heightened centre of gravity, the machine must be aligned horizontally
before use. In horizontal alignment, the centre of gravity of the uppercarriage is
over the centre of the undercarriage, which reduces the risk of tilting.
– The machine can still sway and tilt despite being aligned!
When moving the machine:
• Rotate the uppercarriage parallel to the undercarriage (transport position).
• Draw the attachment as close as possible to the machine.
• Only at this point may the support feet be retracted and the machine moved.
• Moving with loads is not permitted.
• Check the terrain to be covered to ensure that the ground is solid and even. Pot-
holes and uneven surfaces jeopardize the stability of the machine.
• Adjust vehicle handling to suit the altered machine characteristics (high centre
of gravity) and environmental conditions.
noeuvres.
rection.
• Ascending gradients and obstacles may only be approached in the longitudinal
direction in order to prevent unacceptable banking of the machine.
• Special care should be taken when driving through narrow passages - drive
slowly!
When loading and unloading:
• The machine must be supported and aligned horizontally before moving (swing)
the uppercarriage out of the transport position.
• It is imperative that you check the contact surface of the support (load carrying
capacity of the substrate). A support subsiding would have disastrous conse-
quences!
• Carry out all movements with increased care.

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• To slew the load, move the attachment as close as possible to the machine
(Caution! swinging grab) and hold the load close to the undercarriage and
above the substrate.
• Avoid braking or accelerating the attachment or uppercarriage abruptly.
• Do not lift any loads which are heavier than those given in the load chart.
Protection from vibration

– Vibrational loads on mobile building machinery are mainly the result of the type
and method of use. The following parameters in particular are decisive influences:
• Terrain conditions: Uneven areas and potholes;
• Operational techniques: Speed, steering, brakes, controlling the machine’s
control elements when driving and working.
– To a large extent, the machine operator determines the vibrational loads since he
selects the speed, gearbox ratio, working method and route himself.
This means that there is a wide range of different vibrational loads for the same
machine type.
Whole-body vibrational load for the machine operator can be reduced if the following
recommendations are observed:
– Select suitable machines, attachment parts and auxiliary devices for each part of
the job.
– Use a machine that has a suitable seat (i.e. for earth-moving machinery such as
hydraulic excavators, this should be a seat which corresponds with EN ISO
7096).
structions.
– Check the maintenance status of the machine, particularly with respect to: tyre
pressure, brakes, steering, mechanical connections etc.
– Do not steer, brake, accelerate, shift gears, move or load the machine’s attach-
ment jerkily.
– To reduce vibrational load, adjust the machine speed to suit the route as follows:
• Reduce speed when driving on difficult terrain;
• Drive around obstacles and avoid driving on very difficult terrain.
– Keep the terrain on which the machine is working and driving in good condition:
• Remove large stones and obstacles;
• Fill in ruts and holes;
• Have machines ready to prepare and maintain suitable ground conditions and
calculate in sufficient time to carry out any work required.
– Drive longer distances (e.g. on public roads) at an appropriate (medium) speed.
– Use special auxiliary systems (if available) which reduce vibration for machines
that are driven frequently.
If such auxiliary systems are not available, regulate speed to avoid "oscillating"
the machine.
3.4.1 Operating the swing gear
Turning the uppercarriage

The uppercarriage is turned using the left joystick.

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Fig. 3-81 Turning the uppercarriage
 Move the left joystick to the left c.

 Uppercarriage turns left.
 Move the left joystick to the right d.
 Uppercarriage turns right.
Braking the uppercarriage

The machine has a hydraulic and a mechanical swing gear brake.
Hydraulic swing gear brake

 Move the left joystick to neutral.
 A sufficient deceleration of the uppercarriage is achieved.
 Move the left joystick to the opposite direction.
 Maximum hydraulic braking action of the uppercarriage is achieved.
Mechanical swing gear brake

The uppercarriage can be locked in any position using a multi disk brake integrated
in the swing gear.
The brake is negatively acting, hydraulically actuated and serves as a holding or
parking brake.
Caution!
Damage to the machine.
 Only lock the mechanical swing gear brake when the uppercarriage is station-
ary.

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 Press "Swing brake" button on the keyboard.

 Swing brake is engaged.
 Uppercarriage is locked.
 Swing brake is released.
 Uppercarriage is unlocked.
The swing brake is engaged if the safety lever is up and the access ladder (if in-
stalled) or the service trap (if installed) are down.
Caution!
The brake only applies when the uppercarriage is near standstill and if no swing mo-
tion is actuated with the joystick.
To stop the uppercarriage when working on a slope:

 Use the joystick to reduce the uppercarriage speed.
 Press "Swing brake" button to operate the swing brake.
 Move the joystick back to "0" position only after the brake operates.
Semi-automatic swing brake control (optional)

 Make sure that the swing brake does not operate.
 Tilt down the rocker switch S57 on the right joystick handle.
 The semi-automatic control of the swing brake is on.
When the semi-automatic control of the swing brake is on:
– When the uppercarriage speed is less than a limit value:
• The swing brake is applied.
• The first and the second LEDs in the "Swing brake" button come on.
• The swing brake symbol shows on the monitoring display.
– When the uppercarriage speed is more than the limit value:
• The swing brake is released.
• The first and the second LED in the "Swing brake" button go off.
• The swing brake symbol disappears from the monitoring display.
 Tilt up the rocker switch S57.
 The semi-automatic control of the swing brake is off.
 The swing brake is released.
Caution!
The brake only applies when the uppercarriage is near standstill and if no swing mo-
tion is actuated with the joystick.
To stop the uppercarriage when working on a slope:

 Tilt down the rocker switch S57.
 Use the joystick to reduce the uppercarriage speed.
 Move the joystick back to "0" position only after the brake operates.

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Emergency stop of the uppercarriage swing motion

The swing brake can be applied independently of the uppercarriage RPM by pushing
"Swing brake" button into position "applied".
Caution!
Perform this braking with the "Swing brake" button only in case of emergency as it
causes fast abrasion of the brake discs.
To check the mechanical swing gear brake:

 Uppercarriage must be stationary.
 Press "Swing brake" button.
 Swing gear brake is engaged.
 LED in switch comes on.
 Push the left joystick to the right and then to the left to stop.
 Uppercarriage must not turn.
 Swing gear brake function is operational.
3.4.2 Working position
Fig. 3-82 Working position – machine
Work with the machine is generally to be carried out over the idler-wheel.
 Drive backwards when you are working lengthwise with the backhoe bucket.
3.4.3 Joystick functions when setting up the machine

Operating the stick cylinder

The stick cylinder is operated using the left joystick 4.

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Fig. 3-83 Operating the stick cylinder
 Move the joystick rearward a.

 Stick will be drawn in.
 Move the joystick forward b.
 Stick will be extended.
Operating the boom cylinder

The boom cylinder is operated using the right joystick 3.

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Fig. 3-84 Operating the boom cylinder
 Move the joystick rearward h.

 Attachment will be raised.
 Move the joystick forward g.
 Attachment will be lowered.
Boom down with pressure
Fig. 3-85 Operating the boom down with pressure
By actuating the boom down as described in the section "Operating the boom cylin-
der", the boom falls pressureless down.
 Move the joystick forward g.

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 Push the button S6R right on top of the right handle at the same time.
 Boom will fall with pressure.
 A buzzer operates in the cabin.
Float position of boom cylinder (with shovel attachment only)
Fig. 3-86 Float position
 Move the right joystick 3 forward g.

 Push the button S6 on top of the joystick at the same time.
 Now the bucket can be used for grabing work while moving the joystick 4 for-
ward to extend the crowd cylinders.
 The attachment can then move freely up or down depending on grade and the
bucket will automatically follow the ground contour.
Operating the bucket

The bucket is operated using the right joystick 3.
Fig. 3-87 Operating the bucket cylinder
 Move the joystick to the left e.

 Bucket will be tilted inwards.

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 Move the joystick to the right f.

 Bucket will be tilted outwards.
Shake the bucket (with backhoe attachment only)

You can shake the bucket to remove dirt collected in the backhoe bucket.
 Operate very quickly the right joystick 3 as follows:
– Move the joystick fully to the right or to the left.
– Move the joystick to the neutral position.
– Move the joystick fully to the right or to the left again.
 While you do this sequence, the bucket shakes.
Caution!
Repetitive shakings cause fast wear of the components.
Operating the bottom dump bucket for shovel attachment
Danger!
Additional operating and control elements (joysticks/pedals) can have different
functions.
 Always check functions of operating and control elements when you start a ma-
chine which has an additional attachment.
Manual flap control

You can control the bottom dump shovel bucket with the pedal or with the joystick.
Fig. 3-88 Rotary switch for control selection
 Use the rotary switch S256 to select one of the two control modes:
– with the pedal
– with the joystick

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Manual flap control with the pedal

 Make sure that the related mode is selected with the rotary switch S256.
Fig. 3-89 Operating the bottom dump shovel bucket
The bottom dump shovel bucket is moved with the two pedals 7a and 7b.
 Push pedal 7a.
 Shovel bucket will be opened.
 Push pedal 7b.
 Shovel bucket will be closed.
Manual flap control with the analog stick
 Make sure that the related mode is selected with the rotary switch S256.
Fig. 3-90 Flap control with the analog stick

 Push the analog stick on the right joystick 3 to the right 7a.
 Shovel flap will be opened.
 Push the analog stick on the right joystick 3 to the left 7b.
 Shovel flap will be closed.

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Semi-automatic flap closing
Fig. 3-91 Semi-automatic flap closing
 Push the button S6L left on the down of the right joystick 3.
 Shovel flap will be closed automatically with full speed.
 Push the button S6L again during semi-automatic flap movement.
 Shovel flap movement will be stopped.
Note!
If you keep the button S6L pushed, the semi-automatic flap closing movement will
not start.
If you operate the shovel bucket pedal 7a or 7b during semi-automatic flap closing
movement, the automatic movement will be stopped and flap control is switched to
manual operation through pedals 7a and 7b.
Deactivation of the attachment damping system

The damping system stops the movement of the attachment before the cylinders get
suddenly the end position of the piston rods. If necessary, the deactivation of this pro-
tection is possible.

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Fig. 3-92 Deactivation of attachment damping system
 Move the attachment until the damping system stops it.

The cylinders are in their end stroke position.
 Let the two joysticks and pedals in neutral position.
 Press down the rocker switch S55 on the left joystick 4.
The attachment damping system is off.
Caution!
Repetitive movements without the damping system cause fast wear of the compo-
nents.
 Move back the attachment to automatically start the damping system back.
Combined movements
Moving a joystick diagonally results in the work functions concerned being combined.
This allows different attachment movements to be activated at the same time.
The operator can do the following movements without any additional manipulations.
When the swing movement is actuated, all working functions / movements are pos-
sible without affecting the swing movement.
During travel, every attachment movement is possible, but the swing movement has
priority. In this case, the travel movement is reduced.
3.4.4 Lowering the work equipment when the engine is not run-
ning
In an emergency, the attachment can be lowered when the diesel engine is not run-
ning.

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General working methods
Fig. 3-93 Lowering the attachment when engine is not running
 Turn the ignition key to contact position 1.

 Operate the joystick or the foot pedals until the attachment has lowered.
The attachment can be lowered because of the control oil unit’s pressure reserve.
This reserve is limited and is only sufficient for small movements of the pilot control
devices.
 Only operate the joystick in the directions for lowering the attachment.
3.5 General working methods
3.5.1 Minimum impact working methods for your machine

To increase the service life of the machine and avoid unnecessary damage and the
resulting repairs, please note the following points:
– Do not stop the rotary motion of the upper carriage when slewing into a ditch by
stopping the equipment on the walls of the ditch.
– Using the machine for applications where the equipment is knocked against the
material to be removed, in the longitudinal direction too, is not permitted. Repeat-
edly hitting the work equipment against rock or other hard material will damage
steel parts and machine components.
– With specific combinations of boom, stick and work tool, the work tool could hit or
break through into the cab. This could damage the cab and injure the machine’s
operator.
– Do not attach buckets which are too big or side cutters when using the machine
in rocky material. This will extend the work cycles and could result in damage to
the bucket and other machine components.
– Please contact your LIEBHERR contractual partner if special teeth are required
for heavy or special applications.

– Operating the drag bearing to bore into material is not permitted.
– Do not raise the machine when working. If this should occur, slowly lower the ma-
chine to the ground. Do not permit the machine to lower quickly and do not inter-
cept the falling movement using the hydraulics, since this could result in damage
to the machine.

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3.5.2 Preparatory activities
Danger!
Risk of fatal injury and damage to the machine when working.
 Observe the safety information “Notes for safe working” at the start of these op-
Fig. 3-94 Working position – machine
 Position the machine so that the load material can be taken up above the idler.
Danger!
Insufficient support and machine damage.
Fig. 3-95 Hazard area
Danger!
Risk of fatal injury due to rotating the machine.

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

R9200 / 11695477 3 - 123
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Caution!
Risk of injury when working.
 Always wear safety shoes and, particularly when leaving the cab when demoli-
tion work is going on, a protective helmet and safety glasses.
 Always wear the seat belt.
 Use the horn to give a short warning signal before starting work.
3.5.3 Positioning of the machine

Setting up properly is a pre-requisite to safe efficient loading, and helps maintain sta-
bility, power and bench levels. It will also reduce operator fatigue. Position the exca-
vator as close to the working face as safety permits.
Caution!
Always ensure there is sufficient clearance between the counterweight and the
face, including allowing for any rocks or material that may fall down.
Fig. 3-96 Recommended digging
The recommended digging range is about a 90° arc in front of the machine (A).
Note!
Avoid digging at right angles to the tracks.
3.5.4 Working with the backhoe bucket

Danger!
Risk of fatal injury and damage to the machine when moving the backhoe bucket.
 Ensure that the backhoe bucket is not slewed too close to the cab.
 The backhoe bucket could damage the cab and injure the machine’s opera-
tor.
 Ensure that nobody is standing within the hazard area of the backhoe bucket.

3 - 124 R9200 / 11695477
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Digging
Fig. 3-97 Optimal angle for digging
Fig. 3-98 30° forward to the vertical.
 Align the shovel arm in such a way that its underside is at an angle of approx. 30°
forward to the vertical.
 Align the backhoe bucket in such a way that its underside can enter the ground
at an angle with the axle of the shovel arm between 10° and 20°.

R9200 / 11695477 3 - 125
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Fig. 3-99 Taking up grab material
 To lift out the grab material, slowly and evenly slew in the shovel arm.
Fig. 3-100 45° backward to the vertical
 As soon as the shovel arm is at an angle of approx. 45° backward to the vertical,
raise the boom slowly and evenly in addition to slewing in the shovel arm and the
backhoe bucket. Stopping suddenly will result in impact loads and vibrations.
 When the backhoe bucket is full or the shovel arm can no longer be slewed in,
raise the boom and backhoe bucket until the filled surface is parallel to the
ground.
Note!
For a efficient digging, the depth of the excavated face shouldn’t exceed the length
of the shovel arm.

3 - 126 R9200 / 11695477
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Loading the transport vehicle
Danger!
Risk of fatal injury due to falling grab material.
 Do not load the transport vehicle so high that the grab material could drop out
over the walls of the vehicle.
 Ensure that nobody is standing in the danger.
 Load an occupied truck only if all safety requirements are fulfilled, notably in or-
der to protect the truck operator.
 Do not slew the equipment over the driver’s cab.
Fig. 3-101 Emptying grab material
 If possible, the machine should stand higher than the transport vehicle to avoid
having to lift the grab material unnecessarily.
 Stop the transport vehicle in a position that allows it to be loaded from the rear or
the side.
 Slew the machine's equipment above the loading area of the transport vehicle.
 Distribute the grab material evenly over the loading area of the transport vehicle
by slewing the backhoe bucket and shovel arm out, slewing the upper carriage
and possibly also moving the boom.
 If the backhoe bucket is not sufficiently emptied or there is still grab material in the
backhoe bucket, slew the backhoe bucket in and out several times to loosen the
grab material.
3.5.5 Working with the Shovel bucket
Digging
To maximise machine power and breakout, maintain grade and fill the bucket, correct
digging angles and technique should be used.

R9200 / 11695477 3 - 127
MJFCIFSS
Fig. 3-102 Digging
 Most digging should be started with the bucket almost fully crowded back (50mm
off stops or end of cylinders).
 When cleaning up or digging at floor level, angle the teeth aggressively to break
out any toe that may be encountered.
 Keeping the heel of the bucket off the ground therefore creating a void under the
rear of the bucket.
 Operate with the teeth and bucket lip doing all the work.
Note!
Avoid digging at right angles to the tracks.
Caution!
 Each time the stick is crowded back to commence a cut, extreme caution must
be taken not to hit the tracks.
 The clam must always be closed when digging, although don’t slam it shut.
Avoid working on the cylinder limits and bucket stops during the digging cycle.
Continual use of these practises will lead to premature failure of seals and O-
rings and can cause stress fractures to the clam, stick and bucket and damage
to the boom and superstructure.
 Crowd the bucket in (down) while closing the clam. This practise makes use of
gravity to help minimise shock loading on the bucket cylinders.
 Never dig, or attempt to bring down any material overhang, with the bucket while
the clam is open or partly open.
 Do not attempt to dig or clean the floor or face with the clam open. These prac-
tises can cause considerable damage to the clam cylinders.

3 - 128 R9200 / 11695477
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Unload the bucket
Fig. 3-103 Unloading of the bucket
When dumping the load, tip the bucket forward slightly as the clam opens. This helps
direct the material to fall centrally into the tray and avoids spillage.
The position of the bucket backboard when the clam opens, directly affects the posi-
tion of the load in the tray.
Bucket in ideal position resulting in material falling straight down. Loading centre of
the haul truck.
Attaching and removing attachment parts safely

– Equipment or attachments made by other manufacturers or those which do not
have general approval from Liebherr for installation or attachment may not be in-
stalled or attached to the machine without Liebherr’s prior written consent.
– Liebherr must be provided with the appropriate technical documentation neces-
sary for this purpose.
– Before carrying out any major repair work on the attachment, position the ma-
chine on level, firm ground.
– Do not work beneath the equipment if it is not safely positioned on the ground or
supported with appropriate supports.
– Before loosening lines or unscrewing bolts, you must store the equipment, switch
off the engine and press the start key to the contact position and both joysticks
and the pushbuttons to “Turn grapple” in order to reduce the pressure in the hy-
draulic system.
and which have sufficient load carrying capacity.
– Do not use cable which is damaged or does not have sufficient load carrying ca-
pacity. Wear work gloves when working with wire cables.

– When working on the attachment: switch off the engine and keep the safety lever
tilted up. Never use your fingers to locate bores; use the correct punch for the pro-
cedure.
– During repair work: ensure that the hydraulic lines are secured correctly and that
all bolts and connections are tight.
– When you have removed and chocked an attachment part, close open areas of
the hydraulic circuit to stop dirt entering. Only allow authorized persons in the vi-

R9200 / 11695477 3 - 129
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Transport
cinity of the machine or the lifting device used.
Removing and installing attachment pins safely

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

The life expectancy of undercarriage components is based on standard working con-
ditions with a maximum travel ratio of 5% per service meter unit. Working and / or
travelling on uneven ground and / or abrasive material will influence the lifetime of
the components and attract additional cost for the undercarriage components.
Downhill or uphill travel on a slope has also an effect on the life expectancy of under-
carriage components and on their wear rate. Indeed, even if the slope angle is below
the maximum permitted travelling angle, the increase of the slope angle causes the
increase of the force and of the contact pressures applied on all track components
(track pad assembly, sprocket, ...). On an indicative basis, the travel force applied on
the track components is multiplied by two from a slope angle of 5° (8,7%) and is mul-
tiplied by 2,5 from a slope angle of 10° (17,6%).
In general travel action has to be kept to the lowest level that is possible. Minimize
travelling with turning through a narrow turning circle and long distance travel.
To minimize the travel ratio, professional mine planning with longfront winning sec-
tions 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 proce-
dures defined by Liebherr to minimize possible machine damage, downtime and
wear have to be taken into consideration.
General
In order to move the machine forwards: with the excavator in standard forward posi-
tion, 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 po-
sition, depress travel pedals all the way down with the heels. Direction of travel is in
direction of the drive sprockets.
Moving the machine during loading operations

Moving the machine during loading operations means adjustment of excavator dig-

3 - 130 R9200 / 11695477
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Transport
ging and / or truck loading position of some meters.

Important procedures:
– Before moving the machine, empty the bucket and close up the attachment to a
position as close as possible to the excavator undercarriage.
– The practice of placing the attachment on the ground and lifting the machine, then
counter turning the undercarriage, is not allowed, because it could cause prema-
ture structural damage to the machine.
– If there is a build up of material around the tracks where the machine will not turn,
you must move the machine several meters forwards and / or backwards and at-
tempt 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.
Walking the machine over distance
Fig. 3-104 Hazard area r
Walking the machine distances means any movement of the machine of more than
100 m or for a time period longer than 3 minutes, whatever comes first.
In addition to above mentioned guidelines, when moving the machine during loading
operations, the following procedures apply:
– Before the start of the travel movement, clean all very dirty parts of the undercar-
riage and remove the unwanted materials.
– It is required to have somebody standby with a heat gun, to monitor the temper-
ature of the drive components, including the track and carrier rollers.
Danger!
During the movement of the machine, the person which is checking the temperature
of the different rollers must always be out of the hazard area r of the machine and
always be in the operator’s sight and in radio contact with him.
For the checking of the temperature, the excavator should stop moving. And only
when the excavator is stopped, the person could go in the hazard area r to check
the temperature of the different rollers.

The machine could only start moving again when the driver has seen the operator
out of the hazard area r.
– If temperature of any moving part is growing up about 20°C above ambient tem-
perature, interrupt travel and only commence again after parts have sufficiently
cooled.
– To prevent overheating during travelling or to speed up cooling procedure it is ad-
visable to have a water truck standby, to hose the heating components during

R9200 / 11695477 3 - 131
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Transport
travelling or cooling break.

– Move with idler and attachment forwards. Whenever possible, and not to contra-
vene with mine safety regulations, swing whilst travelling to equally load track roll-
ers. 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 5,7° (10%), it would be better to walk
the machine down with the track motor first, i.e. the machine is moved backwards.
– When travelling up an incline, the final drives must be at the rear of the excavator.
– When walking down from a bench, firstly prepare a ramp. Respect the angle value
indicated in the "Technical data" section of this manual (machine must be able to
walk up unaided). When moving down the ramp never allow the machine to fall
down on the attachment. When walking up the ramp never use attachment to as-
sist 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 lubri-
cation problems during further life. Therefore when travelling the machine the first
time aside from all above mentioned guidelines it is strongly recommended to move
carefully and at reduced speed.
Note!
Warranty may become void if failure to recognize and comply with the recommend-
ed travel operating procedures, as outlined in this document, is noted.
3.6.2 Excavator lifting and lashing operations
Danger!
For safety reasons, always consider the precautions given in this section.
Lifting precautions
Lift element:
– always checking and respecting the lifting configuration indicated on the corre-
sponding transport drawing,
– only with the provided lifting appliances,
– with adequate and approved lifting devices of other kind (cables, chains, slings)
if necessary,
– only after mounting the lifting appliances in accordance with the regulations,
– only at the declared threads or lugs shown on the assembly drawing,
– with the best possible equal load distribution,
– only being sure that the lifted element has been already dismounted,
– only after having drained tanks (hydraulic, fuel…),
– if no specific value is indicated on the corresponding transport drawing, always

3 - 132 R9200 / 11695477
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Transport
respecting the angles given on the sticker for lifting and lashing operations (refer
to the description below).
Additional lifting precautions for backhoe buckets

When you lift the backhoe bucket, also obey the precautions that follow:
– Only use the lifting points shown in the stickers placed on the bucket.
– You can use the bucket teeth as lifting points.
– Be careful about the position of the center of gravity of the bucket.
– The bucket has two possible transport positions. The height B1 gives the correct
transport position as shown in the transport drawing.
– If the height B1 is more than 3,6 m, turn over the bucket safely.
Additional lifting precautions for shovel buckets

When you lift the shovel bucket, also obey the precautions that follow:
– Only use the lifting points shown in the stickers placed on the bucket.
– Do not use the bucket teeth as lifting points.
– Do not use the welded beam to lift the bucket.
Lashing precautions
Lash element:
– always using necessary and appropriate devices or tools (e.g. elevating platform)
in order to ensure safe lashing,
– always checking and respecting the lashing configuration indicated on the corre-
sponding transport drawing,
– if no specific value is indicated on the corresponding transport drawing, always
respecting the angles given on the sticker for lifting and lashing operations (refer
to the description below),
– always ensuring a sufficient coefficient of friction (0,6 or higher) between load and
supporting surface so as to avoid element to slip (e.g. using wooden parts, non-
slip mats...),
– when using non-slip mats:
• always ensuring that the coefficient of friction is guaranteed by manufacturer
certificates,
• always positioning the non-slip mats between each contact surface (e.g. be-
tween the load and the support, between the support and the flatbed trailer),
– always ensuring that the contact surfaces between the flatbed trailer and the load
carried are free of dirt, ice, snow, oil and grease.
Additional lashing precautions for backhoe buckets

When you lash the backhoe bucket, also obey the precautions that follow:
– Only use the lashing points shown in the stickers placed on the bucket.
– You can use the bucket teeth as lashing points.

– Wedge the bucket during transport.
– The bucket has two possible transport positions. The height B1 gives the correct
transport position as shown in the transport drawing.
– If the height B1 is more than 3,6 m, turn over the bucket safely.

R9200 / 11695477 3 - 133
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Transport
Additional lashing precautions for shovel buckets

When you lash the shovel bucket, also obey the precautions that follow:
– Only use the lashing points shown in the stickers placed on the bucket.
– You can use the bucket teeth as lashing points.
– Do not use the welded beam to lash the bucket.
– Wedge the bucket during transport.
Sticker for lifting and lashing operations

The following sticker is placed next to each transport drawing on the related part and
package. It shows rules and precautions which you must obey for transport opera-
tions.
Fig. 3-105 Sticker for lifting and lashing operations
The Lashing Capacity LC is the maximum force that the lashing ring can hold in ac-
cordance with the angles given on the transport drawing.
The Safe Working Load SWL is the maximum load that the lifting ring can hold in ac-
cordance with the angles given on the transport drawing.
Transport drawings
The following drawings indicate the different lashing and lifting points on the ele-
ments of the excavator. Weight (with and without transport tooling and packaging),
overall dimensions as well as center of gravity are also given.
The aim of these drawings is to ensure safe operation during transport, handling and
storage.

3 - 134 R9200 / 11695477
MJFCIFSS
Transport
Note!
The lashing and lifting points are indicated on the concerned elements of the exca-
vator by specific labels (see § "Signs on the machine"). To be easily recognized,
lifting points are painted in yellow (in red if excavator is yellow) as well.
Danger!
The lifting points given on a transport drawing for an element are designed to lift this
element only and nothing else.
 Never lift an assembly of several elements by the lifting points of only one of
these elements.

R9200 / 11695477 3 - 135
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Transport

3 - 136 R9200 / 11695477
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MJFCIFSS
4 Malfunctions
Warning messages and fault messages:

– Various faults are displayed on screen in the form of indicator lights or symbols
(see chapter “Control and operating elements”).
– Warning functions can also be supported acoustically (buzzer).
Identifying and rectifying faults and errors:
– Faults can very often be traced back to incorrect operating or maintenance of the
machine.
For each fault, therefore, read the relevant chapter in the operating instruc-
tions carefully once more.
– Analyse the cause of the fault and rectify it immediately.
– Describe the fault and all accompanying circumstances as precisely as possible
if you contact LIEBHERR customer service.
Precise information makes it possible to find and rectify the cause of the fault
quickly. Additionally, therefore, precise information on the type and serial number
of the machine is also required.
– Do not carry out any work which you have not been trained to do.
Fig. 4-1 LIEBHERR service
If the cause of the fault cannot be recognised or rectified using the error codes
and fault charts, please consult LIEBHERR customer service.

R9200 / 11695477 4-1
MJFCIFSS
Malfunctions Operating manual
Error code charts
4.1 Error code charts
Danger!
When switching over to emergency operation, the engine operation and monitoring
may no longer be achieved using display and control keyboard (in case of electronic
failure). In this case, use emergency functions.
 Please also note the section “Emergency operations” in the chapter “Control and
operation” in this regard.
4.1.1 Heating/air conditioning system

The error codes that follow related to the heating and air-conditioning system are dis-
played directly on the front panel of its control unit.
Error code Affected elements Description / possible causes Possible effects / measures
F0 Room temperature sensor Short circuit or disconnection of Control function no longer opera-
cable, connector or control unit. tional.
Defective sensor.
F1 Exhaust air temperature Short circuit or disconnection of Control function no longer opera-
sensor cable, connector or control unit. tional.
Defective sensor.
F2 Exhaust air temperature Short circuit or disconnection of Control function no longer opera-
sensor (head area) cable, connector or control unit. tional.
Defective sensor.
F3 Outside temperature sen- Short circuit or disconnection of Control function no longer opera-
sor cable, connector or control unit. tional.
Defective sensor.
F4 High-/Low pressure switch Failure on condenser fan, evapo- Control function no longer opera-
rator blower, expansion valve, tional.
compressor or refrigerant circuit.

4-2 R9200 / 11695477
MJFCIFSS
Operating manual Malfunctions
Faults and remedies
4.2 Faults and remedies
4.2.1 Diesel engine and fuel system
Fault / error Cause Solution

Diesel engine does not start Fuel tank almost or completely emp- Fill tank and vent fuel system
ty
Shut off valve closed Open the shut off valve
Fuel filter dirty Clean or change filter and vent fuel
system, drain fuel / clean tank
Outside temperature below 0°C For operation under specific climatic
conditions, see operating instruc-
tions
Starter motor not drawing through Check line connections, overhaul
starter motor
Batteries have no power Charge / replace
Engine starts but stops immediately Fuel tank empty (low pressure in Fill tank and vent fuel system
after or runs irregularly tank)
Fuel filter dirty Clean or change filter and vent fuel
system (tank)
Particularly in winter: too viscous Use engine oil suitable for the out-
engine oil used side temperature
Dry-air filter dirty Clean or change main filter element
Air in fuel system Bleed fuel system
Ventilation in fuel tank obstructed Clean
Fuel line bent Check line and repair if required
Diesel engine emitting grey or black Dry-air filter dirty Clean or change filter
smoke
Diesel engine continually emitting Water in combustion chamber Consult customer service
white smoke (steam)
Diesel engine does not reach full Speed adjustment not set to maxi- Set speed adjustment to maximum
speed mum value value
Injection system is set incorrectly Consult customer service
Dry-air filter dirty Clean or replace filter
Bad fuel supply Clean or change fuel filter, check
lines, drain water from tank
Diesel engine becomes too hot Too little coolant Fill coolant, check for leaks
Water pump defective Repair
Thermostats do not work Change thermostats

Coolant contaminated Clean coolant
Diesel engine has insufficient oil Oil level too low Correct oil level
pressure Oil pressure display faulty Change oil pressure switch
Note!
Switch off diesel engine immediate-
ly

R9200 / 11695477 4-3
MJFCIFSS
Faults and remedies

Diesel engine consumes too much External leak on diesel engine Retighten screws, replace seals if
oil required
Oil in coolant or coolant in oil Consult customer service
Unusual noise / sound development Exhaust system leaking Check exhaust system / repair
on exhaust side
4.2.2 Hydraulic system

Unusual noise / sound development Shutoff valve on hydraulic tank Open the shutoff valve
at hydraulic pumps closed
Note! Hydraulic pumps taking in air Check oil level in hydraulic tank,
Switch off diesel engine immediate- check intake lines for leaks
ly
Hydraulic oil temperature too high Coolant contaminated Clean coolant
Fan or fan control defective Rectify error / consult customer ser-
vice
Hydraulic oil level too low Oil loss Repair leaks, exchange hoses, refill
oil via return-line filter
Cannot drive Push the safety lever up Push the safety lever down
Swing gear not functioning No servo control Push the safety lever down
Switch on servo control
Swing gear brake activated Push the safety lever down
Release swing gear brake
No working movement No servo control Push the safety lever down
Switch on servo control
No servo pressure present Consult customer service
No pump high pressure present Consult customer service
4.2.3 Transmission

Oil flowing out on track rollers, sup- Seal defective Replace seal
port rollers or leading wheel
Insufficient crawler tracking on lead- Leading wheel tracking on track roll- Adjust the leading wheel tracking
ing wheel er mounting has too much play play

Chain jumps off or over Chain tension too low / crawler Adjust chain tension
wheel worn
Correctly tensioned crawler losing Chain tensioning cylinder defective Check chain tensioning cylinder,
tension quickly during chain change if required or seal (only au-
thorized specialist personnel)
Track roller or support roller sticking Running gear extremely dirty Clean running gear

4-4 R9200 / 11695477
MJFCIFSS
Faults and remedies
4.2.4 Electrical system

Battery charge indicator light does Drive belt for alternator loose or torn Tension or replace drive belt
not goes out Alternator defective Replace alternator
Batteries do not charge or charge Batteries defective Replace batteries
poorly Battery connections dirty / oxidised Clean battery connections
Cable loose or damaged Connect or replace cable
indicator light or display instrument Bulb burnt out, display instrument Replace defective part
not functioning or functioning incor- defective
rectly
Some or all functions on instrument Plug connector separated or dam- Mount plug connector correctly or
panel drop out aged, earth lead interrupted, short change, rectify short circuit, replace
circuit fuse defective fuse or activate overload cut-outs
Servo control cannot be activated Excavator electrics faulty Switch on emergency function using
using switch switch S73 in the right control panel
Swing gear brake cannot be re- Caution: Servo circuit and brake cir-
leased using switch cuit can only be switched off using
the safety lever. Keypad not func-
tioning. Consult customer service.
4.2.5 Heating/air-conditioning system

Heating not giving out warm air Shutoff valves for coolant line on Open shutoff valve
diesel engine closed
Engine not at operating temperature Bring engine to operating tempera-
ture
Heating fan does not operate No power supply Check fuse and wiring / repair
Fan motor defective Change fan motor
Only low air flow in cab Outside air filter / recirculated air fil- Clean air intake opening, replace
ter dirty outside air filter
Air vent closed Open air vent
4.2.6 Work equipment

Cylinder stretches when loaded Piston seal in cylinder defective Overhaul cylinder
Bearing clearance too high on Bearing points worn out Replace bearing parts
equipment
Bucket does not move Valve block on tilting cylinder incor- Switch over valve block
rectly switched

R9200 / 11695477 4-5
MJFCIFSS
Fuses and relays
4.3 Fuses and relays
Danger!
Incorrect or bypassed fuses do not let have the necessary degree of protection of
the machine's operator or the electrical system.
 Only use original fuses.
 Never bypass electrical fuses.
 If required, order replacement fuses from Liebherr.
4.3.1 Power electrical box E1003

The access door of the power electrical box E1003 is located on the outer rear side
of the cab.
Fig. 4-2 Access door of E1003 electrical box


4-6 R9200 / 11695477
MJFCIFSS
Fuses and relays
Fig. 4-3 Fuses of power electrical box E1003
F20_1 Fuse 100 A F134* Fuse 15 A /

Dual air-conditioning (option)
F20_2 Fuse 100 A F135* Fuse 25 A /
F90 Fuse 15 A F136* Fuse 25 A /

R9200 / 11695477 4-7
MJFCIFSS
Fuses and relays
F91 Fuse 15 A F142_1 Fuse 15 A

F96 Fuse 15 A F143 Fuse 15 A
F132 Fuse 15 A F246 Fuse 7,5 A
F134 Fuse 15 A
Fig. 4-4 Relays of power electrical box E1003
K19_1 Relay K302 Relay

K23 Relay K304 Relay

K28 Relay K399_1 Relay
K99 Relay K399_1* Relay /
K122 Relay K399_2 Relay
K123 Relay K399_2* Relay /

4-8 R9200 / 11695477
MJFCIFSS
Fuses and relays

K141 Relay KT51 Relay
K141_1 Relay KT53 Relay
K141_2 Relay KT57_1 Relay
K141_3 Relay KT57_2 Relay
K273 Relay KT277 Relay
K301 Relay Kres_5 Relay /
4.3.2 Cab connection box E1005

The cab connection box E1005 is located in the cab, behind the operator’s seat.
Fig. 4-5 Locations of the electrical plates in E1005
A161 Electrical plate A1004 Electrical plate

A1002 Electrical plate A1014 Electrical plate

R9200 / 11695477 4-9
MJFCIFSS
Fuses and relays
Fig. 4-6 Fuses and relays of cab connection box E1005
F21-1 Fuse 100 A F172 Fuse 7,5 A

F21-2 Fuse 100 A K19-2 Relay
F160 Fuse 7,5 A K126 Relay
F161 Fuse 15 A K184 Relay
F171 Fuse 15 A Kres_11 Relay

4 - 10 R9200 / 11695477
MJFCIFSS
5 Maintenance
5.1 Servicing the machine safely

– Maintenance and repair work may only be carried out by specially trained person-
nel.
– Observe statutory timetables or intervals given in the operating instructions for re-
peat tests / inspections. It is imperative that a suitably equipped workshop is avail-
able in order to carry out maintenance work.
– The inspection and maintenance schedule given at the end of these operating in-
structions defines precisely who is required / permitted to carry out what work.
Jobs listed as daily / weekly work may be carried out by the machine's driver or
maintenance personnel when they have received appropriate instruction.
The remaining work may only be carried out by specialist personnel with appro-
priate training.
– Replacement parts must correspond to the technical requirements determined by
the manufacturer. Original replacement parts are always guaranteed to meet
these criteria.
– Always wear safe work clothes when carrying out maintenance work. Avoid the
wearing of rings, wrist watches, ties, scarves, open jackets, baggy clothing etc...
There is a risk of injury from, for example, getting caught up or being drawn in.
Protective goggles, safety helmets, safety shoes and gloves, reflective vests and
ear protection etc. are required for specific jobs.
– Do not remain in direct proximity of the diesel engine while the diesel engine is
running.
Persons with pacemakers should not approach within 20 cm of the running diesel
engine.
Do not touch voltage-carrying parts on the electrical connection of the individual
solenoid injection pumps (Unit Pumps UP) while the diesel engine is running.
– Do not permit unauthorised persons to approach the machine during mainte-
nance work.
– Cordon off a wide maintenance area if required.
– Inform operational personnel before starting to carry out any special work and re-
pair work. Designate persons in charge of supervision.
– In the absence of any other information in the operating instructions, carry out all
maintenance work on the machine on level, firm ground with the working equip-
ment set aside and the engine switched off.
– For some machines, the only one position which enables a secured access to
every maintenance locations on the uppercarriage, is when the uppercarriage is
aligned with the undercarriage so that the sprockets locate at the back-end.
The ladder situated on the undercarriage only corresponds with the uppercar-
riage’s access when the excavator is in this configuration.
– Pull out the ignition key and shut off the main battery switch.
– Always tighten any loose screw connections during maintenance and repair work.
– The mounting bolts of the main components, of the hydraulic hoses and of the
counterweight must be replaced after every removal.
– If safety devices have to be dismantled during set-up, maintenance and repair
work, they must be immediately reinstalled and checked at the end of the work.

R9200 / 11695477 5-1
MJFCIFSS
Maintenance Operating manual
– When carrying out repair work, particularly when working under the machine,
hang a “Do not start” warning sign in a clearly visible position on the control panel.
Pull out the start key and shut off the main battery switch.
– Operate combustion motors and fuel operated heaters only in well ventilated ar-
eas. Before operating these units, check ventilation.
– In addition, always follow applicable local regulations.
Cleaning
– Clean oil, fuel or care products off the machine before starting maintenance or re-
pair work and pay particular attention to connections and screw fittings.
Do not use aggressive cleaning products and use lint-free cleaning cloths.
– Do not use aggressive cleaning products or steam jet devices to clean the ma-
chine for the first two months after initial set-up of the machine (or after repaint-
ing).
– Do not use combustible liquids to clean the machine.
– Before cleaning the machine with water or steam jets (high pressure cleaner) or
other cleaning materials:
• lubricate all bearing points, bolt connections and the rim bearing to prevent wa-
ter or steam entering the bearing points.
• cover or glue shut all openings into which for safety or functional reasons water
or steam may not be permitted to enter.
Electric motors, electrical components, control boxes, plug connections and air
filters are particularly at risk.
– Ensure that the fire warning systems and fire extinguishers of the engine compart-
ment’s temperature sensor do not come into contact with hot cleaning products
during cleaning work.
The fire extinguisher could start.
– If you use a high pressure cleaner with steam or hot water to clean the machine,
observe following recommendations :
• the distance between the nozzle and the surface to be cleaned must be no low-
er than 20 inches
• the water temperature should not exceed 60°c (140°F)
• limit the water pressure to 80 bar maximum (1160 PSI)
• if you employ cleaning fluid, only use neutral cleaning agents such as custom-
ary car shampoos diluted to 2 or 3 percent maximum
– After cleaning:
• remove all covers completely.
• check all fuel, engine oil and hydraulic lines for leakage, loosened connections,
chafing and damage.
• rectify any defects found immediately.
• lubricate all bearing points, bolt connections and the rim bearing to displace any
water or cleaning products that may have entered.
Corrosion protection
– The corrosion protection of the machine must be inspected and renewed at reg-
ular intervals. For further information, refer to the Maintenance manual for corro-
sion protection.
Field of view
– Mirrors and cameras, which were possibly removed for the transport, must be in-
evitably reinstalled and correctly adjusted before the initial set-up of the machine.
– Regularly check that the interior and exterior mirrors as well as the cameras are

5-2 R9200 / 11695477
MJFCIFSS
Operating manual Maintenance
correctly adjusted.
– Control the surroundings, and particularly the nearness area of the machine, dur-
ing operation or when travelling.
– Mirrors are installed on the machine:
• on the left to check the left side of the machine.
• on the front to check the front side of the machine.
• on the right to check the right side of the machine.
• above the counterweight to check the rear side of the machine.
– On some machines, some mirrors may be replaced with cameras.
– At each extension, construction or change on the machine, the sight conditions
must be maintained. These conditions must otherwise be checked according to
ISO 5006.
– Mirrors and cameras must always be clean.
– Damaged mirrors and cameras must be immediately replaced.
– The site has to be organised so that the dangers due to a restricted field of view
are minimized, particularly for machines with an operating weight which is supe-
rior to 40 tons.
Crack testing
– Even when the machine is operated carefully, there is a possibility of individual
cases of overloading occurring, which could lead to cracks or loose connections.
The machine should therefore be checked regularly for cracks, loose connections
or other visible damage to maintain operational safety.
– In order to be able to check for cracks, it is essential that the machine is kept clean
and cleaned regularly.
– The tests should be carried out in accordance with the monitoring and mainte-
nance plan:
• every 250 operating hours by the machine owner’s maintenance personnel.
• every 500 operating hours by authorised specialist personnel.
– It is advisable to carry out these tests: supported, on firm, horizontal substrate,
with the equipment in longitudinal and cross direction for variable loads. Current
accident prevention regulations must be adhered to.
– Especially check the supporting components, in particular :
• framed construction undercarriage with axle and gearbox storage, support out-
riger, lower slewing ring support with tower and slewing ring.
• framed construction uppercarriage with bearing for boom and hoist cylinder, up-
per slewing ring support, cab suspension, mounting for slewing gear and coun-
ter weight.
• framed construction components of attachments, e.g. boom, stick, quick
change adapter, digging tool and grapple.
• hydraulic cylinders, axles, steering, pins and pin connections, ascents, ladders
and mounting elements.
– The crack test should be carried out visually. If a crack is suspected, the dye pen-
etration test should be carried out as a crack test on areas which do not have
good visibility, such as the ring bearing support, in order to increase testing safety.
– Any damage found must be rectified immediately. Welding work on load-bearing
parts of the earth-moving machinery, loading devices and transport devices may
only be carried out by trained specialist personnel and only in accordance with the
accepted rules of welding engineering. In case of doubt, contact the LIEBHERR
customer support service to discuss suitable remedies.

R9200 / 11695477 5-3
MJFCIFSS
Welding, drilling, firing and grinding work

– Any welding on structural parts (as undercarriage, uppercarriage, equipment
parts,…) may only be done by the manufacturer, or authorized official dealer. If
this rule is neglected, the warranty is voided.
– Only carry out welding, drilling, firing and grinding work on the machine with ex-
press authorization. Clean dust and combustible materials off the machine and its
surrounding areas before welding, drilling, firing or grinding.
Ensure adequate ventilation. Risk of fire or explosion.
– Before welding repairs on other parts, always disconnect the battery. Always re-
move the negative terminal first and reconnect it last.
– Nevertheless if welding repair should be done on components which may contain
inflammable gases (welded counterweight, hydraulic tank, fuel tank, …), these
components must be previously and sufficiently ventilated with pressurized air to
avoid all fire or explosion hazard
– Before welding, connect the ground cable as close as possible to the welding
point, so the welding current will not run through parts like the swing ring, rotary
connection, gears, bushings, bearings, hinges, joints, hydraulic hoses, sockets,
rubber parts or seals.
Process materials
– When working with oils, greases and other chemical substances, observe the ap-
propriate current safety regulations for the product.
– Ensure that process materials and replacement parts are disposed of in a safe
and environmentally acceptable manner.
– Take care when handling hot process materials
(Risk of burning and scalding).
Repair work
and which have sufficient load capacity. When replacing single parts and larger
subassemblies, carefully secure them on lifting devices so that they do not pres-
ent a risk. Only use suitable and correctly functioning lifting devices and load take-
up devices with adequate load capacity.
Do not stand or work under swinging loads.
– Do not use lifting devices which are damaged or do not have sufficient load car-
rying capacity.
Wear work gloves when working with wire cables.
crane operator. This people must be in the operator’s sight or in radio contact with
him.
– When working above body height, use safe climbing devices and working plat-
forms which are appropriate for the job.
Do not use machine parts as climbing devices if they are not designed for this pur-
pose.
When working at height, wear a harness to prevent falling.
Ensure that all grips, steps, rails, platforms and ladders are free of dirt, snow and
ice.
– Pneumatic cylinders do not have to be used as handles. Open doors and covers
carefully, so that pneumatic cylinders do not hit their stops, because this could
cause mechanical damages.
– Make sure the equipment on which you will operate is securely supported before
working (e.g. replacing teeth). Prevent metal touching metal when doing this.

5-4 R9200 / 11695477
MJFCIFSS
– For safety reasons, never open and remove a track chain unless having previous-
ly totally released the pretension of the chain tensioning unit.
– Never lay under the machine if it is raised with work equipment and has not been
securely supported with appropriate supports.
– Always jack the machine up in such a way that any weight displacement does not
jeopardize stability and prevent metal touching metal while doing this.
– Work on the suspension, brake and steering systems may only be carried out by
trained specialist personnel.
– If the machine has to be repaired on a slope, secure the crawler with chocks and
connect the upper structure to the chassis using stop bolts.
– Only personnel with special training and experience may work on hydraulic equip-
ment.
– When searching for leakage, wear protective gloves. A fine jet of liquid under
pressure can penetrate the skin.
– Do not unscrew any lines or connections before you have set aside the equip-
ment, switched off the engine and depressurized the hydraulic system. After
switching off the engine, with the start key in contact position and with the safety
lever down into its lowest position, you must operate all pilot control devices (joy-
stick and pedals) in all directions in order to reduce the actuating and dynamic
pressures in the work circuits. You must then reduce the internal tank pressure
as described in these operating instructions.
Electrical system
Have all faults, such as loose connections, blown fuses and lamps and clogged
or abraded cables rectified by personnel.
– Only use original fuses with approved current strength.
– For machines with electrical neutral and high tension leads:
• switch the machine off immediately in the event of malfunctions in the power
supply.
– Work on the machine’s electrical equipment may only be carried out by skilled
electrical personnel or by trained personnel under the supervision of an electri-
cian in accordance with electrical regulations.
– When working on live parts, ensure that a second person is available to operate
the emergency-off or the main switch and overvoltage release. Cordon off the
working area with a red and white safety chain and a warning sign. Only use in-
sulated tools.
– When working on neutral and high tension subassemblies, after releasing the
voltage, briefly disconnect the supply cable at earth and electronic devices such
as capacitors using an earthing rod.
– First test the released parts to make sure that they are off circuit, earth them and
then disconnect them briefly. Insulate adjacent live parts.
– Disconnect the battery before working on the electrical system or carrying out any
electric arc welding on the machine.
First disconnect the negative, then the positive pole. When reconnecting, proceed
in the reverse order.
Hydraulic accumulator
– All work on the hydraulic accumulators must be carried out by trained specialist
personnel.
– Inexpert assembly and handling of hydraulic accumulators can cause serious ac-

R9200 / 11695477 5-5
MJFCIFSS
cidents.
– Do not operate damaged hydraulic accumulators.
– Before working on a hydraulic accumulator, you must reduce the pressure in the
hydraulic system (hydraulic system including hydraulic tank), as described in
these operating instructions.
– Do not carry out welding or soldering or do any mechanical work on the hydraulic
accumulator.
The hydraulic accumulator can be damaged by heat penetration and can be
made to rupture by mechanical working. RISK OF EXPLOSION!
– Only charge the hydraulic accumulator with nitrogen. There is a RISK OF EXPLO-
SION if oxygen or air is used.
– The accumulator body can become hot during operation; there is a risk of burning.
– New hydraulic accumulators must be charged with the pressure required for the
purpose of use before installation.
– The operating data (minimum and maximum pressure) are marked permanently
on hydraulic accumulators. Ensure that this marking remains visible.
Hydraulic lines and hoses

– It is forbidden to carry out repair work on hydraulic lines and hoses!
– All lines, hoses and bolt connections must be checked regularly for externally vis-
ible damage and any possible damage must be immediately checked for leakage.
– Never check for leaks with your bare hands, use a sheet of paper or something
else.
– Any damaged parts must be removed immediately! Spurting oil can lead to injury
and burns.
– Even with correct storage and permitted load, lines and hoses are subject to the
natural aging process. This restricts their duration of use.
• Incorrect storage, mechanical damage and unauthorized load are the most
common causes of failure.
• In relation to duration of use, current norms, regulations and guidelines pertain-
ing to lines and hoses at place of use must be adhered to.
• Use at the limit range of permissible load can shorten duration of use (e.g. high
temperatures, frequent movement cycles, extremely high pulse frequencies,
multiple shift usage).
– Lines and hoses should be replaced if the following are found during inspection:
• Damage to the outer sheath as far as the liner (e.g. chafing, cuts and cracks);
• Brittleness of the outer sheath (fracture formation in hose material);
• Deformations which do not correspond to the natural form of the line or hose,
whether in a unpressurized or pressurized state or on bends e.g. sheath sepa-
ration, blistering;
• Unsealed areas;
• Non-adherence to requirements during installation;
• Damage or deformations to the hose fittings which reduce the tightness of the
fittings or the hose / fitting connection;
• Hoses working themselves out of the fittings;

• Corrosion of the fittings which reduces function and tightness;
– When replacing lines and hoses, use only original replacement parts.
– Install and mount lines and hoses correctly. Do not mix up the connections.
– The following is to be noted when replacing lines and hoses:
• Always ensure that the lines and hoses are installed free of torsion. For high-
pressure hoses, the screws from the half-clamps or full flange must always be
attached to both hose ends and should only be tightened afterwards.
• When tightening the flange on high-pressure lines and hoses with bent fittings,

5-6 R9200 / 11695477
MJFCIFSS
Maintenance access doors
the side with the bent fitting must always be tightened first and then the side with
the straight fitting tightened afterwards.
• Any mounting clamps which are located in the centre of the hose may only be
attached and tightened subsequently.
• Check daily to ensure that all clamps, covers and protective devices are prop-
erly fastened. Doing this will prevent vibration and damage during operation.
• Install the lines and hoses in such a way that they cannot chafe on other lines,
hoses or parts.
• A minimum distance from other parts of approx. half the exterior diameter of the
hose is recommended. The distance should not, however, be less than 10 to
15 mm.
• When replacing the lines or hoses on moving parts (e.g. from the boom to the
stay), check before initial start-up that there are no chafing areas in the entire
area of movement.
5.2 Maintenance access doors
5.2.1 Overview of access doors

The machine has access doors for maintenance. The locks integrated in the handles
must be unlocked before starting to drive.
Caution!
For oil and engine coolers access, use an external safety device (e.g. a ladder or
stepladder).
Caution!
Access doors can close accidentally and trap the operator or maintenance person-
nel.
 When you have opened the access doors, latch them using the retainer.

R9200 / 11695477 5-7
MJFCIFSS
Maintenance access doors
Access doors
Fig. 5-1 Access doors and covering
1 Pump box doors 5 Engine cooler access

2 Engine doors 6 Oil cooler access
3 Cab elevation door 7 Left side door
4 Engine covering

5-8 R9200 / 11695477
MJFCIFSS
Lubricants and operating fluids
5.3 Lubricants and operating fluids
5.3.1 General information on changing lubricants and operating

fluids
Note
The quantities given in the lubrication and operating material chart and on the lubri-
cation chart in the cab are only guide values.
 After each oil change or refill, check the level in the relevant unit.
Note!
Adhering to regulations for lubrication, level checks and operating material changes
guarantees a high degree of reliability and a long service life for the machine.
It is particularly important to adhere to the oil change intervals and use the specified
type of lubricant.
 Observe the following when using and checking lubricants and operating fluids:
– see "Lubricants and operating fluids"
– see "Inspection and maintenance schedule"
Note!
Cleanliness is of the utmost importance when changing oil.
 Clean all filler plugs, filler covers and drain plugs and their surroundings before
opening.
 For preference, drain off oil when it is at operating temperature.
 Ensure that old oils are collected and disposed of in an environmentally accept-
able manner using the removable oil filter cartridges.
Danger!
When checking and changing lubrication and operating materials, ensure that the
following precautions are adhered to:
 Unless otherwise indicated, carry out all work on the machine on level, solid
ground and with the engine switched off.
 Whenever you reach into the engine compartment, always secure the cover and
side doors against accidentally falling back or closing.
 Only refuel the machine when the engine is switched off, do not smoke and
avoid naked flame.
 Turn the main battery switch to position 0 (off) and remove the ignition key.

R9200 / 11695477 5-9
MJFCIFSS
5.3.2 Lubricating chart
Fig. 5-2 R9200 lubricating chart

5 - 10 R9200 / 11695477
MJFCIFSS
Symbol Display
Diesel engine
Engine coolant
Hydraulic system
Swing gear
Travel gear
Lifetime sealing interspace (optional)
Splitterbox
Fuel
Grease / Swing ring teeth
Grease
Windshield washer
Check oil level
Oil change
First oil change
Oil analysis
(1) If filled with COB-2, COB-3 or COB-4 gear oil
(2) If filled with COB-1 gear oil
Refer to the Operating manual (section "Lubricat-

(3)
ing and operating material specifications")
Tab. 5-1 Lubricating chart key
5.3.3 Service trap

Couplings
To simplify the oil change and the refilling procedure, the drain of the following major
components on the uppercarriage are centrally connected to a service trap:
– the lube oil for the Diesel engine
– the splitterbox
– the two swing gears
– the fuel tank
– the hydraulic oil tank

R9200 / 11695477 5 - 11
MJFCIFSS
– the grease tank for general lubrication

– the grease tank for swing ring teeth lubrication
Component Adapter Flow max.

Swing gear To add oil:
WIGGINS ONC2A 50 L/min
To drain oil:
WIGGINS OSP2 50 L/min
Splitterbox WIGGINS C-1807 50 L/min
Engine oil WIGGINS OSP2 50 L/min
Hydraulic oil WIGGINS 6000B12 100-200 L/min
Fuel WIGGINS ZZ9A 1 500 L/min
Principal grease WIGGINS OSP2 15-30 L/min
Pmini 100 bar
Teeth grease WIGGINS 6000B12 15-30 L/min

Pmini 100 bar
Tab. 5-2 Service trap couplings
Fig. 5-3 Service trap
Grease control box

The open service trap lets also access to the control box E1043 which monitors the
levels of attachment and swing ring greases.

5 - 12 R9200 / 11695477
MJFCIFSS
Fig. 5-4 Grease control box E1043
H58 Swing ring grease

H59 Attachment grease
When a grease level is maximum:

 The related warning light H58 or H59 goes off.
5.3.4 Lubricant chart
Designation Medium Symbol Classification Viscosity Quantity*
Diesel engine Engine oil See the Operation and Maintenance 142 L
Manual for CUMMINS engine.
Hydraulic tank Hydraulic oil See section "Lubricating and oper- 3400 L in
ating material specifications". whole cir-
cuit
2000 L in
hydraulic
tank
Swing gear Transmission See section "Lubricating and oper- 2 x 32 L

oil ating material specifications".
Travel gear Transmission See section "Lubricating and oper- 2 x 38 L

oil ating material specifications".
Lifetime travel gear (optional)

R9200 / 11695477 5 - 13
MJFCIFSS
Designation Medium Symbol Classification Viscosity Quantity*
Lifetime sealing interspace Hydraulic oil Use same oil as used for hydraulik 2 x 3,4 L
(optional) tank.
Splitterbox Transmission API-GL-5 SAE 90 10 L

oil MIL-L 2105 B, C or SAE 80W-90
D
Swing ring roller bearing races Lubricating See section "Lubricating and oper- 200 L
and general lubrication points grease ating material specifications".
Swing ring teeth Lubricating See section "Lubricating and oper- 15 L

grease ating material specifications".
Track roller AGIP DIESEL ISO 100 16 x 2700

SIGMA S30 cc
Cold climate conditions:

AGIP BLASIA ESB 220
Carrier roller AGIP BLASIA 220 ISO 220 4 x 3350 cc

AGIP BLASIA ESB 220
Idler Wheel VARIAX - EP 80W90 2 x 3300 cc

AGIP BLASIA ESB 220
Hinges, joints, locks Engine oil - - - -
Rubber seal on doors and trim Silicon spray - - - -

panels or talc
Tab. 5-3 Lubricant chart
*The given quantities are only guidelines. Check fluid level after each change or refilling.
5.3.5 Operating material chart
Designation Medium Symbol Quantity*

Fuel tank See the Operation and Maintenance Manual for CUMMINS 4477 L
engine.
Engine coolant See the Operation and Maintenance Manual for CUMMINS 300 L
engine.

5 - 14 R9200 / 11695477
MJFCIFSS
Designation Medium Symbol Quantity*
Windshield washer Commercially available windshield washer fluid or dena- 30 L

system tured alcohol
Air conditioning system Refrigerating agent: - 2,2 kg

R134a
Refrigerant oil in a new compressor: - 0,2 L

Sanden PAG SP-10
Refrigerant oil to add in the system after a compressor re- - 0,153 L

placement:
Sanden PAG SP-10
Refrigerant oil in the full system: - 0,353 L

Sanden PAG SP-10
Dual air conditioning Refrigerating agent: - 3,6 kg

system (optional): front R134a
condenser unit
Sanden PAG SP-10

placement:
Sanden PAG SP-10

Sanden PAG SP-10
Dual air conditioning Refrigerating agent: - 2,2 kg

system (optional): rear R134a
condenser unit
Sanden PAG SP-10

placement:
Sanden PAG SP-10

Sanden PAG SP-10
Tab. 5-4 Operating material chart
*The given quantities are only guidelines. Check fluid level after each change or refilling.
5.3.6 Service trap

For safety reasons and ease of maintenance, you must drain and fill the oil of the
connected components only through the quick-change couplings of the service trap,
which is located under the machine uppercarriage.
However, these components are also equipped with oil drain valves, see description
for oil change procedure of these components.

R9200 / 11695477 5 - 15
MJFCIFSS
Lower and lift the service trap

The service trap is manually moved up and down from the ground level.
Fig. 5-5 Service trap handle
 Use the handle 1 and the lever which is installed on the access ladder (one more
lever is installed into the cab elevation).
Caution!
The service trap must be moved down only if the uppercarriage and the undercar-
riage are aligned.
Caution!
For safety reasons, the machine can only be operated if the service trap is locked
in its top position. This means that the swing and travel movements remain locked.
If the service trap is not on its top position, the warning light H68 on the control board
comes on.
Fig. 5-6 Warning light H68: trap control lock

5 - 16 R9200 / 11695477
MJFCIFSS
Lubricating and operating material specifications
This safety measure can be bypassed as long as the button S122 on the control
board is activated.
Fig. 5-7 Button S122: Disable trap control lock
5.4 Lubricating and operating material specifica-

tions
5.4.1 Lubricating oil for the Diesel engine
Standard or with the Oil reserve system (optional) or with the Centinel system (op-
tional).
Refer to the Operation and Maintenance Manual for the CUMMINS Diesel en-
gine.
5.4.2 Fuel
gine.

R9200 / 11695477 5 - 17
MJFCIFSS
5.4.3 Coolant
gine.
5.4.4 Hydraulic oil specifications for LIEBHERR Mining excava-

tors
Hydraulic oils must meet the requirement outlined below (depending on temperature
range).
Non-compliance with these requirements shall void all warranty and liability by LIEB-
HERR.
LIEBHERR recommends maintaining the hydraulic oil to a cleanliness level that
meets contaminant code 20/18/15 according to ISO 4406.
Maximum water content of hydraulic oil: <0,1%.
Caution!
According to the oil type used for the hydraulic system, the fans speed regulation
must be set specifically ("STANDARD", "COLD" or "EXTRA-COLD").
– If the excavator is delivered without arctic kit, it is set to "STANDARD" at

delivery.
– If the excavator is delivered with an arctic kit, it is set to "COLD" at delivery.
Before first start of the excavator or if an oil type change is done afterwards, the fans
speed regulation setting must be checked and corrected if necessary.
 Contact LIEBHERR Customer Service.
LIEBHERR oils for hydraulic system
Requirements
Fig. 5-8 LIEBHERR oils for hydraulic system
A Ambient air temperature

B Operating range
C Extra-cold start range if excavator fitted with operating Liebherr arctic kit (with

5 - 18 R9200 / 11695477
MJFCIFSS
warm-up instruction)
Fans speed regulation settings
LIEBHERR oil fans speed regulation setting
Liebherr Hydraulic Plus "STANDARD"
Liebherr Hydraulic Basic 68 "STANDARD"
Liebherr Hydraulic Basic 100 "STANDARD"
Liebherr Hydraulic HVI "COLD"
Liebherr Hydraulic Plus Arctic "EXTRA-COLD"
Engine oils for hydraulic system
Requirements
Fig. 5-9 Engine oils for hydraulic system

B Operating range
Caution!
Minimum ambient air temperature for extra-cold start depends on oil type and brand
and equals to oil pourpoint temperature +5 degrees K.
Recommended and approved are engine oils, which conform to the following speci-
fications:
– Single viscosity oils: API - CD / ACEA - E1

Mercedes-Benz specifications Nr. 226.0 and 227.0
– Multi viscosity oils: API - CD, CE, CF / ACEA - E2, E3, E4
Mercedes-Benz specifications Nr. 227.5, 228.1, 228.3
and 228.5

R9200 / 11695477 5 - 19
MJFCIFSS
Engine oil fans speed regulation setting
SAE10W30 "STANDARD"
SAE10W40 "STANDARD"
SAE20W-20 (ISO VG68) "STANDARD"
SAE15W40 "STANDARD"
SAE30 (ISO VG100) "STANDARD"
SAE 10W (ISO VG46) "EXTRA-COLD" or "COLD"
Hydraulic oils for hydraulic system
Requirements
Fig. 5-10 Hydraulic oil for hydraulic system

B Operating range
Caution!
Minimum ambient air temperature for extra-cold start depends on oil type and brand
and equals to oil pourpoint temperature +5 degrees K.
Hydraulic oils must conform to the following specifications:
DIN 51524-2 (HLP) / ISO 11158 (HM)

DIN 51524-3 (HVLP) / ISO 11158 (HV)
DIN 51524-2 with detergent-/dispergent additives: HLP-D

DIN 51524-3 with detergent/-dispergent additives: HVLP-D
Shear stability KRL/C < 15% according to DIN 51350-6, CEC L 45-A-99
Air release properties LAV < 10 min at 50°C according to DIN ISO 9120

5 - 20 R9200 / 11695477
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Hydraulic oil fans speed regulation setting
ISO VG68 "STANDARD"
ISO VG100 "STANDARD"
ISO VG46 "COLD"
ISO VG32 "EXTRA-COLD"
Warm-up procedure
The black bar C indicates that the ambient temperatures are maximum 20 °C below
the operating range B.
In the event of a cold start at an ambient temperature included in range C, the follow-
ing warm-up instruction applies to the hydraulic oil:
 1. Start the diesel engine and run it at approx. 1/2 rated speed. Carefully activate
the working hydraulic circuits. Operate a hydraulic cylinder (Stick for example)
and move them to the stop quickly and many times. After approx. 5 minutes, start
the travel hydraulic circuits.
Warm-up duration: approx 10 minutes
For temperature below the limits A :
 2. Preheat hydraulic oil in the tank before starting the engine.
Biodegradable hydraulic oils

The use of biodegradable hydraulic oils must in any case be discussed with LIEB-
HER MINING EQUIPMENT COLMAR SAS.
 Do not mix biodegradable hydraulic oils from different suppliers and never mix
with mineral oils.
 Do not use vegetable oils as they do not possess the necessary thermal stability.
Depending on the temperature range, LIEBHERR recommends its poly-alpha-olefin
(PAO, HEPR) oils, that are biodegradable according to CEC-L-103-12 (21 days, >
60%, primary decomposition):
Liebherr Hydraulic Plus or Liebherr Hydraulic Plus Arctic
If these oils are not available locally or if further specifications are required, use one
of the following oils (before choosing an oil, contact our Customer Service):
Fully saturated synthetic ester-based oils, HEES
Depending on the temperature range, the viscosity grade of the HESS oil must con-
form to the above specifications hor hydraulic oils.
Caution!
LIEBHERR recommends to limit the use of HEES oils to areas where HEES oils are
mandatory by local regulations.
Lifetime of components made out of rubber material such as hoses, seals, compen-
sators might be reduced while using HEES oils!
When mixing ester-based biodegradable hydraulic oils with mineral oils, there is a
risk of agressive chemical reactions, which might damage the hydraulic equipment.

R9200 / 11695477 5 - 21
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Hydraulic oil selection for cold climate conditions

When a LIEBHERR Mining excavator works under cold climates conditions, in any
case, the appropriate arctic kit must be installed.
Oil must match the above prescription for engine oils or hydraulic oils.
Oil’s pourpoint temperature must be at least 5 K below the minimal air ambient tem-
perature.
Oil’s flash point temperature > 160°C (recommended > 200°C).
The operating range of the arctic oil depends on the ambient air temperature and
must be checked as follow:
– If the maximal ambient air temperature stays below +20°C, the oil viscosity at
+50°C (oil temperature) must be over 16 cst.
In this case, the fans speed regulation "EXTRA-COLD" must be selected.
+60°C (oil temperature) must be over 16 cst. In this case, the fans speed regula-
tion "EXTRA-COLD" or "COLD" must be selected.
+70°C (oil temperature) must be over 16 cst. In this case, the fans speed regula-
tion "COLD" must be selected.
 Contact LIEBHERR Customer Service for additional questions about oil selection.
Oil mixing
In principle, oil mixing between two different oil types must be avoided. Mixing two
different oil types leads to an unknown lubricant with resultant unknown physical
properties (viscosity, pourpoint, flash point, ageing behaviour, lubricity, reaction with
additives...).
 However, if mixing is absolutely necessary, respect the following maximum mix-
ing proportions:
– Mixing LIEBHERR oils with hydraulic oils, or LIEBHERR oils with mineral oils, or
hydraulic oils with mineral oils, or two different mineral oils together, or two differ-
ent hydraulic oils together:
max. 10%
– Mixing HEES oils with hydraulic oils or mineral oils or LIEBHERR oils:
max. 2%
Hydraulic oil change intervals
Oil changes at pre-set intervals (mineral oils and PAO oils only)
This procedure is applicable only for mineral oils and PAO oils. If you use HEES bi-
odegradable oil, refer to the next section.
Fig. 5-11 Oil changes at pre-set intervals

5 - 22 R9200 / 11695477
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A Mineral oils and PAO oils

h Operating hours
 Liebherr recommends that you sample the hydraulic oil every 500 operating hours
(refer to the section "Condition monitoring with oil analysis").
 Change the hydraulic oil every 2000 operating hours.
Oil changes at optimized intervals

This procedure is applicable for mineral oils, PAO oils and HEES biodegradable oils.
Fig. 5-12 Oil changes at optimized intervals
A Mineral oils and PAO oils 1 First oil sample

B HEES biodegradable oils 2 Second oil sample
h Operating hours 3 Next oil samples at regular intervals
You can extend the oil change intervals (up to 6000 operating hours and possibly
even more) as long as the properties of the oil are satisfactory.
 Get a sample of the new hydraulic oil.
 If you use mineral oil or PAO oil, you must sample the hydraulic oil every 500 op-
erating hours after the first 1500 operating hours.
 If you use HEES biodegradable oil, you must sample the hydraulic oil every 250
operating hours.
 Change the hydraulic oil immediately if the results of the analysis are not satisfac-
tory (refer to the section "Condition monitoring with oil analysis").
5.4.5 Swing and travel gear oils
Note!
For a given machine operating temperature range, and if different viscosity grades
are approved according to the following specifications, always choose the lubricant
with the highest viscosity grade.
Caution!
Gears flushing is necessary when switching from mineral oil to synthetic oil.
 Use new oil to flush the gear when switching from mineral oil to synthetic oil.
Flushing with cleaning fluid or Diesel fuel is not permitted.

R9200 / 11695477 5 - 23
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Use gear oil meeting following viscosity classes and specifications (depending on the
ambient temperature):
Fig. 5-13 Swing gear and travel gear oils
* COB-1: Gear oil according to DIN 51517, part 3, CLP-HC(1)

(1)
HC / Synthetic carbon hybrid (poly-alpha-olefin PAO)
TEST / REQUIREMENT STANDARD / REFER- REQUIRED LEVEL /
ENCE PERFORMANCE
Relative scuffing load-carrying capacity A/8.3/90 DIN ISO 14635-1 >14
Relative scuffing load-carrying capacity A/16.6/140 DIN ISO 14635-1 >12
FVA-FZG micro-pitting load capacity GT-C/8.3/90 FVA Information sheet GT-High
no. 54/I-IV
FE-8 roller bearing wear tests 7.5/80/80 and 7.5/100/80 DIN 51819-3 Pass (excellent)
FLENDER AG approval - Approved
Tab. 5-5
FVA = Forschungsvereinigung Antriebstechnik e.V. ("Research association for drive technologies")

FZG = Forschungsstelle für Zahnräder und Getriebebau der TU München ("Gear Research Center
of the Technical University of Munich")
** COB-2: Gear oil according to DIN 51517, part 3, CLP

ENCE PERFORMANCE
FVA-FZG micro-pitting load capacity GT-C/8.3/90 FVA Information sheet GT-High
no. 54/I-IV
FE-8 roller bearing wear tests 7.5/80/80 and 7.5/100/80 DIN 51819-3 Pass (excellent)
FLENDER AG approval - Approved
Tab. 5-6

5 - 24 R9200 / 11695477
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** COB-2: Gear oil according to DIN 51517, part 3, CLP
Pour point temperature ISO 3016 VG220: TPour point < -15°C
VG320: TPour point < -15°C
Tab. 5-6
*** COB-3: Gear oil according to API classification GL5

ENCE PERFORMANCE
API classification GL 5 -
Scuffing load capacity FZG test A/8.3/90 DIN ISO 14635-1 >12
MIL-L 2105 B/C/D -
MAN 342 type M1 -
Mercedes Benz 235.0 -
ZF Friedrichshafen TE-ML 05A, 16C, 17B, -
19B, 21A
Tab. 5-7
**** COB-4: Gear oil according to API classification GL5

ENCE PERFORMANCE
API classification GL 5 -
Scuffing load capacity FZG test A/8.3/90 DIN ISO 14635-1 >12
MIL-L 2105 D, PRF-2105E -
MAN 342 type N -
ZF Friedrichshafen TE-ML 05A, 07A, 16D, -
21A
Tab. 5-8
5.4.6 Splitterbox oil

Use gear oil with viscosity classification SAE 90 or SAE 80W90 and meeting speci-
fications API-GL-5 and MIL-L-2105 B, C or D.
Fig. 5-14 Gear oils for use as splitterbox oil

R9200 / 11695477 5 - 25
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5.4.7 Lubricating grease and other lubricants
Lubricating grease
Use grease which agrees with the specifications that follow (depending on the ambi-
ent temperature).
Lubricating grease for the swing ring, attachment bushings and swing gear bearing / general lubricating
points:
– KP2K or KPF2K according to DIN 51502
– ISO-L-XBCEB2 according to ISO 6743-9
TEST / REQUIREMENT STANDARD / REFERENCE REQUIRED LEVEL / PERFOR-
MANCE
Consistency ISO 2137 / ASTM D 217 NLGI grade 2
Grade according to DIN 51818
Soap / Thickener - Greases made of calcium simple
soap are not permitted
Base oil viscosity at 40°C ISO 3104 / ASTM D 445 > 400 mm²/s
Dropping point ISO 2176 / ASTM D 566 > 160°C
Four ball wear test DIN 51350 / ASTM D 2596 > 2300 N
Lubricating solids, maximum particle size: -
– Maximum grain size for Graphite 25 microns
– Maximum grain size for MoS2 15 microns
– Maximum grain size for other solids ad- 15 microns
ditives
Lubricating solids, maximum content: -
– Maximum for Graphite 8%
– Maximum for MoS2 5%
– Maximum for other solids additives 5%
Tab. 5-9
Grease for swing ring teeth:

– KPF2K according to DIN 51502
MANCE
Consistency ISO 2137 / ASTM D 217 NLGI grade 2
Grade according to DIN 51818
Soap / Thickener - Greases made of calcium simple
soap are not permitted

Base oil viscosity at 40°C ISO 3104 / ASTM D 445 > 400 mm²/s
Dropping point ISO 2176 / ASTM D 566 > 160°C
Four ball wear test DIN 51350 / ASTM D 2596 > 5500 N
Water resistance DIN 51807-1 1 - 90 or better
Water washout ASTM D 1264 79°C - 5% loss or better
Tab. 5-10

5 - 26 R9200 / 11695477
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Grease for swing ring teeth:

– KPF2K according to DIN 51502
MANCE
Lubricating solids, maximum particle size: -
– Maximum grain size for Graphite 25 microns
– Maximum grain size for MoS2 15 microns
– Maximum grain size for other solids ad- 15 microns
ditives
Lubricating solids, maximum content: -
– Maximum for Graphite 8%
– Maximum for MoS2 5%
– Maximum for other solids additives 5%
Tab. 5-10
Cold climate conditions

Till -25°C:
 Greases must obey the specifications of the tables above.
 Use a grease with consistency classification 1 of NLGI.
Till -50°C:
 Greases must obey the specifications of the tables above.
 Use a grease with consistency classification 0 or 00 of NLGI.
 Use only synthetic greases.
Depending on the ambient temperature all year round, it can be necessary to adapt
the consistency grade.
Other lubricants
 Refer to the table that follows for other lubricants.
Lubricant Description / manufacturer

Contact spray for slip rings Cramolin
Lubricant for pistons, piston Gleitmo 800
nuts and piston bearing in-
stallations on the hydraulic
cylinders
Special anti-corrosive materi- Castrol-Tarp
al for installation areas of
sealing elements on hydraulic

cylinders
Anti-corrosion grease for Liebherr special grease CTK
open piston rods (cylinders
that do not move often or
transportation)

R9200 / 11695477 5 - 27
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Condition monitoring with oil analysis
5.4.8 Lubricants specifications for -40°C
Engine oil
 Refer to the Operation and Maintenance Manual for the CUMMINS Diesel engine.
First filling
Use BP Vanellus Ultima 5W30 from -40°C to +30°C (if the excavator is equipped with
a preheating the temperature range can start at -50°C instead of -40°C).
Hydraulic oil
 Refer to the section "Lubricating and operating material specifications" of this
manual.
Gear oil
SAE 75W90 API GL5 with pourpoint < -54°C:
– BP gear oil Syntrax Universal Plus 75W90
– AVIA gear oil Synthogear FE 75W90 EP from -50°C to +40°C
Grease: general lubepoint

– low temperature grease: Liebherr Universalfett Artic
– grease Castrol Spheerol SY 4601 from -30°C to +30°C
– grease Liebherr Spezialfett 1026 LS from -30°C to +60°C
– grease Petro-Canada Multiflex Moly EP1 from -50°C to +20°C
– Fuchs Urethym HGO from -55°C to +0°C
Grease for swing ring teeth

– low temperature grease: Liebherr Universalfett Artic
– grease Petro-Canada Vulcan Synthetic Arctic from -55°C to -20°C
5.5 Condition monitoring with oil analysis
5.5.1 General information

Oil analysis helps to monitor the main components condition by observing oil chem-
ical and physical properties which can show either the oil contamination by foreign
or wear particles, or the degradation of its properties.
Component oil analysis in accordance with the recommended procedures, intervals

and specifications and the records of a component oil analysis are strongly recom-
mended because this will support any warranty claim raised upon LIEBHERR.
By comparing the oil properties and contaminants to reference levels and even more
by observing their trends over a period of operation, it is possible to optimize the com-
ponent lifetime, possibly to prevent further damage (preventive exchange) and po-
tentially to reduce rebuild and maintenance costs.
An oil analysis will give an indication of the component condition. But the measured
values and their trend over a period of operation need always to be interpreted in re-
lation to the machine operating conditions and to events such as services, top-up,

5 - 28 R9200 / 11695477
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component change-out, etc.

The interpretation of the analysis results need also to be compared to samples of the
new oil. Therefore, new oil needs to be analysed twice a year and when changing to
another oil supplier.
This procedure is applicable for these components:
– splitterbox(es)
– swing gears
– travel gears (not on pontoon machines)
– hydraulic oil
– Diesel engine(s) (not on electrical machines)
These parameters must be monitored:
– iron level
– copper level
– silicon level
– water content
– viscosity change
– additives change (e.g. Ca, Mg, B, Zn, P, Ba or S)
5.5.2 Oil sampling
Sampling intervals
– For each component, get an oil sample according to the Control and maintenance
chart.
– When changing oil, get an oil sample of the used oil immediately before draining
it.
– For new oil, get an oil sample twice a year and when changing to another oil sup-
plier.
Sampling instructions
General sampling instructions:

 Wear personal protective equipment.
 Get the sample:
– during operation or immediately after stop
– at normal operating temperature
– not just after an oil change
– not just after a top-up
 Clean the area around the sampling point before you get the sample.
 Use an appropriate sampling kit.

 Keep the sampling material away from humidity and dust. Take these precautions
to choose a storage area.
 Make sure the sampling material is perfectly clean (without dust, water, fuel...).
 If different sampling procedures are applicable for a component, always use the
same sampling point and the same sampling procedure for this component to
make sure that the analysis records stay relevant.

R9200 / 11695477 5 - 29
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 Fill the sampling bottle with oil to 80% level. Do not fill the sampling bottle to the
top.
 Close the sampling bottle tightly to ensure the integrity of the sample.
 Identify the sample with a label.
 Carefully fill in a sample information sheet. In any case, it is mandatory to give this
information with the sample:
– machine type and serial number
– machine hours
– sampled component name:
• splitterbox (front/rear)
• swing gear (front/rear and left/right)
• travel gear (left/right)
• hydraulic oil
• Diesel engine (front/rear)
– sampled components hours
– sampled oil hours
– top-up oil quantity since last sample
– sampled oil type
 Send the sample in oil-proof adapted material.
 Check for the required sample delivery time and for sample export licence (if the
laboratory is located out of the country, make sure that the export of the sample
is authorized from your location to the laboratory).
 Do not wait before sending the sample to the laboratory.
 Record and save sampling operations and results.
If you get the oil sample with a sampling pump:
Fig. 5-15 Sampling pump
 Use a sampling pump if you get the sample directly in the tank or on the compo-
nent (machine stopped).

5 - 30 R9200 / 11695477
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 Always use a new sampling hose.

 Cut the sampling hose to the correct length (e.g. dipstick length plus 20 mm).
 First, let sufficient oil flow to flush the sampling hose.
 If you get the oil sample in the tank, take the sample in the middle of the tank.
If you get the oil sample through a sampling valve:

 Always use a new sampling hose.
 First, let sufficient oil flow to flush the sampling hose.
 Get the oil sample in the mid-stream, i.e. first let a small amount of oil flow through
the valve before sampling it.
Sampling material
 You can order LIEBHERR approved sampling material to get the samples:
Note!
These sampling kits are prepaid kits and include the cost of the analysis.
Before ordering these sampling kits, check for sample export licence: make sure
that the export of the sample is authorized from your location to Europe.
Ident Nr. Description Quantity Illustration
8145660 Sampling kit for mineral and synthetic oils: 1

– sample bottle
10029626 4
– envelope addressed to OELCHECK GmbH
7018368 6
– sample information sheet
7018369 12
7026817 Sampling kit for biodegradable oils: 1
7026088 – sample bottle 6

– envelope addressed to OELCHECK GmbH
– sample information sheet
8145666 Sampling hand pump: 1

– hand pump
– sampling hose

R9200 / 11695477 5 - 31
MJFCIFSS
Ident Nr. Description Quantity Illustration
5613844 Sampling valve 1
7019068 1
Compact sampling valve:
12203274 – for hydraulic oil 1
12203276 – for engine oil 1
12203277 – for swing gear oil 1
12203278 – for engine coolant 1
12203279 – for splitterbox oil 1
12203794 Fitting for sampling hose 1

(for compact sampling valve)
7023359 ADR spill kit (International Carriage of Dangerous 1

Goods by Road):
– pads
– absorbent socks (SOCs)
– disposable bag
– pair of gloves
– instruction sheet

5 - 32 R9200 / 11695477
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Oil sampling points
Splitterbox
Fig. 5-16 Sampling valve 1 for splitterbox oil
To get a sample of the splitterbox oil:
Note!
Two sampling procedures are applicable for this component.
 Always use the same sampling point and the same sampling procedure for this
component to make sure that the analysis records stay relevant.
 Use the sampling valve 1 which is installed next to the hydraulic oil cooler.
or
 Use a sampling pump and get the oil sample through the dipstick tube of the split-
terbox.

R9200 / 11695477 5 - 33
MJFCIFSS
Travel gear
Fig. 5-17 Oil sampling points 1 for travel gear oil
To get a sample of the travel gear oil:

 Use a sampling pump and get the oil sample through the filling and level plugs 1.
Hydraulic oil
Fig. 5-18 Sampling valve 1 for hydraulic oil

To get a sample of the hydraulic oil:

 Use the sampling valve 1 which is installed in the pumps box on the piloting oil
filter.

5 - 34 R9200 / 11695477
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Diesel engine
Fig. 5-19 Sampling valve 1 for Diesel engine oil
To get a sample of the Diesel engine oil:
Note!
Two sampling procedures are applicable for this component.
 Always use the same sampling point and the same sampling procedure for this
component to make sure that the analysis records stay relevant.
 Make sure that the access ladder stays lowered during the sampling operation.
 Make sure that the engine cooling fans turn at lowest speed.
 Use the oil sampling valve 1 which is installed on the oil filter head.
or
 Use a sampling pump and get the oil sample through the dipstick tube of the Die-
sel engine.
5.5.3 Sample processing

Analysis standards
LIEBHERR recommends to submit the oil samples to OELCHECK GmbH for oil anal-
ysis.
If another laboratory is used, the oil analysis must be done according to these stand-
ards:
– DIN 51 396-1, DIN 51391-3 (wear metals, contamination and additives by ICP)
– DIN 51 562 (viscosity)

R9200 / 11695477 5 - 35
MJFCIFSS
– DIN 51 451 (water by FT-IR)
Action level values

These tables give the action level values for the different monitored parameters for
each component and the action to be taken if the action level value is reached.
These values are applicable for mineral and synthetic oils.
Caution!
If three analyses one after the other give out-of-range results:
 Contact LIEBHERR Customer Service with the related analysis records.
Caution!
Comments and recommendations given by the laboratory on the analysis report
must also be taken into account.
Splitterbox
Component Parameter Action Action

level value
Iron level 100 ppm Change oil (get a sample again after 250 hours).
Copper level 10 ppm Change oil (get a sample again after 250 hours).
Silicon level 20 ppm Check component for entrance of dust (sealing, breath-
ers...).
Flush and change oil (get a sample again after
Splitterbox 250 hours).
Water content 0,10% Change oil (get a sample again after 250 hours).
Viscosity change <15%(*) Change oil (get a sample again after 250 hours).
(at 40°C and 100°C)
Additives change ±20%(*) Change oil (get a sample again after 250 hours).
(*)
Difference compared to new oil value.

5 - 36 R9200 / 11695477
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Swing gear

level value
ers...).
Swing gear 250 hours).
(at 40°C and 100°C)
(*)
Travel gear

level value
ers...).
Travel gear 250 hours).
(at 40°C and 100°C)
(*)

R9200 / 11695477 5 - 37
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Hydraulic oil

level value
Silicon level 15 ppm Check for entrance of dust (cylinders, breathers...) (get a
sample again after 250 hours).
(at 40°C and 100°C)
Water content 0,10% 1. If the machine has a bypass filter element with water
separator installed, replace the filter.
– If not available, use an external filtration system until
you get a satisfactory range.
– If not available, change oil.
2. Get a sample again after 250 hours.

If the results are still out-of-range:
– Use an external filtration system until you get a satis-
factory range.
Hydraulic oil Particle Quantifica- 50 1. Change the return filters, pilot oil filters, leak oil filters
tion (PQ Index) and replenishing filters.

– Use an external filtration system until you get PQ Index
< 20 or less.
Cleanliness level 21/19/16 1. Change the return filters, pilot oil filters, leak oil filters
(ISO 4406) and replenishing filters.

– Use an external filtration system until you get contam-
inant code 20/18/15 or less.
(*)
Diesel engine

level value
Diesel engine Please contact your engine manufacturer local representative.

5 - 38 R9200 / 11695477
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Diesel engine
5.6 Diesel engine
 Refer to the Cummins operation and maintenance manual for detailed description
of maintenance work to be performed.
 The engine manufacturer reserves the right to change information, specifications
and maintenance guidelines in its manuals at any time. Thus, to make sure that
you have the latest version of its documentation, contact your local representative
of the engine manufacturer.
 In addition, accurately observe the following items and perform all maintenance
work according to the intervals given in the control and maintenance chart.
5.6.1 Check the engine oil level

The dipstick for the oil level indication is installed on the two sides of the engine.
Fig. 5-20 Dipstick for indication of engine oil level
10 Dipstick
Danger!
Risk of burning.
The engine oil is hot when it is at operating temperature.
Avoid contact with hot oil and components containing oil as it can cause dangerous
burns.
 Park the machine tightly on level ground.

R9200 / 11695477 5 - 39
MJFCIFSS
Diesel engine
 Stop the engine.

 Wait a minimum of 15 minutes to let the oil collect at the bottom of the engine oil
pan.
 Check the oil level with the dipstick 10.
5.6.2 Change the engine oil
Drain the oil
Drain the oil with the service trap
Fig. 5-21 Engine oil drain coupling on service trap
 Make sure the engine oil is at operating temperature.

 Use the oil drain coupling on the service trap.
Drain the oil through the drain plug

As a help way, the oil can also be drained through the oil drain plug. It is located at
the bottom of the oil pan of the Diesel engine.

5 - 40 R9200 / 11695477
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Diesel engine
Fig. 5-22 Engine oil pan
 Make sure the engine oil is at operating temperature.

 Remove the oil drain plug.
 Attach a drain hose. Drain the oil into an applicable container.
 Remove the hose. Check and clean.
 Install the oil drain plug again.
 For detailed description of maintenance work to be performed, see also Cummins
operation and maintenance manual.

R9200 / 11695477 5 - 41
MJFCIFSS
Diesel engine
Fill the oil
Fig. 5-23 Oil filler neck of the Diesel engine
20 Oil filler neck
 Add oil through the quick change coupling of the service trap until the oil gets the
maximum mark of the dipstick 10.
 A small quantity of oil can also be filled through the filler neck 20.
 For oil quantities, oil specifications and oil change intervals, see lubrication and
maintenance chart.
5.6.3 Replace the oil filter elements
Danger!
Risk of burning.
 When you remove the filter, be careful to avoid contact with hot oil as it can
cause dangerous burns. Use gloves to avoid burns and personal injury because
of possible sharp edges on the filter elements.
 To prevent personal injury, make sure that the engine and the rotation of the
bowl are completely stopped before any disassembly. Wait at least 5 to 10 min-
utes after stopping the engine before disassembling the filter.

5 - 42 R9200 / 11695477
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Diesel engine
Fig. 5-24 Oil filters on Diesel engine
 Loosen and remove the filter elements.

 Clean the sealing surfaces on the filter mounts.
 Lightly lubricate the rubber seal on the new filters with oil.
 Install and tighten the filters.
 Check after every oil change, or after adding oil, that you get the correct oil level
on the dipstick 10.
5.6.4 Mounting screws

Any incorrect fastening can decrease very much the expected life of the rubber
mounts.

R9200 / 11695477 5 - 43
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Diesel engine
Fig. 5-25 Engine mounting screws
Torque Quantity
112 Screw M20x120 560 Nm 2
117 Screw M24x130 965 Nm 4
145 Screw M30x300 (if installed) 1920 Nm 2
 Check the mounting screws on the engine brackets and the engine gear mounts
regularly for tightness. Retorque if necessary.
 For maintenance intervals, see control and maintenance chart.
Caution!
 Apply Loctite nr. 243 on the mounting screws 112, 117 and 145 when you install,
in order to avoid possible damages on the parts.
 Only tighten the screws 112, 117 and 145 after the engine and the splitterbox
has been positioned on the PowerPack frame as a complete unit, to avoid a pre-
tentioning of the rubber mounting.

5 - 44 R9200 / 11695477
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Splitterbox
5.6.5 Elastic bedding
Fig. 5-26 Engine elastic bedding
 The four rubber buffers 115 at the front face of the engine must be checked and
replaced at regular intervals.
5.6.6 Alternator belt

 Regularly check belt for correct condition, tension, alignment...
 For detailed description of maintenance work to be performed, see Cummins op-
eration and maintenance manual.
5.7 Splitterbox
5.7.1 Splitterbox mounting screws

Any incorrect fastening can decrease very much the expected life of the rubber
mounts.

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Splitterbox
Fig. 5-27 Splitterbox mounting screws
Torque Quantity
1 Screw M20x100 560 Nm 8 (2x4)
2 Screw M24x130 965 Nm 4 (2x2)
 Check the mounting screws on the splitterbox brackets regularly for tightness, re-
torque if necessary.
Caution!
 Apply Loctite nr. 243 on the mounting screws 1 and 2 when you install, in order
to avoid possible damages on the parts.
 Only tighten the screws 1 and 2 after the engine and the splitterbox has been
positioned on the PowerPack frame as a complete unit, to avoid a pretentioning
of the rubber mounting.

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Splitterbox
Fig. 5-28 Splitterbox mounting screws on engine
Torque Quantity
11 Screw 1/2" UNC X2 3/4" 130 Nm 16
 Check the tightness of mounting screws 11 from the splitterbox to the Diesel en-
gine housing regularly, retorque if necessary.
Caution!
 Apply Loctite nr. 243 on the mounting screws 11 when you install, in order to
avoid possible damages on the parts.

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Splitterbox
5.7.2 Elastic bedding
Fig. 5-29 Elastic bedding
 The four rubber buffers 3 at the splitterbox sides must be checked and replaced
at regular intervals.

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Cooling system
5.7.3 Breather filter
Fig. 5-30 Breather filter on splitterbox
The breather filter 1 on the splitterbox must be checked, cleaned and replaced reg-
ularly.
Clean the breather filter

 Open breather filter 1 by pushing it and turning it 1/4 turn.
 Remove the filter element 2 from the breather housing.
 Check filter condition and clean it with fuel.
 Reinstall the filter element in the breather housing.
 Close breather 1.
 For check, clean and change intervals, see maintenance and control chart.
5.8 Cooling system
5.8.1 Check and clean the cooling system

To get optimal cooling, the cooler must be kept clean.

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Cooling system
Fig. 5-31 Expansion tank
1 Coolant expansion tank

2 Level indicator
3 Filler neck
 Check the engine, fan and cooler for damage.

 If necessary, clean with pressurized air.
 If the cap of the filler neck 3 is leaking, replace the cap.
 Regularly check the connector hoses between the radiator and the engine.
 Regularly check the heater hoses for condition and leaks.
 Check the tightness of hose clamps.
5.8.2 Check the coolant level
Danger!
At near operating temperature, the engine coolant is hot and under pressure.
 Avoid contact with components containing coolant as it can cause dangerous
burns.
 Make sure the engine coolant is cold and the radiator is sufficiently cool to touch.
 Check the coolant level.
The coolant level must be at the middle of the level indicator 2.

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Cooling system
5.8.3 Coolant antifreeze and anti-corrosion fluid

The system must be filled with antifreeze all year round.
Upon dispatch, the coolant contains antifreeze for temperatures up to -35 °C (this is
equal to approximately 50% antifreeze).
 For volume, see operating material chart.
Fig. 5-32 Coolant filters
The coolant filters are installed on the Diesel engine and they contain a corrosion
protector.
 Check the corrosion protection concentration in the coolant circuit at regular inter-
vals.
 If necessary, corrosion protective additives must be added to the coolant, see
Cummins Operation and Maintenance Manual.
5.8.4 Change the coolant
Danger!
Risk of burning because of hot coolant.
 Only change the coolant when the engine is cold.

 For coolant change interval, see Cummins operation and maintenance manual.
 For the detailed procedure to drain and fill the engine cooling system, refer to the
Cummins engine operation and maintenance manual.
 If an optional water heater is installed, bleed it after maintenance works on the
Diesel engine cooling system. Refer to section "Starting aids" in chapter 5.

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Cooling system
Drain the coolant

Two drain plugs 3 are located on the tubes connected to the radiator 2.
Fig. 5-33 Coolant drain
1 Engine cooler box

2 Engine coolant radiator
3 Drain plug
Fill the coolant
Caution!
When you fill the system, the coolant level in the expansion tank must be correct
and stable.
 Make sure that the expansion tank is filled to correct level on the indicator 2 and
until coolant level no longer drops.
5.8.5 Replace the coolant filters

The filters contain a paste-like corrosion protection additive, which ensures the cor-
rect corrosion protection properties of the coolant.

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Fuel system
Fig. 5-34 Coolant filters
 Turn the shutoff valve of the coolant filters to the OFF position.
 Loosen and remove the filter elements.
 Lightly oil the seal rings on the new filter element.
 Tighten the new filters elements until the seal ring touches the filter housing.
 Then turn it manually by one more 1/2 - 3/4 turn. Do not use any tools to tighten
the filters.
 Turn the shutoff valve to the ON position.
5.9 Fuel system
Danger!
Risk of explosion!
 Avoid naked flame when working on the fuel system and when refuelling.
 Do not smoke.
 Only work on the diesel engine when it is switched off.
5.9.1 Refuel
The display shows the fuel level.

 If the fuel level is too low, fill the fuel tank before you start the work.
The machine has different refuelling devices.

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Fuel system
Refuel through the fuel cover
Fig. 5-35 Lockable fuel tank cap
1 Fuel tank
2 Fuel tank cap
3 Padlock of fuel tank cap
 Unlock padlock 3.
 Remove tank cap 2.
 Add fuel.

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Fuel system
Refuel through the service trap
Fig. 5-36 Service trap
 Use the related coupling on the service trap.
5.9.2 Drain the fuel tank

Two drain valves 1 are located at the bottom of the fuel tank.
Fig. 5-37 Drain valves of fuel tank

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Fuel system
1 Drain valve
2 Cap of drain valve
Drain the water of the fuel tank

 Put an applicable container below the drain valve 1 of the fuel tank.
 Loosen cap 2 about two turns.
 Drain the water until water free fuel flows out.
 Close cap 2.
 To reduce the formation of condensate in the tank, keep the fuel level as high as
possible.
Drain the fuel tank

 Remove cap 2 from the drain valve 1.
 Attach a drain hose. Drain the fuel into an applicable container.
 Remove the drain hose.
 Close the cap 2 again.
 For maintenance intervals, refer to control and maintenance chart.
5.9.3 Clean the fuel tank

Cleaning access to the tank is possible through the covers located on the tank.
 Drain the fuel tank (refer to section above).
 Always use an applicable container to collect the water and the fuel.
 Check and clean the fuel tank.
 Close covers again.
5.9.4 Fuel filtering system

The fuel filtering system is composed of the preliminary filter 1 and the fuel filters 2. LEC/en/Edition: 04 / 2017

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Fuel system
Fig. 5-38 Fuel filters assembly
1 Preliminary filter
2 Fuel filters
3 Engine cooler box
 Check the preliminary filter 1 for water and debris every day.
 Drain the fuel-water separator on preliminary filter 1 every day.
 Replace all preliminary filters and fuel filters when the fuel level gets the red mark
on the bell of the preliminary filter 1.
 For preliminary and fuel filters replacement intervals, see control and mainte-
nance chart.
Drain the fuel-water separator

The fuel-water separator is located on the preliminary filter 1.

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Fuel system
Fig. 5-39 Fuel-water separator on preliminary filter
1 Preliminary filter
2 Drain valve

 Open manually the drain valve 2 of the fuel-water separator located at the bottom
of the fuel filter 1.
 Turn the drain valve 2 counterclockwise until it falls down.
 Drain water of the fuel filter until clear fuel is visible (approximately 3,5 turns).
 Lift the drain valve 2 and turn it clockwise manually to close it.
 For detailed description of maintenance work to be performed, see also CUM-
MINS operation and maintenance manual.
Caution!
The drain valve must be tightened manually.
Do not overtighten the drain valve as it can damage the threads.

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Fuel system
Replace the fuel filter elements
Fig. 5-40 Supply shutoff valve
1 Fuel tank
2 Supply shutoff valve
Remove the fuel filter

 Close the fuel supply shutoff valve 2.
 Clean the area around the filter and the filter head.
 Loosen and remove the filter with an applicable wrench.
 Clean the sealing surfaces on the filter head with a clean and free-lint cloth.
Install the fuel filter

 Do not fill the new filter with fuel.
 Apply a light film of clean engine oil on the filter element seal.
 Install and tighten manually the filter element on the filter head.
 Open the fuel supply shutoff valve 2.
Caution!
The filter element must be tightened manually.
Do not overtighten the filter element as it can damage the threads.
Priming the fuel system

Fuel filters and preliminary filter must be primed after filter replacement and before
to start the engine. The procedure that follows is available for the two types of filter.
 Check that the drain valve of the preliminary filter is closed.
 Close the fuel supply shutoff valve 2.
 Remove the vent cap from the top of the preliminary filter.

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Fuel system
 Fill the filter with clean fuel.

 Install the vent cap again.
 Tighten the vent cap manually.
 Open the fuel supply shutoff valve 2.
 Actuate the ignition key 2 to 3 times to prime the fuel system.
The fuel priming pump will operate for 120 seconds when the ignition key is switched
to contact position.
 When the priming pump stops operating, turn the ignition key to the "OFF" posi-
tion for approximately 30 seconds before do it again.
5.9.5 Replace the dust filter for the vent valve
Fig. 5-41 Dust filter for the vent valve
1 Dust filter
 Replace the filter element of the optional dust filter 1 at regular intervals.

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Dry air filter
5.10 Dry air filter
Fig. 5-42 Air intake system
1 Housing of dry air filter 18 Warning window

16 Vacuum indicator 19 Reset button
17 Red stripe
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.
The air cleaner with primary and safety elements is designed to give maximum pro-
tection at long maintenance intervals.
Maintenance also includes the replacement of the filter elements.
For safety reasons, we do not recommend to clean the filter elements.
The vacuum indicator 16 storages the maximum recorded vacuum pressure on the
filter outlet, during the Diesel engine operation.
The red stripe 17 is shown in the window 18 when the maximum permitted vacuum
gets the value of 63 mbar.
 You must replace the primary filter element:
– Immediately when the maximum vacuum pressure has been reached.

– At the intervals specified in the control and maintenance chart, if the maximum
vacuum pressure has not been reached first.
 Press the button 19 to reset the vacuum indicator.
If the filter elements are removed and installed too often, the seals between the filter
elements and the filter housing can be damaged.
The safety elements must be replaced after the primary elements have been re-
placed three times, or at intervals specified in maintenance schedule.

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Dry air filter
Before installing a new element, carefully clean the seal and the sealing surface of
the filter housing.
5.10.1 Replace the primary filter element
Fig. 5-43 Primary filter element
1 Primary filter element

2 Wing nut

 Remove the wing nut 2.
 Remove the dirty primary filter element 1.
 Clean the inner surface of the air filter housing.
 Wipe off the sealing surface in the filter housing with a moist rag.
 Do not blow the housing with compressed air.
 Insert the new primary filter element.
 Make sure it is installed correctly.
 Tighten wing nut 2.

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Dry air filter
5.10.2 Replace the safety element
Fig. 5-44 Safety element
3 Safety element
4 Wing nut
We recommend that the safety elements are replaced by a qualified maintenance or

Liebherr service technician.
 Remove the primary filter element as given before.
 Remove wing nut 4.
 Remove the dirty safety element 3.
 Carefully clean the inner surface of the air filter housing with a moist rag.
 Clean the sealing surfaces in the housing and check for damage.
 Carefully insert the new safety element.
 Tighten wing nut 4.
 Install the primary filter element as given before.

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Dry air filter
5.10.3 Clean the housing of the air filter elements
Fig. 5-45 Housing of air filter elements
1 Housing of air filter elements

2 Filter cover
 Do a check of the condition of the dry air filter housing 1 at the intervals specified
in the control and maintenance chart.
 Open the filter cover 2 and check the inner housing.
 If the inner housing is clogged with dust, use compressed air to blow it from the
inlet side inside the housing.
Caution!
Do not use steam.
The safety elements must stay in position.
Do not point the air flow through the filter elements.

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Dry air filter
5.10.4 Check the air intake system, hoses, elbow tubes, clamps
Fig. 5-46 Air intake hoses, tubes and elbow tubes
1 Elbow tubes 3 Tubes

2 Air intake hoses 4 Clamps

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Hydraulic system
The hoses and tubes 2, 3 and the elbow tubes 1 between the filter housings and the
engine must be checked for damage, wear, tightness and leaks when the filter ele-
ments are replaced.
 If necessary, retighten the screws on the clamps 4.
 If necessary, include the visual inspection of the air intake system in the daily
maintenance.
5.11 Hydraulic system
Maintenance work on the hydraulic system is restricted mainly to the hydraulic tank.
All other units on the system do not require any special maintenance.
Strict cleanliness is of particular importance for the hydraulic system.
 Obey the intervals given to:
– replace the return-line filter
– replace the hydraulic tank breather filter
– clean the oil cooler
– change the oil
– check pipe and hose network for leaks
5.11.1 Preparatory activities
Fig. 5-47 Machine check position for hydraulic oil level check or level adjustment
Check or adjust the oil level

 The machine must stay on level ground.
 The attachment must stay on the ground, with stick and tilt cylinders fully extend-
ed and bucket closed.

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5.11.2 Check the oil level in the hydraulic tank
Fig. 5-48 Hydraulic tank oil level
1 Maximum oil level (warm and with 4 Minimum oil level (cold and with
fully retracted cylinders) fully extended cylinders)
2 Warm oil check level (in check 5 Cold sight gauge
position)
3 Cold oil filling level (in check posi- 6 Warm sight gauge
tion)
The "MAX" mark 1 shows the maximum oil level if all cylinders are fully retracted with
excavator at nominal operating temperature.
The "MIN" mark 4 shows the minimum oil level if all cylinders are fully extended with
oil at minimum temperature.
Fill the hydraulic tank with oil initially (e.g. for first start, after
maintenance...)
 Make sure that the machine and the hydraulic oil are at ambient temperature.
 Make sure that the machine is set in the check position given before in this sec-
tion.
 Add oil to the hydraulic tank until the oil level is at level 3.
Check the oil level in the hydraulic tank

 Make sure that you do the check of the hydraulic oil level only when the hydraulic
oil is at nominal operating temperature (warm). You can get the nominal operating
temperature as given below.
 Start the engine.
 Operate the excavator with standard movements until the hydraulic oil tempera-
ture is over 50°C.

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Hydraulic system
Caution!
 During this warm-up, make sure that the hydraulic oil level is not above the
"MAX" mark 1.
 Set the excavator in the check position given before in this section.
 Check that the oil level is at level 2.
 If the oil level is below level 2, add oil through the filling coupling or through a re-
turn filter until you get correct oil level.
 If the oil level is over level 2, drain the unwanted oil until you get correct oil level.
During the operation, if the oil level falls below a safety level, this warning symbol is
shown on the display.
The oil level gauge on the hydraulic tank does not show this safety level.
5.11.3 Release the pressure from the hydraulic system
Danger!
A fine stream of liquid can penetrate the skin when under high pressure and cause
serious injury.
 Before working on the hydraulic system, always release the pressure.
 Do not inspect leaks with bare hands.
Release the hydraulic pressure

 Make sure that the machine is set in the position given before.
 Make sure that the ignition key is on contact position.
 Move the operating and control elements (joystick and pedals) in all directions.
Danger!
The hydraulic oil is hot when at operating temperature.
 Do not allow the hot oil or oil-bearing parts to touch the skin. LEC/en/Edition: 04 / 2017

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Fig. 5-49 Depressurize the hydraulic system
1 Hydraulic tank
2 Breather filter
3 Locking pin
 Put the locking pin 3 into the breather filter 2.

 Loosen the breather filter 2 only one turn.
The pressure in the hydraulic system will decrease.
 At the end of the work, tighten the breather filter 2.
 Remove the locking pin 3.
It is no longer possible to loosen the breather filter.
The breather filter 2 must be replaced at regular intervals.
5.11.4 Drain and fill the hydraulic tank

Caution!
 Before draining the oil or before adding oil through the service trap or a filter cov-
er, always release the hydraulic tank pressure.
 After each hydraulic oil change, bleed the hydraulic pumps.

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Hydraulic system
Fill the oil through the service trap
Fig. 5-50 Hydraulic oil change coupling on service trap
 Set the excavator in the check position described previously in this section.
 Release hydraulic pressure.
 Use the related quick change coupling of the service trap to refill hydraulic oil until
you get the correct oil level.
 Close the breather filter.

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Hydraulic system
Add oil manually
Fig. 5-51 Return-line filter on the hydraulic tank
1 Leak oil filter

2 Return-line filter
As a help way, or for small quantities, hydraulic oil can be added manually.
 Remove the cover of the return-line filter 2 (see section below about the return-
line filter opening).
 Add oil through the return-line filter until you get the correct oil level.
 Install the cover back.

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Hydraulic system
Drain the oil
Fig. 5-52 Hydraulic tank bleeding valve
3 Bleeding valve
 Lay down the attachment on the ground in order to have a maximum quantity of
oil in the hydraulic tank: stick and bucket cylinders fully retracted, bucket on the
ground.
 Remove the cover of the return-line filter 2 (see section below about the return-
line filter opening).
 Install the drain hose on the hydraulic tank bleeding valve 3 and let the oil flow in
a suitable container.
 Remove the drain hose.
 Install the cover again.
Drain the water of the hydraulic tank

 See maintenance chart for the bleeding intervals.

 Attach a drain hose on the bleeding valve 3. Drain the water until water free oil
flows out.

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Hydraulic system
5.11.5 Hydraulic oil coolers

Cleaning hydraulic oil coolers is necessary to get optimum hydraulic oil cooling.
 Clean hydraulic oil coolers with compressed air or a steam cleaner at the intervals
given in the control and maintenance chart, and more often if working conditions
make it necessary.
5.11.6 Leak oil filter and return-line filter

The leak oil filter and the return-line filter are located on the top of the hydraulic tank.
Fig. 5-53 Leak oil filter parts
1 Return pipe 5 Cover

2 Screw 6 Hexagonal screw

3 Filter insert 7 Magnetic rod
4 Seal kit

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Hydraulic system
Fig. 5-54 Return-line filter parts
1 Return pipe 5 Cover

2 Screw 6 Hexagonal screw
3 Filter insert 7 Magnetic rod
4 Seal kit
The magnetic rods 7 of the two types of filters must be cleaned at fixed intervals (refer
to the control and maintenance chart) and the glass fibre filter insert 3 replaced.
Clean the magnetic rod and replace the filter insert

This section is available for the two types of filters.
 Loosen the screws 6 on the filter cover and lift out cover 5 and magnetic rod 7.
 Carefully clean any metal particles collection on the magnetic rod 7.

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Hydraulic system
 Remove the used filter insert 3 on the bracket.

 Insert a new filter insert on the bracket vertically in the tank and press down lightly.
Caution!
 Make sure that the filter insert is standing vertical in the tank.
 Centre the cover unit on the filter insert 3 and position. Make sure that the sealing
4 is put correctly and it is in good condition.
The filling opening of the hydraulic tank has a return pipe. This prevents objects get-
ting into the hydraulic tank. The protective cylinder can be removed from the filling
opening if necessary.
 Each time you replace the filter insert 3, also replace the pressure filter insert that
is integrated in the servo oil unit.
 Install the cover 5 back.
 Tighten the screws 6.
5.11.7 Piloting and replenishing oil filters

Two hydraulic filters, located in the pumps box 3, do the filtration of the auxiliary cir-
cuits:
– one piloting oil filter 1
– one replenishing oil filter 2
Fig. 5-55 Piloting and replenishing oil filters location

1 Piloting oil filter

2 Replenishing oil filter
3 Pumps box

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Hydraulic system
Fig. 5-56 Piloting and replenishing oil filters
1 Piloting oil filter

2 Replenishing oil filter
 For the filters replacement interval, refer to the control and maintenance chart.
It is not permitted to clean the filter element.
 Replace the filter element each time you open the filter housing.
Replace the filter element
Fig. 5-57 Piloting and replenishing oil filters parts

1 Filter head 3 O-ring

2 Filter housing 4 Filter element
 Release hydraulic pressure before the replacement of the filter element 4.

 Make sure the filter head 1 and housing 2 are in good conditions.
 Make sure sealings and o-ring 3 are correctly installed.

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Hydraulic system
 Lightly lubricate the threads of the housing 2.

 Turn the filter housing 2 in the filter head 1 to the stop.
5.11.8 High pressure filters in working circuit

Four high pressure filters are installed on the inlet ports of the control valves.
Fig. 5-58 High pressure filters on valve bank
1 High pressure filter 3 Compression ring

2 Compression ring 4 Coupling
The filter elements must be checked or replaced at the intervals specified in the con-
trol and maintenance chart.
Caution!
The related filter elements must be replaced after each replacement or repair of a
working pump.

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Hydraulic system
Check or replace the filter element
Caution!
Risk of oil spilling when removing the filter housing. Oil spilling could be reduced by
using a vacuum pump.
Fig. 5-59 High pressure filter parts
1 Filter head 4 O-ring

2 Filter element 5 O-ring
3 Compression spring 6 Filter housing

 Remove the filter housing 6.
 Remove the filter element 2, check it and clean it with non flammable cleaning flu-
id, or replace it if necessary with a new element.
The filter element 2 can be cleaned up to three times. Then it must be replaced by a
new one.
 Check for leaks each time you check or you replace the filter element:
– Start the engine.
– Operate the machine for a short period.
– Check for leaks between the filter housing 6 and the filter head 1.
 Clean the filter housing 6 and the filter head 1 and install it again, making sure the
o-rings are correctly installed.
 Turn the filter housing 6 in the filter head 4 up to the stop.

5.11.9 Control circuit

It is not necessary to do special maintenance on the control circuit (servo oil circuit).

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Fig. 5-60 Accumulator on valve bank
1 Accumulator
2 Valve blank
 Examine the pipe network and connections on all units (pressure accumulator,
pressure limiting valve, pressure filter, etc.) regularly for leaks.
As
Danger!
As the accumulator 1 keeps the control circuit under pressure, this control pressure
must be depressurized as follows before working on the control circuit.
 Put the work equipment on the ground.
 Operate the two joysticks (with ignition key in contact position).

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Hydraulic system
5.11.10 Remove the intake hoses from the pumps
Fig. 5-61 Pumps aspiration (intake hoses)
1 Working pump compensators 4 Replenishing pump intake hose

2 Cooling fans pump intake hose 5 Intake pipe
3 Pilot oil pump intake hose

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Hydraulic system
Fig. 5-62 Hydraulic shutoff valve
If you must remove intake hoses/compensators from their related pump or from the
hydraulic tank, the hydraulic shutoff valve must be closed.
Remove intake hoses/compensators

 Release the hydraulic pressure.
 Turn the hydraulic shut-off valve from position 1 to position 2 to close it.
 Remove related intake hose/compensator.
 Drain the hydraulic oil out of the pump and intake hose/compensator in a suitable
container.
 Once the repair work is completed, turn the hydraulic shutoff valve from position
2 to position 1 to open it.
5.11.11 Bleeding of hydraulic pumps

After working on the pumps or after oil change in the hydraulic system, the hydraulic

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Hydraulic system
pumps must be bled.

 Make sure that the breather filter is closed.
 Slightly loosen the plugs (shown by the arrows in the drawings that follow) and let
the air to escape.
 As soon as hydraulic oil flows out densely, close the plugs again.
Before starting the pump for the first time after repairing or replacing the pump, the
pump housing must be filled with hydraulic oil through the same hole.
Bleeding of working pumps
Fig. 5-63 Bleeding points of the working pumps
P1 Working pump 1 P3 Working pump 3

P2 Working pump 2 P4 Working pump 4
There are four working pumps on the machine (two double-pumps).

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Hydraulic system
Bleeding of swing pump
Fig. 5-64 Bleeding of the swing pump
P5 Swing pump

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Hydraulic system
Bleeding of cooling fans pumps
Fig. 5-65 Bleeding points of the cooling fans pumps
P6.1 Engine cooling pump

P6.2 Oil cooling pump
5.11.12 Bleeding the hydraulic cylinders

The cylinders must be bled after each cylinder replacement and after work carried
out on the cylinders (replacement of seals, etc.) or the hydraulic circuits (replacement
of hose, etc.).
 Operate the engine run at low idle.
 If possible, move the attachment to put the side to be bled (not-supplied side) in
the upper position.

 Slowly extend the cylinder to the extreme position and then slowly fully retract it
again. Make sure that all movements are slow and smooth. Do this process a min-
imum of 5 minutes.
Danger!
If the cylinder is not correctly bled, gas bubbles can form in the system (mixture of
air and hydrocarbon). At high operating pressures in the cylinder, these gases can
explode (Diesel effect).

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Hydraulic system
5.11.13 Servicing the hydraulic cylinder
Checking the condition of the piston rod mounting
Fig. 5-66 Piston rod mounting
Note
When a leak comes into view on the hydraulic cylinder piston rod mounting (see ar-
row above), the sealing kit must be replaced by a LIEBHERR dealer.
Protecting the piston rods
Fig. 5-67 Machine with piston rods retracted
When the machine is out of service for more than 4 weeks and particularly for trans-
portation by sea, the following measures must be taken:
 Position or transport the machine in such a way that the piston rods are fully re-
tracted into the cylinders.
 Apply a thick layer of non-corrosive anti-corrosion fluid on all exposed sections of
loose piston rods.
 For grease quality, see “Lubricating and operating materials”.
 For sea transportation, check the condition of the piston rods once more after
loading.
 For sea transportation (salt water), or in winter (road salt), check the condition of
the piston rods once more after loading the machine, because the wiper ring can
remove the anti-corrosive grease.
 Additionally, cover piston rods with anti-corrosion fluid if a cylinder only has a low
stroke for certain work, meaning that the piston rod is not regularly moistened with
hydraulic oil (eg. cylinder on slewing arm when working over ground).
 Check the condition of hydraulic cylinders which are not moved a great deal reg-
ularly.

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Hydraulic system
5.11.14 Replacement of the hydraulic hoses
Service life
Danger!
It is necessary to replace the hydraulic hoses at specified intervals to maintain their
maximum operating performance and to reduce the risk of personal injury and/or
machine damage.
 Obey the replacement intervals given below.
Natural ageing of the hose assemblies

Two types of hose assemblies are installed on the machine, with different natural
ageing:
– the critical hoses
– the non-critical hoses
Critical hoses
The critical hoses are all the hoses in which oil flows, except the oil suction hoses.
 When you check a hose assembly or you install a new one, refer to the date of
assembly marked on the hose assembly fittings.
T Date when the hose assembly has been made

T+2 Date T + 2 years
 If the hose assembly is in storage, install it on the machine (or on a preassembled

module) before the date T + 2 years. If not, dispose of it.
 If the hose assembly is installed on a machine which was never in operation, put
the hose assembly in operation before the date T + 4 years. If not, dispose of it.
 When the hose assembly is T + 6 years old, dispose of it even if it is installed on
a working machine.
Non-critical hoses
All other hoses are non-critical:
– oil suction hoses
– all the hoses in which other fluids flow (coolant, grease, heating and air-condition-
ing fluid)
T Date when the hose assembly has been made


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Hydraulic system
 If the hose assembly is in storage, install it on the machine (or on a preassembled

module) before the date T + 2 years. If not, dispose of it.
 If the hose assembly is installed on a machine which was never in operation, put
the hose assembly in operation before the date T + 6 years. If not, dispose of it.
 When the hose assembly is T + 8 years old, dispose of it even if it is installed on
a working machine.
Operating stress
 For the replacement intervals given in working hours of the hydraulic hoses, refer
to the section "Control and maintenance chart" of this manual.
General information
Fig. 5-68 SAE flanges

1 Flat single-part flange 4 Half flange with boss

2 Flat half flange 5 Conical flange
3 Single-part flange with boss 6 Monobloc flange (welded)

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Hydraulic system
Danger!
A defective hydraulic hose can cause accidents and injuries.
 Replace defective hydraulic hoses (bubbles, moisture, damaged top edge etc.)
immediately.
 Install new hoses in such a way that torsion loading is avoided.
 Ensure that the hydraulic hose is not twisted when mounting.
 Tighten the mounting screws of the SAE fittings with the following tightening tor-
ques and respecting the progressive criss-cross tightening procedure described
further in this chapter:
Size of the Thread pitch Valid for flange Valid for flange Screw with Oil/grease on
screw (quality (mm) size CODE 61 size CODE 62 thread screw or inside
class 10.9) (in) (in) completely dry the thread
(Nm) (lb.ft) (Nm) (lb.ft)

M8 1,25 1/2 1/2 25 18 20 15
M10 1,5 3/4, 1, 1-1/4 3/4 55 41 45 33
M12 1,75 1-1/2, 2 1 100 74 80 59
M14 2 1-1/4 140 103 110 81
M16 2 1-1/2 230 170 180 133
M20 2,5 2 430 317
Tab. 5-11 Tightening torques for SAE flanges
Note!
These tightening torque values are also applicable to the mounting screws of the
sealing flanges and hydraulic blocks.
Fig. 5-69 Sealing flange 1 and hydraulic block 2

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Hydraulic system
SAE half flanges installation
Caution!
SAE half flanges must not touch hose bearing surface.
To install half flanges:

 Pre-install first half flange (screw in only by a few threads).
 Install seal in hose.
 Install hose into bottom of mounted half flange without touching the bearing sur-
face.
 Put the hose onto the bearing surface.
 Install the second half flange.
 Tighten mounting screws to the prescribed torque value and by following the pro-
gressive criss-cross tightening procedure described further in this chapter.
5.11.15 Progressive criss-cross tightening procedure
Note!
Always use this procedure to install the following flanges types:
– half flanges,
– single-part flanges,
– conical flanges,
– monobloc flanges (welded).
Fig. 5-70 Criss-cross tightening

 Make sure that all mounting surfaces have no damage, grease or contamination.
 Install the O-ring without grease in the groove of the hose fitting.
 Put the hose in position onto the mounting surface (be careful that you do not
cause damage to the O-ring or remove the O-ring).
 Pre-install the flange and pre-tighten the mounting screws by hand.
 Tighten the screws progressively in a criss-cross pattern:

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Oil changes on components
– first to 50% of the prescribed torque value,

– then to 100% of the prescribed torque value.
 Check the tightening torque clockwise.
5.12 Oil changes on components

 The machine must be standing level.
 Switch off the engine.
 Wait briefly until the oil has collected in the oil sump.
 Drain off the oil (preferably when oil is at operating temperature)
 Add the oil.
 Check the oil level.
Oil quality and quantity: see lubricant chart.
Change intervals: see lubrication and maintenance chart.
5.12.2 Swing gear – Oil change
Fig. 5-71 Oil change on the swing gear
1 Oil filling couplings 4 Filling connection

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2 Oil drain couplings 5 Ventilation connection

3 Drain plug
Fig. 5-72 Expansion tank
6 Sealing cap 9 Sight gauge - Minimum level

7 Filler tube 10 Chamber connected to the front
swing gear
8 Sight gauge - Maximum level 11 Chamber connected to the back
swing gear
 For oil specifications and oil quantity, refer to the lubrication chart.
 For oil change intervals, refer to the control and maintenance chart.
Check the oil level

 Make sure that the oil is at operating temperature.
 Do a check of the oil level through the sight gauges 8 and 9 of the expansion tank.
If the oil level is less than the minimum value:
 Add oil.
Drain the oil

 Remove the sealing cap 6 of the expansion tank located behind the cab.
Each chamber of the expansion tank is connected to the upper section of a swing
gear through filling and ventilation connections 4 and 5. The lower oil drain plug 3 of
each swing gear is directly connected to an oil drain coupling 2 of the service trap:

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no oil drain is possible at the lower section of the gears.

 Connect a vacuum pump to the oil drain coupling 2 of the service trap.
 Drain the oil.
 Install the sealing cap 6 of the expansion tank back.
Fill the oil

 Use the oil filling coupling 1 of the service trap.
 For small quantities, you can fill the oil through the filler tubes 7 on the top on the
expansion tank.
Caution!
When you fill the oil through the expansion tank, make sure that you fill the correct
chambers dedicated to the swing gears.
5.12.3 Travel gear and Lifetime travel gear (optional) – Oil change
Caution!
The components that follow are filled with protective oil on delivery:
– the travel brakes (one for each travel gear)
– if installed, the optional Lifetime sealing interspaces (one for each travel gear)
Before the first start of the excavator:
 Drain the travel brakes and the Lifetime sealing interspaces (if installed) and fill
it with the same oil as used to fill the hydraulic tank.
 If installed, fill the travel gear elements that follow with the same oil as used to
fill the hydraulic tank:
– the chamber of the special Lifetime expansion tank
– the hydraulic lines between the Lifetime sealing interspaces and the special ex-
pansion tank
Danger!
When the oil is hot, the travel gear elements can be under pressure.
 Before you drain the oil, carefully loosen the oil filling plugs to release the inter-
nal pressure.
 For oil specifications and quantity, refer to the lubrication chart.

 For oil change intervals, refer to the control and maintenance chart.

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Change the travel gear oil
Fig. 5-73 Oil change on travel gear
1 Filling plugs and oil level

2 Drain plug
Each travel gear has:

– two filling plugs 1 to do a check of the oil level and add oil
– one drain plug 2
Before you drain or fill the oil

 Move the excavator until the drain plug 2 is in vertical position below the gear axle.
Drain the oil

 Carefully loosen the filling plugs 1 to release the internal pressure.
 Remove the filling plugs 1.
 Remove the drain plug 2.
 Drain the oil into an applicable container.
 Install all the plugs 1 and 2 back.
Fill the oil

 Make sure that the drain plug 2 is installed.

 Remove the filling plugs 1.
 Fill the oil through one of the filling plugs 1 until you get the level of the second
one.
 Install all the plugs 1 back.

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Change the oil of the Lifetime sealing interspaces (optional)
Fig. 5-74 Special expansion tank of Lifetime sealing interspaces
1 Cab elevation 4 Oil filler neck

2 Special expansion tank of Lifetime 5 Standard expansion tank of swing
sealing interspaces gears
3 Sealing cap
Fig. 5-75 Oil change on Lifetime sealing interspaces
6 Filling and drain plug
Drain the oil

 Remove the sealing cap 3.

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 Remove drain plug 6.

 Install sealing cap 3 and plug 6 back.
Flush the Lifetime sealing interspace
Caution!
To prevent damages to the travel gear in case of clogging, the flushing line must
have a pressure relief valve (3 bar).
 Set the flushing device above the travel gear level.

 Remove filling plug 6.
 Connect a vacuum pump to filling plug 6 and operate it.
 Remove drain plug 6.
 Connect a hose between the drain plug 6 and the return line of the flushing de-
vice.
 Disconnect the vacuum pump from filling plug 6 and connect the flushing line of
the flushing device to filling plug 6.
 If necessary, do the procedure again and make sure that you flush all the inter-
space oil. Refer to the lubrication chart for quantity.
 Remove the flushing device.
 Install all the plugs 6 back.
Fill the oil

 Make sure that you use the same oil as used to fill the hydraulic tank.
 Make sure that drain plug 6 is installed.
 Remove the sealing cap 3.
 Fill the oil through the filler neck 4. Make sure that you do not add oil under pres-
sure (more than 3 bar).
 Do a check of the oil level with the sight gauge located on the expansion tank 2.
 When you get the correct oil level, install sealing cap 3 back.

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Change the travel brake oil
Fig. 5-76 Oil change on travel brake
1 Hydraulic motor 4 Pressure port

2 Travel brake 5 Oil level plug
3 Filling plug 6 Drain plug
Drain the oil

 Remove the filling plug 3 located on the upper side of the travel brake.
 Remove the drain plug 6 located on the lower side of the travel brake.
Fill the oil

 Make sure that you use the same oil as used to fill the hydraulic tank.
 Make sure that the plugs 5 and 6 are installed.
 Remove the filling plug 3 located on the upper side of the travel brake.
 Apply a pressure of 19 bar through the pressure port 4 to release the brake.
 Fill the oil through filling the filling plug 3 until free-air oil flows out.

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 Correct the level with level plug 5: add oil or let excess oil flows out as necessary.
5.12.4 Swing gears and travel gears flushing
Caution!
Gears flushing is necessary when switching from mineral oil to synthetic oil.
 Use new oil to flush the gear when switching from mineral oil to synthetic oil.
Flushing with cleaning fluid or Diesel fuel is not permitted.
To flush the swing gears:

 Fill up the swing gear (it is not necessary to fill the line to the expansion tank).
 Turn the uppercarriage for 1 minute.
 Drain the oil.
 Fill the swing gear again and the expansion tank to correct level.
To flush the travel gears:

 Fill half the travel gear (i.e. with half the total quantity of oil).
 Lift one track off the ground.
 Turn the track chain for 1 minute.
 Put the track back down.
 Follow the procedure again for the second track chain.
 Drain the oil.
 Fill the travel gear again to correct level.

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5.12.5 Splitterbox – Oil change
Fig. 5-77 Oil change on the splitterbox
1 Service trap coupling 4 Oil inlet

2 Dipstick 5 Service trap plug
3 Drain valve
Check the splitterbox oil level

 Wait a minimum of 15 minutes to let the oil collect at the bottom of the oil pan.
 Check of the oil level with dipstick 2.
Change the splitterbox oil

 Make sure that the splitterbox oil is at operating temperature.
 Change the splitterbox oil with the service trap coupling 1.
 Use a vacuum pump connected to the quick-change coupling 1 to drain the oil.
 Add oil up to the mark on the dipstick 2. Do not overfill.
 Let the engine run for a few minutes and stop the engine.
 Wait a minimum of 15 minutes and check the oil level with the dipstick 2 again.
 For oil specification and oil quantity, refer to the lubrication chart.
 For oil-changing intervals, refer to the control and maintenance chart.

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Track components
As a help way, the oil can also be changed via the drain valve 3 and the oil inlet 4
located on the splitterbox.
Drain oil this way

 Remove cap on the drain valve 3.
 Screw on drain hose.
 Drain oil into a suitable container.
 Remove hose and reinstall cap on drain valve 3.
Fill oil this way

 Remove cap on the oil inlet 4.
 Add oil via the oil inlet 4 up to the mark on the dipstick 2.
 After each oil change, let the engine run for a few minutes, stop the engine then
wait 15 minutes and check the oil level with the dipstick 2 again.
5.13 Track components
The track components are maintenance-free until the track needs to be recondi-
tioned or has to be replaced.
The design of the carrier rollers, track rollers and idlers increases track components
lifetime and metal sealing make them insensitive to dirt.
5.13.1 Check the track components mounting

 Regularly check the tightening of the track components mounting screws.
 For tightening values, refer to the tables that follow.

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Track components
Fig. 5-78 Undercarriage components
1 Track chain 7 Cover

2 Rotary connection 8 Track guide
3 Central part 9 Track roller
4 Idler wheel with tensioning unit 10 Travel gear
5 Side frame 11 Sprocket wheel
6 Carrier roller

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Track components
Fig. 5-79 Travel gear components (right and left sides)
Torque
2 Sprocket wheel -
3 Travel gear -
10 Hydraulic motor -
20 Travel brake -
21 Screw M30x2x200 x quantity 30 for each side 2085 Nm
31 Screw M36x3x250 x quantity 24 for each side 3495 Nm
101 Screw M24x65 x quantity 4 for each side 965 Nm
 Apply teeth grease to the bolts 21 and 31 after a part replacement.


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Track components
Fig. 5-80 Track pad
Torque
1 Track link -
2 Track pad -
3 Screw M36x168-12.9 x quantity 4 for each track pad 5200 ± 260
Nm
Fig. 5-81 Carrier roller
Torque
5 Carrier roller -
51 Screw M24x150 x quantity 4 for each carrier roller 965 Nm

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Track components
Fig. 5-82 Track roller
Torque
8 Track roller -
81 Screw M30x200 x quantity 4 for each track roller 1920 Nm
Fig. 5-83 Idler wheel and tension unit
Torque
9 Idler wheel -
10 Grease tensioner -
11 Cover -
20 Hydraulic cylinder -
30 Hydraulic block -
101 Screw M30x290 x quantity 2 for each idler wheel 1920 Nm

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MJFCIFSS
Track components
Fig. 5-84 Track guide
Torque
6 Track guide -
Fig. 5-85 Travel motor protection

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Track components
Torque
12 Protection plate -
13 Support of travel motor protection 15 -
14 Support of travel motor protection 16 -
15 Travel motor protection -
16 Travel motor protection -
5.13.2 Check the track tension

With normal wear on the sprocket and on the track chain, it is necessary to check the
track tension regularly and to tension the track again if necessary.
Fig. 5-86 Track when insufficiently (A) and correctly (B) tightened.
Check the track tension

Fig. 5-87 Check of the track tension
 Release the tracks by driving the machine forward and rearward. Stop the ma-
chine after a forward movement.
 Place the measuring rod 1 between the carrier rollers.
 Measure distance A between the measuring rod and the track.
The distance A must be, under operating conditions, approximately 30 mm be-
tween the carrier rollers.

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Track components
 If necessary, tighten the track chains again.
5.13.3 Increase the track tension
Fig. 5-88 Tightening the track
1 Access cover
2 Grease nipple
 Remove the cover 1 on the side frame of the undercarriage.

 Through this access, connect to the grease nipple 2 of the grease tensioner the
high pressure hose with manual grease gun.
 Put grease until the track is sufficiently tensioned.
 Check the track tension as described above.
 Remove the pressure hose and reinstall the cover 1.

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Track components
5.13.4 Decrease the track tension
Danger!
Risk of injury because of sudden falling of the track chain or a spray of grease under
high pressure.
 Because of the risk of grease spray, always wear protective gloves and glasses
when releasing the track tension.
 When releasing the tension of the track chain, keep your head away from the
opening 1 in the track side frame. Never touch the grease nipple 2 with your
hand but always use an applicable tool to loosen or tighten it.
 To tighten or loosen the grease nipple 2, always catch it at its rear part and never
at its front part.
 Before trying to release the track chain tension, loosen and remove every item
which can be blocked in the track chain while driving forward and rearward or do-
ing as described in the section "Cleaning the track components" that follows.
 Carefully loosen the grease nipple 2 until the grease goes out of the nipple.
 Tighten grease nipple 2 as soon as you get the correct track tension.
 After the adjustment, drive the machine forward and rearward and check the track
tension again.
Fig. 5-89 Cylinder shutoff valves CVTL and CVTR
 Turn on the lever CVTL (left side) or CVTR (right side) to release the track tension
pressure on the side you are working on.
 Turn off the lever CVTL or CVTR to tighten the track back.

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Electrical system
5.13.5 Clean the travel gear
Caution!
Do not operate the machine if large stones, pieces of wood or metal, wires or cables
are blocked in the travel gear.
Dried or frozen mud and stones or other foreign items in the travel gear parts can
cause important damage to the machine if it is operated or if you try to deblock it
using the engine power.
After a track chain replacement, all the track pins of the travel gear must be greased
with teeth grease.
After any operation on a track component, the related track pin must be cleaned and
greased as well.
5.14 Electrical system
5.14.1 Notes on the electrical system
Danger!
Risk of injury due to formation of sparks.
 Avoid sparks and naked flame when charging batteries or working on the batter-
ies.
 Always wear protective goggles and gloves.
 Check that the machine’s electrical system is functioning correctly at regular in-
tervals.
 Burnt-out fuses and bulbs should be replaced immediately once the cause of the
defect has been rectified.
 Rectify defects such as loose connections, abraded cables or badly fastened
clamps immediately.
 Disconnect the batteries when working on the electrical system. Also disconnect
the connectors from the engine ECM (Electronic Control Module) system when
carrying out electric arc welding on the machine.
Danger!
Risk of injury due to formation of sparks.
 Disconnect the negative terminal (-) first and connect it last.
5.14.2 Principal batteries switches and ECM connectors
Caution!
Take particular care with machines with built-in independent heating.
 Only switch off the principal batteries switches when the independent heating’s
run-on is over.

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Electrical system
Fig. 5-90 Principal batteries switches
1 Pumps box
Fig. 5-91 Engine ECM circuit breaker S9_3

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Electrical system
S9_3 ECM circuit breaker
Fig. 5-92 Connectors on engine
1 ECM connectors
2 16-pins, 23-pins and 31-pins connectors
3 Datalink connector 3 poles
 Before starting any work on the electrical system, switch the principal batteries
switches S9_1, S9_2 and S9_3 to position "OPEN".
 For welding work on the excavator, also disconnect:
– The connectors 1 from each engine ECM (there are two ECM on the engine).
– The 16-pins, 23-pins and 31-pins connectors 2 on the engine.
– The datalink connector 3 on the engine.
 When washing the machine, cover the electrical units (particularly the alternator,
generator, cabling, electronic components and measured value sensor) to pre-
vent water penetrating.
 When cleaning the engine with a water / steam jet, do not subject electrical meas-
ured value sensors such as oil pressure switches to any direct jets.

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Electrical system
 If this happens, moisture could penetrate and lead to contact corrosion and the
failure of the measuring function.
 Oil pressure switches are not watertight due to the necessary presence of
membrane ventilation.
Note!
Batteries can become flat if the machine is out of service for longer periods.
 Before laying up the machine for longer periods, switch the principal batteries
switches to position "OPEN".
5.14.3 Battery care

The batteries must always be kept clean to ensure that it is able to function perfectly.
 Particular care should be taken to clean the pole ends and cable terminals 1 reg-
ularly and to then cover them with a thick layer of acidproof grease.
Danger!
Bent rubber hoses on the central gas outlet increase the risk of explosion!
The hydrogen contained in the batteries should not be allowed to build up in the ac-
cumulator box and must be able to escape via the rubber hoses. The central gas
outlet hoses must be routed without kinks.
 Check the condition of the hoses regularly, particularly after installing a battery.
The fluid level in the cells should be 10 to 15 mm above the top of the plate. Only
distilled water is to be used for any refilling.
Fig. 5-93 Battery care
1 Cable terminals
2 Acid tester
 From time to time, measure the acid concentration 2 using an acid tester.
When the battery is fully charged, the unit weight is 1.28 kg/l (31.5° Bé).

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Electrical system
 If the acid tester shows a lower value, the batteries is virtually flat and should be
charged if necessary.
5.14.4 Electrical components location
Fig. 5-94 Electrical components location

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Electrical system
A2 Radio E1005 Cab connection box

A15 Greasing module E1022 Control box of the access lad-
der
A161 Electrical plate E1043 Grease control box on the
service trap
A168 PowerPack keypad E1086 Electrical box on the Power-
Pack
A169 Standard functions keypad 1 G1 - G4 Batteries
A170 Standard functions keypad 2 H15 Horn of travel alarm
A171 Optional functions keypad H16 Horn of ladder alarm
A1002 Electrical plate P5 Hour meter
A1004 Electrical plate S1 Ignition key
A1014 Electrical plate S7 Safety lever
C1 Camera 1 / Opposite side of S9_1/2 Principal battery circuit break-
the cab ers
C2 Camera 2 / Counterweight S100_1 Emergency stop on the con-
trol board
D Display S100_2 Emergency stop on E1086
electrical box
E1 Front working light / Upper- S100_3 Emergency stop under the
carriage (cab elevation) counterweight
E18_1/2 Rear working lights / Counter- S100_4 Emergency stop on the en-
weight gine box
E22 Light of travel alarm S125 External push-button / exter-
nal cab lighting
E58_1/2 Front working lights / Top of U21 Left joystick
cab
E59_1/2 Rear working lights / Top of U22 Right joystick
cab
E59_3 Ladder lighting U23 Right travel pedal
E60_1/2 Front working lights / Fuel U24 Left travel pedal
tank
E61_1 Camera lighting / Fuel tank U103_1 Module air conditioning
E61_2 Camera lighting / Counter- U103_2 Optional module air condi-
weight tioning (if installed)
E1003 Power electrical box X60 Auxiliary start receptacle

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Heating/air-conditioning system
5.14.5 Cab pressurization
Fig. 5-95 Aeration device
The aeration device is located on the rear top of the cab.

The air filters for the cab pressurization must be cleaned regularly.
Clean the air filters

 Press to open the dust discharge valve 5.
 Regularly replace the main element and the safety element of the air filter system
of this device.
 For maintenance interval, refer to the control and maintenance chart.
5.15 Heating/air-conditioning system
The machine has a heating and an air-conditioning systems as standard.

The heating system operates with a heater under the cab floor.
The air-conditioning system operates with:

– an evaporator in the cab roof
– a belt driven compressor on the Diesel engine
– a dryer/receiver unit on the oil cooler box
– a condenser on the oil cooler
A dual air-conditioning system can be installed as an option. It operates with:
– the same evaporator as the standard system

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– two condenser units which have:

• an hydraulically driven compressor (an hydraulic pump is specially installed on
the splitterbox to supply the two condenser units)
• a dryer/receiver unit
• a condenser battery
5.15.1 Heating system
Fig. 5-96 Coolant shutoff valves on Diesel engine
1 Coolant shutoff valve

2 Coolant shutoff valve
Fig. 5-97 Heater

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3 Fresh air filter

4 Heat exchanger
If filters are dirty, the airflow in the heating and in the air-conditioning systems is re-
duced. A reduced airflow causes frost and system shutoff.
 Remove and clean the heat exchanger 4 and the fresh air filter 3 at intervals spec-
ified in the control and maintenance chart.
 Do not operate the machine, even momentarily, without the air filter. It can quickly
cause the blockage of the heat exchanger 4.
Independently from weather conditions:
 Make sure that the coolant shutoff valves 1 and 2 located on the Diesel engine
are always open.
 Close the shutoff valves 1 and 2 when you change the coolant.
Clean and replace the fresh air filter

 Remove the fresh air filter 3.
 Never wash the filter elements with hot water or a steam jet.
 Never wash the filter elements with acids or aggressive solvents.
 If damaged or in a bad condition, replace the filter elements.
 Clean the filter elements.
5.15.2 Air-conditioning system

 Switch on the air-conditioning system for approximately 10 minutes every 2 or 3
weeks, independently of the season.
 During the warm season, do the checks or maintenance works that follow.
In case of repair at the condenser or at the receiver, the refrigerant must be removed
and collected in an applicable container. The collected refrigerant can be cleaned
and re-prepared by refrigerant manufacturers.
Check the filter

Fig. 5-98 Evaporator in the cab

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1 Evaporator
The evaporator is located in the roof of the cab.

 Check and clean the recirculated air filter installed into the evaporator 1.
Check the condenser
Fig. 5-99 Condenser
1 Condenser
2 Oil cooler box
3 Oil radiator
 Check the condenser 1.

 If necessary, blow it out with pressurised air or steam from the inner (fan side) to
outside.
Check the dryer/receiver unit

The maintenance works below must be done:

– at least once a year
– by a specialist in refrigeration engineering

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Fig. 5-100 Location of the dryer/receiver unit
1 Dryer/receiver unit
2 Oil cooler box
Fig. 5-101 Dryer/receiver unit
1 Dryer/receiver unit 3 Float

2 Sight glass 4 Indicator

 Start the air-conditioning system.

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 Do the check of the refrigerant level of the dryer/receiver 1 through the sight glass
2 and the float 3 (white colour):
– If the float 3 is at the bottom of the sight glass 2, the level is not sufficient.
– If the float 3 is at the middle of the sight glass 2, the level is correct.
– If the float 3 is at the top of the sight glass 2, there is too much refrigerant.
 If necessary, refill the system.
 Do the check of the moisture degree of the dryer/receiver 1 through the sight
glass 2 and indicator 4:
– If the indicator 4 has orange color, the moisture degree in the coolant circuit is cor-
rect.
– If the indicator 4 has no color, the dryer/receiver 1 is saturated with moisture.
 If necessary, replace the dryer/receiver 1 immediately: empty, check for leaks and
abrasion and refill the coolant circuit.
 Do a visual check of the dryer/receiver 1 conditions (e.g. hoses connections,
damages, rust, mounting bolts, ...). Replace if necessary.
Check the compressor
Fig. 5-102 Air-conditioning compressor on Diesel engine
1 Air-conditioning compressor
2 V-belt
 Examine the compressor 1 for possible damages.

 Do a check of compressor fastening.
 Do a check of condition, alignment and tension of the related V-belt 2.

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5.15.3 Dual air-conditioning system (optional)
Fig. 5-103 Location of the optional air-conditioning system
1 Cab elevation
2 Rear condenser unit
3 Front condenser unit
If installed, the optional dual air-conditioning system (condenser units 2 and 3) re-
places the standard air-conditioning system.
 Switch on the air-conditioning system for approximately 10 minutes every 2 or 3
weeks, independently of the season.

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Fig. 5-104 Components of the optional air-conditioning system
2 Rear condenser unit 6 Dryer/receiver unit

3 Front condenser unit 7 Condenser battery
4 Fan 8 Compressor (with hydraulic motor)
5 Fan
 During the warm season, do the same checks or maintenance works as for the
standard air-conditioning system:
– on the dryer/receiver unit 6
– on the condenser battery 7
– on the compressor 8
In case of repair at the condenser or at the receiver, the refrigerant must be removed
and collected in an applicable container. The collected refrigerant can be cleaned
and re-prepared by refrigerant manufacturers.
The fans must be free of dirt and damages.

 Also do a check of fans 4 and 5. Replace if necessary.
5.15.4 Additional maintenance work

 Do a check of the operation of evaporator blowers and condenser fans. All blow-
ers must operate correctly to prevent air short circuit.

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Greasing the machine
 Do a check of the electric installation.

 Do a check of all hose fittings and couplings for leakage.
 Do a check of the adjustment and function of defrosting thermostat at the evapo-
rator coil.
 Do a check of the pressure switch on the dryer/receiver unit.
5.15.5 Additional cab heater (optional)

 If the additional cab heater is installed, refer to section "Starting aids" in chapter
5 for the maintenance to do.
5.16 Greasing the machine
5.16.1 Lubrication of attachment bearing points
Automatic lubrication
The lubrication points of the working attachment, with those in the grab tool area, are
connected to the centralized lubrication system of the machine. Thus, they are lubri-
cated automatically with grease at regular intervals during the operation.
 For grease specifications, refer to the lubricant chart.
Manual lubrication
If the lubrication points that follow are installed on the machine, you must lubricate
them manually.
 For grease specifications, refer to the lubricant chart.

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Check mounting bolts for tightness
Grease the piston rod protections for bucket cylinders (if installed)
Fig. 5-105 Protection device for bucket cylinders
1 Piston rod protection for bucket cylinder

2 Grease nipple M14x1,5
 Use the grease nipples 2.

 Because the nipples configurations X (internal sides) and Y (external sides) are
not the same, make sure that you use all the grease nipples 2.
5.17 Check mounting bolts for tightness
The mounting bolts listed below must be regularly checked and retighten if neces-
sary. Refer to the control and maintenance chart for checks intervals.
Note!
When installing bolts of size bigger than M40 the thread of the screw must be slight-
ly coated with a MoS2 based grease. Also grease the bolt head supporting surface,
unless hereafter otherwise specified.

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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 tension-
ing 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 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 steaded during operation, use alternative means of
securing the tool during operation.
Caution!
The mounting bolts of the main components (especially the bolts listed below), of
the hydraulic hoses and of the counterweight must be replaced after every removal.
5.17.1 Counterweight mounting bolts
Fig. 5-106 Counterweight bolts
Torque Quantity
1 Counterweight - -
2 Hexagonal head screw M42x320 5001 Nm 8

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5.17.2 Mounting bolts of the swing ring

The swing ring is installed on the uppercarriage and on the undercarriage with an an-
gular tightening method.
Swing ring installation on uppercarriage
Fig. 5-107 Swing ring bolts on uppercarriage
Quantity
1 Swing ring -
2 Uppercarriage -
3 Hexagonal head screw 96
11 Outer ring -
12 Inner ring -
Check the screws tightening

 Apply a torque of 1600 Nm.
 If a screw 3 is loosened, replace it.
Install a new screw

Till SN 40002:
– The height of the outer ring 11 is 225 mm.
– The screws 3 are M30x280.
 Torque the new screw 3 to 600 Nm.
 Apply a angle of rotation of 103°.
From SN 40003:
– The height of the outer ring 11 is 205 mm.
– The screws 3 are M30x260.
 Apply a angle of rotation of 90°.

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Swing ring installation on undercarriage
Fig. 5-108 Swing ring bolts on undercarriage
Quantity
1 Swing ring -
4 Undercarriage -
5 Hexagonal head screw M30x240 96
Check the screws tightening

 Apply a torque of 1600 Nm.
 If a screw 5 is loosened, replace it.
Install a new screw

 Apply an angle of rotation of 90°.

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5.17.3 Mounting bolts of the fuel tank
Fig. 5-109 Fuel tank bolts
Torque Quantity
1 Fuel tank - -

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5.17.4 Mounting bolts of the hydraulic tank
Fig. 5-110 Hydraulic tank bolts
Torque Quantity
1 Hydraulic tank - -

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5.17.5 Mounting bolts of the engine cooler box
Fig. 5-111 Bolts of engine cooler box
Torque Quantity
1 Engine cooler box - -
5.17.6 Mounting bolts of the oil cooler box

Fig. 5-112 Bolts of the oil cooler box

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Torque Quantity
1 Oil cooler box
5.17.7 Mounting bolts of the pumps box
Fig. 5-113 Pumps box bolts
Torque Quantity
3 Pumps box - -

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5.17.8 Mounting bolts of swing gear and swing motor
Fig. 5-114 Bolts of swing gear and swing motor
Torque Quantity
1 Socket head screw M24x320 960 Nm 32 (2x16)
2 Hexagonal head screw M24x70 960 Nm 4 (2x2)
3 Swing gear - -

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5.17.9 Mounting bolts of hydraulic pumps
Fig. 5-115 Hydraulic pumps bolts
Bolts Description Torque Quantity

1 Bolts between charging/piloting Hexagonal head 117 Nm 2
double pump and working pump screw
M12x35
2 Bolts between two working Hexagonal head 560 Nm 8 (2x4)
pumps screw
M20x70
3 Bolts between working pumps Hexagonal head 560 Nm 8 (2x4)
and splitterbox screw
M20x55
4 Bolts between cooling fans pump Hexagonal head 280 Nm 4
and swing pump screw

M16x50
5 Bolts between swing pump and Hexagonal head 560 Nm 4
splitterbox screw
M20x55
The four nuts of the splitterbox cooling pump must also be checked regularly.

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5.17.10 Mounting bolts of the cab elevation
Fig. 5-116 Cab elevation bolts
Torque Quantity
1 Cab elevation - -

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5.17.11 Mounting bolts of the cab
Fig. 5-117 Cab bolts
Torque Quantity
1 Hexagonal head screw M16x65 280 Nm 12 (4x3)
2 Socket head screw M16x45 280 Nm 12 (4x3)

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5.17.12 Mounting bolts of the service trap
Fig. 5-118 Service trap bolts
Torque Quantity
1 Support of the service trap - -
5.17.13 Mounting bolts of side frames

Fig. 5-119 Side frames bolts
Torque Quantity
1 Screw M39x260 4280 Nm 24 (2x12)

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Drive unit brakes and swing gear brakes
2 Screw M42x320 4810 Nm 12 (2x6)
 After a part replacement, grease bolts 1 and 2 with teeth grease.
5.18 Drive unit brakes and swing gear brakes
Both the drive unit brakes and the swing gear brakes are spring-applied, pressure-
released multi-plate brakes. They are ventilated hydraulically and are fully sealed
and integrated in the travel gear or swing gear transmission.
Their usage purely as parking brakes makes them wear-free and therefore mainte-
nance free.
5.19 Starting aids (option)
5.19.1 Coolant heater (basic equipment)

The heater of the Diesel engine coolant is a 35 kW - 24 V fuel operated device which
is installed on the uppercarriage structure.
 Refer to the Operating and Maintenance Instructions of the coolant heater man-
ufacturer for:
– detailed description of maintenance work to be performed on this device
– maintenance intervals

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Starting aids (option)
Fig. 5-120 Preheating devices for Diesel engine coolant
1 Coolant heater 3 Cap of special fuel tank

2 Special fuel tank of coolant heater 4 Sight gauge
Check the fuel level and refuel

The special fuel tank 2 is installed on the engine cooler box. Its capacity is 35 L.
 Check the fuel level with the sight gauges 4.
 Make sure the Diesel engine and the coolant heater are switched to off.
 Add fuel in the special tank 2 through the tank cap 3.
5.19.2 Bleed the water system

You must bleed the water system of the optional starting aids after maintenance
works on:
– the basic equipment of the optional starting aids:

• the coolant heater system (filling, draining or other)
• the water system of the additional cab heater
– the Diesel engine cooling system
You must also bleed the water system of the optional starting aids after it does not
work for a long time.

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Bleed the coolant heater

 Refer to section "Start the coolant heater" of the "Starting aids" in chapter 3 and
make sure that:
– The excavator Diesel engine and the coolant heater are switched to off.
– The Diesel engine and the coolant heater system are cold.
– The manual valves are opened.
 Open the expansion tank of the Diesel engine cooling system. Refer to section
"Cooling system" in chapter 5.
Fig. 5-121 Water system of coolant heater
1 Water drain plug

S258 Water pump actuator
 Loosen the water drain plug 1.

 Let the air escape until free-air coolant flows out.
 Tighten the water drain plug 1.
 Start the water pump of the coolant heater with the button S258 which is adjacent
to the heater.
 Let the pump work. Stop it with the button S258.
 Do a check of free-air coolant through the drain plug 1. Tighten it back.
 Close the expansion tank of the Diesel engine cooling system.

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Bleed the additional cab heater
Fig. 5-122 Bleed valve of additional cab heater (if installed)
1 Additional cab heater

2 Bleed valve
 Start the excavator.

 Make sure that the Diesel engine is at operating temperature.
 Start the additional cab heater.
 Loosen the water drain plug 2.
 Let the air escape until free-air coolant flows out.
 Tighten the water drain plug 2.
5.19.3 Starting fluid system (basic equipment)

The starting fluid system works automatically and helps the combustion process at
Diesel engine start.

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Fig. 5-123 Starting fluid system (if installed)
1 Pumps box
2 Starting fluid cylinder
5.19.4 Circulating heating system (if installed)

 Refer to the Operating and Maintenance Instructions of the manufacturer of the
circulating heating system for:
– detailed description of maintenance work to be performed on this device
– maintenance intervals
Fig. 5-124 Overview of circulating heating device (if installed)
1 Circulating pump
2 Heating tank
3 Electrical box

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General maintenance points
5.20 General maintenance points
5.20.1 Replacing working parts

In addition to the normal maintenance and repair work that is to be carried out at the
given intervals, the machine operator and maintenance personnel can also carry out
the repairs referred to below:
– Replacing defective sealing material on the pipe and hose system and on the hy-
draulic unit connections (not, however, on pressure relief valves which are lead
sealed at the works).
– In addition, high pressure hoses, hydraulic lines and bolt connections on the hy-
draulic system can be replaced.
It should be noted that only original LIEBHERR replacement parts are to be used.
This is particularly relevant for hoses and hydraulic lines, which must be preassem-
bled at the works. For all other repairs, particularly when dismounting the counter-
weight, works and dealership fitters are to be consulted.
5.20.2 Welding work on the machine

Welding work on all main components serving the power transmission (such as the
chassis frame, rotating platform, equipment parts etc.) may only be carried out by the
manufacturer or by an authorized workshop.
 Disconnect the batteries before starting any electric arc welding work on the ma-
chine.
 Disconnect the connectors of the engine control unit.
 Always disconnect the negative terminal (-) first and reconnect it last.
 Switch off the main battery switch!
Nevertheless if welding repair should be done on components which may contain in-
flammable gases (welded counterweight, hydraulic tank, fuel tank, ...) these compo-
nents must be previously and sufficiently ventilated with pressurized air to avoid all
fire or explosion hazard.
Caution!
If high currents flow through the bearings or sealing elements, these could be burnt.
 Move the earthing cable of the welding tool as close as possible to the welding
surface so that the welding current cannot flow over parts like the swing ring, ro-
tary connection, gears, bushings, bearings, hinges, joints, hydraulic hoses,
sockets, rubber parts or seals.

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Control and maintenance chart
5.21 Control and maintenance chart
Caution!
Careful maintenance can only be carried out when the machine is clean. Visual
checks such as crack testing are only applicable on a clean machine.
 Clean the machine before you start maintenance work (see also the chapter
“Servicing the machine safely”, sections “Cleaning" and "Crack testing”).
Caution!
You must do the weekly additional maintenance tasks. Liebherr recommends that
you schedule this maintenance interval carefully.
Note!
If you find damage(s) on structural components (boom, stick, bucket, central part,
side frames, rotating deck, hydraulic tank, fuel tank or cabin) please fill out the
"Structural Inspection" form in Service Manual - Chapter 4.
In addition:
- a visual inspection is required every 500 hours,
- a detailed inspection is required every year or at least every 7500 hours.

The following maintenance chart will help you to do the adequate maintenance on
your excavator.
It is mandatory to follow these maintenance charts, to keep your excavator into best
and safe condition.
The pre-requisite to any claim to Liebherr for operation issues or warranty, is that
these maintenance charts are strictly followed and recorded.
It is mandatory to follow these requirements in order to keep your excavator safe, ef-
ficient and also for warranty reason. Liebherr is not responsible in case of damage if
the maintenance requirements are not correctly followed. Moreover, your machine
may not be running as efficiently and productively as it could be.
For lubricants and operating fluids, refer to the Operating Manual chapter 5.3.
Two types of inspection
Visual Check
– A visual examination of an interior or exterior area, installation or assembly to de-

tect obvious damage, failure or irregularity. This level of inspection is made from
within touching distance unless otherwise specified. A mirror may be necessary
to ensure visual access to all surfaces in the inspection area. This level of inspec-
tion is made under normally available lighting conditions such as daylight, hangar
lighting, flashlight or drop-light and may require removal or opening of access
panels or doors. Stands, ladders or platforms may be required to have safe ac-
cess to the area being checked.

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Detailed Check
– An intensive examination of a specific item, installation or assembly to detect
damage, failure or irregularity. This examination may require the use of special-
ized inspection techniques and/or equipment. Surface cleaning and elaborate ac-
cess may also be required.
5.21.2 How to use the maintenance chart

The following maintenance chart is split in 5 individual check lists:
– a daily,
– a 250 hours,
– a 500 hours,
– a 1000 hours,
– and a 2000 hours.
Intervals:
– daily,
– 250 hours, 750 hours, 1250 hours, 1750 hours, ...
Examples:
At 750 hours you must follow the 250 hours maintenance chart.
At 2500 hours you must follow the 500 hours maintenance chart.
At 3000 hours, you must follow the 1000 hours maintenance chart.
At 6000 hours, you must follow the 2000 hours maintenance chart.
Fig. 5-125 How to use the check lists (in addition to the daily maintenance)

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5.21.3 Daily Maintenance Schedule - R9200

Serial Number:
Completed by :
Fleet Number:
SMU HOURS:
Date and Signature :
Travel Hours:
WORK TO BE PERFORMED DAILY
Initials
Check
Comments
Check  for first and only interval or Check  for repeat interval
GENERAL HYDRAULIC SYSTEM
Do a visual check of all hoses, pipes and fittings for any external damage 
or leakage
Do a visual check of the hydraulic components for leaks and/or damages 
Do a visual check of the hydraulic cylinder rods for leaks and good condi- 
tion
GENERAL FASTENING
General hydraulic: Do a visual check for missing, broken or loosen 

mounting screws of all hoses, pipes, fittings and clamps, tighten if neces-
sary
Track components: Do a visual check for missing, broken or loosen 

mounting screws of the sprockets, rollers, idlers, track guides and track
pads, protection covers and final drives, tighten if necessary
Undercarriage: Do a visual check for missing, broken or loosen mounting 

screws of the side frames, tighten if necessary

screws of all parts, tighten if necessary
Attachment: Do a visual check for missing, broken or loosen mounting 

screws of the pin covers fastening and greases connections, tighten if
necessary
Uppercarriage: Do a visual check for missing, broken or loosen mounting 

screws of the counterweight, tanks, Powerpack, control valve console,
cab, catwalks, grease box, ladder, tighten if necessary
Swing gear: Do a visual check for missing, broken or loosen mounting 

bolts of the swing gear and hydraulic motors, tighten if necessary
Diesel engine: Do a visual check for missing, broken or loosen mounting 

screws of the thermic protection on exhaust manifold fastening, tighten if
necessary
Diesel engine: Do a visual check for missing, broken or loosen mounting 

bolts of the starter motors, alternator and AC compressor, tighten if nec-

essary
TRACK COMPONENTS
Clean track chains (after the end of each shift) 
Do a visual check of the tensioning cylinders, idler, carrier and track rollers 
for leaks

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Initials
Check
Comments
Do a visual check of the track chains tension 
TRAVEL GEAR
Do a visual check of the gear for leaks, if there are leaks, check oil level 
UNDERCARRIAGE
Do a visual check of all parts for damages and cracks 

If necessary fill out the "Structural Inspection" form in Service Manual -
Chapter 4
ATTACHMENT
Do a visual check of the bucket teeth and wear kit for wear 
Do a visual check of the grease supply at each lube point 
Do a visual check of cable harness and sensors for damage 
UPPERCARRIAGE
Do a visual check of the service trap for leaks or damage 
Do a visual check of oil, grease or fuel for leaks 
Do a visual check of mirrors and cameras, clean and adjust if necessary 
SWING GEAR
Do a visual check of the swing gears for leaks and oil level in expansion 
tanks
CENTRALIZED LUBRICATION SYSTEM
Perform a complete daily maintenance given in the LINCOLN Operating 

Instructions Manual
Do a check of the grease tank level 
DIESEL ENGINE AND SPLITTERBOX
Do a visual check in and around the engine compartment for leaks, con- 
taminations and damage
Check engine oil level 
Check coolant level 

Do a visual check of the engine and external pipework for leaks 
Do a visual check of the exhaust gas system connections for leaks 
Do a visual check of the oil supply / return pipework for leaks 
Do a visual check of the water separator on fuel filters, drain if necessary 
Replace all preliminary filters and fuel filters as soon as fuel level reaches 
the red mark on the bell of the preliminary filters (replace the filters at least
every 500 hours)

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Initials
Check
Comments
Do a visual check of the vacuum indicators for air filters clogging, clean or 
replace if necessary and reset the indicator
Check oil level in the splitterbox 
Do a visual check of the splitterbox input shaft seal or engine main rear 
seal for leaks
Do a visual check of the starter motors, alternator and AC compressor for 

cables, and brackets
Do a visual check of the coolers for clogging and damage, clean or replace 
if necessary
Perform the complete "Daily" Maintenance Echelon given in the CUM- 

MINS Operating and Maintenance Manual
HYDRAULIC SYSTEM
Check oil level in hydraulic tank 
Clean magnetic rods of the leak oil filter (daily during the first 250 hours) 
ELECTRICAL SYSTEM
Press to open dust discharge valve on aeration devices for cabin and elec- 
trical boxes
FIRE FIGHTING SYSTEM
Do a visual check of the fire fighting system condition (optional equipment, 

refer to the fire fighting system documentation)
- If any issue contact fire fighting local dealer
Follow the inspection intervals recommended by the specific Health and 

Safety rules existing in country and/or on mine site
START THE ENGINE TO CHECK THE FOLLOWING ACTIONS
General: Maintenance work must include the check of the correct func- 
tions of hydraulic and electric systems before starting operation
Attachment: Check function of the working attachment lubrication system 

during operation
Attachment: Check if the damping system on equipment is working cor- 

rectly
Uppercarriage: Check position of the hydraulic shut-off valve 

Uppercarriage: Check that the swing movement of the uppercarriage is 

locked when the access ladder is lowered
Swing Gear: Check function and operation of the swing brake 
Swing Ring: Check function of the swing ring bearing lubrication system 
during operation

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Initials
Check
Comments
Swing Ring: Check function of the swing ring teeth lubrication system 
during operation
Diesel engine: Check speed on RPM gauge 
Diesel engine: Check running noises 
Diesel engine: Check exhaust gas colour 
Diesel engine: Check oil pressure and coolant temperature during oper- 
ation
Diesel engine: Check if the prelub system is working properly 
Electrical system: Clean and check LCD screen of the display for proper 
function when starting
Electrical system: Check indicator lights and gauges on the control panel 
when starting
Electrical system: Check for warning and fault messages on display 

(monitoring, grease, air conditioning, ...). If necessary refer to chapter 4 in
the Operating Manual to identify and rectify faults and errors.
Cabin: Check if the safety lever is working properly 
Cabin: Check the horn 
Cabin: Check for green flash light on control module if fire fighting system 
is installed
WEEKLY CHECK THESE STEPS IN ADDITION TO THE DAILY REQUIREMENTS
UPPERCARRIAGE
Check level in reservoir for windshield washer, refill if necessary 
Perform the complete weekly maintenance given in the LINCOLN Operat- 

ing Instructions Manual
Do a visual check of the air intake hose for condition and leaks 
Do a visual check and clean the radiator core and fan 

Do a visual check of the radiator cap for leaks, replace if necessary 
Drain off water and sediment at fuel tank 
HYDRAULIC SYSTEM
Clean magnetic rods of all return filters (weekly during the first 250 hours) 
Do a visual check of the hydraulic tank breather filter, clean if necessary 

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Initials
Check
Comments
ELECTRICAL SYSTEM
Do a visual check of the head and floodlights, clean and adjust if neces- 
sary
Do a visual check of the wiring system for damage 
CABIN, CABIN ELEVATION AND HEATER/AIR CONDITIONER
Operate air conditioner every week for 10 minutes 
Visual check condenser unit and evaporator filter 
Check refrigerant level, if necessary refill circuit 
Do a detailed check of the V-belt tension for air conditioner 

5 - 148 R9200 / 11695477
MJFCIFSS
Initials
Check
Comments
General comments:
Tab. 5-12 Daily maintenance schedule - R9200

R9200 / 11695477 5 - 149
MJFCIFSS
5.21.4 250 Hours Maintenance Schedule - R9200
Serial Number:
Completed by :
Fleet Number:
SMU HOURS:
Travel Hours:
WORK TO BE PERFORMED AT 250, 750, 1250 HOURS, ...
Initials
Check
Comments
Do a visual check of all hoses, pipes and fittings for any external damage or leak- 
age
Do a detailed check for good condition of pipes, hoses, clamps and fittings for 
damage and leakage
Do a visual check of the hydraulic cylinder rods for leaks and good condition 
GENERAL FASTENING
General hydraulic: Do a visual check for missing, broken or loosen mounting 

screws of all hoses, pipes, fittings and clamps, tighten if necessary
Track components: Do a visual check for missing, broken or loosen mounting 

screws of the sprockets, rollers, idlers, track guides, track pads, protection cov-
ers and final drives, tighten if necessary


Attachment: Do a visual check for missing, broken or loosen mounting screws 

of the pin covers fastening and greases connections, tighten if necessary

screws of the counterweight, tanks, Powerpack, control valve console, cab, cat-
walks, grease box, ladder, tighten if necessary
Swing gear: Do a visual check for missing, broken or loosen mounting bolts of 
the swing gear and hydraulic motors, tighten if necessary
Diesel engine: Do a visual check for missing, broken or loosen mounting screws 
of the thermic protection on exhaust manifold fastening, tighten if necessary
Diesel engine: Do a visual check for missing, broken or loosen mounting bolts 
of the starter motors, alternator and AC compressor, tighten if necessary
TRACK COMPONENTS
Do a visual check of the tensioning cylinders, idler, carrier and track rollers for 
leaks

5 - 150 R9200 / 11695477
MJFCIFSS
Initials
Check
Comments
TRAVEL GEAR
UNDERCARRIAGE

If necessary fill out the "Structural Inspection" form in Service Manual - Chapter 4
ATTACHMENT
If installed, grease the piston rod protection 

Do a visual check of the fastening of pin covers 
UPPERCARRIAGE
Do a visual check of the non-slip surfaces for wear and damage 
SWING GEAR
Do a visual check of the swing gears for leaks and oil level in expansion tanks 
Perform a complete daily maintenance given in the LINCOLN Operating Instruc- 

tions Manual
Do a visual check in and around the engine compartment for leaks, contamina- 
tion and damage
Sample and analyse engine oil 
Change oil in Diesel engine 
Replace engine oil filters 

R9200 / 11695477 5 - 151
MJFCIFSS
Initials
Check
Comments
Do a visual check of the vacuum indicators for air filters clogging, clean or replace 
if necessary and reset the indicator
Replace primary element of the air filter (if necessary or at least once a year) 
Replace safety element of the air filter if indicated (if necessary or at least once 
a year)
Change oil in splitterbox 
Do a visual check of the splitterbox input shaft seal or engine main rear seal for 
leaks
Do a visual check of the starter motors, alternator and AC compressor for cables, 
and brackets
Do a visual check of the coolers for clogging and damage, clean or replace if nec- 
essary
Do a visual check of the radiator core and fan, clean if necessary 
Perform the complete "Daily" Maintenance Echelon given in the CUMMINS Op- 
erating and Maintenance Manual
Every 250hours or 6 months, perform a complete Maintenance Echelon given in 

the CUMMINS Operating and Maintenance Manual
See CUMMINS Operation and Maintenance Manual for other maintenance 

(Eliminator, Centinel, Fleetguard, valves and injectors adjustment)
HYDRAULIC SYSTEM
Sample and analyse hydraulic oil and change oil if necessary (if filled with HEES 
biodegradable oil)
Clean magnetic rods of the leak oil filter 
Clean magnetic rods of all return filters 
ELECTRICAL SYSTEM
Do a visual check of the head and floodlights, clean and adjust if necessary 

5 - 152 R9200 / 11695477
MJFCIFSS
Initials
Check
Comments
Press to open dust discharge valve on aeration devices for cabin and electrical 
boxes
Do a visual check of electric harness, sensors for damage and/or rubbing zone 
Do a detailed check of fuses and circuit breakers 
CABIN
Do a visual check of the cabin for oil/fluids leaks 
Do a visual check of the fire fighting system condition (optional equipment, refer 
to the fire fighting system documentation)
Follow the inspection intervals recommended by the specific Health and Safety 
rules existing in country and/or on mine site
General: Maintenance work must include the check of the correct functions of 
hydraulic and electric systems before starting operation
Attachment: Check function of the working attachment lubrication system dur- 

ing operation
Attachment: Check if the damping system on equipment is working correctly 
Uppercarriage: Check that the swing movement of the uppercarriage is locked 

when the access ladder is lowered
Swing Ring: Check function of the swing ring bearing lubrication system during 
operation
Swing Ring: Check function of the swing ring teeth lubrication system during op- 
eration

Diesel engine: Check oil pressure and coolant temperature during operation 
Electrical system: Clean and check LCD screen of the display for proper func- 
tion when starting
Electrical system: Check indicator lights and gauges on the control panel when 
starting

R9200 / 11695477 5 - 153
MJFCIFSS
Initials
Check
Comments
Electrical system: Check for warning and fault messages on display (monitor- 
ing, grease, air conditioning, ...). If necessary refer to chapter 4 in the Operating
Manual to identify and rectify faults and errors.
Cabin: Check for green flash light on control module if fire fighting system is in- 
stalled

5 - 154 R9200 / 11695477
MJFCIFSS
Initials
Check
Comments
General comments:
Tab. 5-13 250 Hours maintenance schedule - R9200

R9200 / 11695477 5 - 155
MJFCIFSS
Serial Number:
Completed by :
Fleet Number:
SMU HOURS:
Travel Hours:
Initials
Check
Comments
age
damage and leakage
GENERAL FASTENING


screws of the sprockets, rollers, idlers, track guides, track pads, protection covers
and final drives, tighten if necessary




Hydraulic: Do a detailed check for missing, broken or loosen mounting screws 

of pumps, motors, clamps, ..., tighten the screws
TRACK COMPONENTS

5 - 156 R9200 / 11695477
MJFCIFSS
Initials
Check
Comments
leaks
TRAVEL GEAR
Sample and analyse gear oil, change oil if necessary 
Change gear oil (if filled with COB-1 gear oil) 
Change gear oil (if filled with COB-2, COB-3 or COB-4 gear oil) 
Sample and analyse lifetime sealing interspace oil, change oil if necessary (op- 
tional equipment)
Change lifetime sealing interspace oil (optional equipment) 
UNDERCARRIAGE

ATTACHMENT

UPPERCARRIAGE
Do a detailed check of all structural parts for damages and cracks 

Do a visual check if the fan guards are in place and secured 
SWING GEAR

R9200 / 11695477 5 - 157
MJFCIFSS
Initials
Check
Comments
Change gear oil (if filled with COB-1 gear oil) 
Change gear oil (if filled with COB-2, COB-3 or COB-4 gear oil) 
SWING RING
Do a detailed check of the grease supply (outlet of new grease around the swing 
ring)

tions Manual
tions and damage
Replace all preliminary filters and fuel filters as soon as fuel level reaches the red 
mark on the bell of the preliminary filters (replace the filters at least every 500
hours)
a year)
Sample and analyse splitterbox oil 
Do a visual check of the splitterbox breather for clogging, replace if necessary 
leaks

5 - 158 R9200 / 11695477
MJFCIFSS
Initials
Check
Comments
and brackets
essary
Every 250 hours or 6 months, perform a complete Maintenance Echelon given in 

Every 1500 hours or 1 year, perform a complete Maintenance Echelon given in 


HYDRAULIC SYSTEM
Drain water sediment from hydraulic tank 
Sample and analyse hydraulic oil and change oil if necessary 
Replace filter element of the return filters 
Replace filter element of the return filters (if hydraulic hammer is used) 
Replace filter element of the leak oil filter 
Replace the hydraulic tank breather filter (if hydraulic hammer is used) 
Replace control oil filter element 
Replace swing pumps replenishing oil filter elements 
Do a visual check of the oil cooler protection filters, clean or replace if necessary 
(optional equipment)
ELECTRICAL SYSTEM
boxes
Replace main element on aeration devices for cabin and electrical boxes (at least 
once a year)

R9200 / 11695477 5 - 159
MJFCIFSS
Initials
Check
Comments
Replace safety element on aeration devices for cabin and electrical boxes, after 
3 services of main element
Do a visual check of wiring system damage 
Check battery electrolyte level (refill if necessary) and clean battery terminals 
CABIN
Do a visual check of the fresh air filter and the recirculated air filter 
Check the condition of the condenser, blow it out if necessary 
Do a visual check of the dryer / accumulator unit for moisture degree, coolant lev- 
el and good condition, replace if necessary (at least once a year)
The function of the air flaps and the defrosting thermostat must be checked year- 
ly by a refrigeration specialist
Perform maintenance for the second air-conditioning system (optional equip- 

ment)
Lubricate all doors seals with silicone or talc (before cold season) 
Do a visual check of the AC for leaks or rubbing hoses or pipes 
Attachment: Check function of the working attachment lubrication system during 

operation
Uppercarriage: Check movement and locking of the access ladder 


5 - 160 R9200 / 11695477
MJFCIFSS
Initials
Check
Comments
operation
eration
tion when starting
starting
stalled

R9200 / 11695477 5 - 161
MJFCIFSS
Initials
Check
Comments
General comments:
Tab. 5-14 500 Hours maintenance schedule - R9200

5 - 162 R9200 / 11695477
MJFCIFSS
Serial Number:
Completed by :
Fleet Number:
SMU HOURS:
Travel Hours:
Initials
Check
Comments
age
damage and leakage
GENERAL FASTENING


Track components: Do a detailed check for missing, broken or loosen mounting 

screws of the rollers, pins locking and track guides, tighten the screws

screws of the idler axis locking keys, tighten the screws

screws of the track pads, tighten the screws
Travel gear: Do a detailed check for missing, broken or loosen mounting screws 
of the gears, sprocket wheels and hydraulic motors, tighten the screws

Undercarriage: Do a detailed check for missing, broken or loosen mounting 

screws of the side frames, tighten the screws




R9200 / 11695477 5 - 163
MJFCIFSS
Initials
Check
Comments
Swing ring: Do a detailed check for missing, broken or loosen mounting screws 
and protective nuts of swing ring, tighten the bolts
Diesel engine: Do a detailed check for missing, broken or loosen mounting 

screws of the splitterbox, tighten the screws
Hydraulic: Do a detailed check for missing, broken or loosen mounting screws 

TRACK COMPONENTS
leaks
TRAVEL GEAR
Change gear oil (if filled with COB-2, COB-3 or COB4 gear oil) 
tional equipment)
Change lifetime sealing interspace oil (optional equipment) 
UNDERCARRIAGE

- If necessary fill out the "Structural Inspection" form in Service Manual - Chapter
4
ATTACHMENT

Do a visual check of all parts for cracks 

4

5 - 164 R9200 / 11695477
MJFCIFSS
Initials
Check
Comments
UPPERCARRIAGE
Do a detailed check of all structural parts for cracks 

4
Do a detailed check and lubricate covers, doors hinges, locks as well as access 
ladder cylinders bushings and swivel pins
SWING GEAR
Change gear oil (if filled with COB-2, COB-3 or COB-4 gear oil) 
SWING RING
ring)

tions Manual
tion and damage

Do a visual check of the thermic protection on the exhaust manifold fastening 

R9200 / 11695477 5 - 165
MJFCIFSS
Initials
Check
Comments
hours)
a year)
Change oil in splitterbox 
Replace filter in splitterbox breather 
leaks
Do a detailed check of the engine and the splitterbox rubber buffers (replace if 
necessary and at least every 10000 hours)
and brackets
essary

Every 1500 hours or 1 year, perform a complete Maintenance Echelon given in 


HYDRAULIC SYSTEM

5 - 166 R9200 / 11695477
MJFCIFSS
Initials
Check
Comments
Replace filter element of the return filters 
Replace filter element of the leak oil filter 
Replace the hydraulic tank breather filter 
Replace control oil filter element 
Replace swing pumps replenishing oil filter elements 
Do a visual check of the oil cooler protection filters, clean or replace if necessary 
Check and adjust primary and secondary pressure relief valves 
ELECTRICAL SYSTEM
boxes
once a year)
CABIN


R9200 / 11695477 5 - 167
MJFCIFSS
Initials
Check
Comments

ment)
Do a visual check of the locks and hinges on doors and windows (lubricate if nec- 
essary)
Do a detailed check of the cabin rubber mounts 

operation

operation
eration

tion when starting

5 - 168 R9200 / 11695477
MJFCIFSS
Initials
Check
Comments
starting
stalled
Cabin: Check the heater function (before the cold season) 


R9200 / 11695477 5 - 169
MJFCIFSS
Initials
Check
Comments
General comments:
Tab. 5-15 1000 hours maintenance schedule - R9200

5 - 170 R9200 / 11695477
MJFCIFSS

Serial Number:
Completed by :
Fleet Number:
SMU HOURS:
Travel Hours:
Initials
Check
Comments
age
damage and leakage
GENERAL FASTENING


Track components: Do a detailed check for missing, broken or loosen mounting 

screws of the rollers, pins locking and track guides, tighten the screws

screws of the idler axis locking keys, tighten the screws

screws of the track pads, tighten the screws
Travel gear: Do a detailed check for missing, broken or loosen mounting screws 
of the gears, sprocket wheels and hydraulic motors, tighten the screws
Undercarriage: Do a detailed check for missing, broken or loosen mounting 

screws of the side frames, tighten the screws



Uppercarriage: Do a detailed check for missing, broken or loosen mounting 

walks, grease box, ladder, tighten the screws

R9200 / 11695477 5 - 171
MJFCIFSS
Initials
Check
Comments
Swing gear: Do a detailed check for missing, broken or loosen mounting bolts of 
the swing gear and hydraulic motors, tighten the bolts
Swing ring: Do a detailed check for missing, broken or loosen mounting screws 
and protective nuts of swing ring, tighten the bolts

screws of the splitterbox, tighten the screws

screws of the engine, tighten the screws
Hydraulic: Do a detailed check for missing, broken or loosen mounting screws 

TRACK COMPONENTS
leaks
Liebherr recommends to measure the track chains with TCM software 
TRAVEL GEAR
Change gear oil (if filled with COB-1 gear oil) 
tional equipment)
Change lifetime sealing interspace oil (optional equipment) 
Change brake oil 
UNDERCARRIAGE

4
ATTACHMENT

5 - 172 R9200 / 11695477
MJFCIFSS
Initials
Check
Comments
Do a visual check of all parts for cracks 

4
UPPERCARRIAGE
Do a detailed check of all structural parts for cracks 

4
Do a detailed check and lubricate covers, doors hinges, locks as well as access 
ladder cylinders bushings and swivel pins
Do a functional test of the camera system and global view around machine (in- 
cluding mirrors)
SWING GEAR
Change gear oil (if filled with COB-1 gear oil) 
SWING RING
ring)
Do a detailed check of the meshing of the swing gears with the swing ring 
Do a detailed check of the swing ring teeth for damage 

Do a detailed check of the swing ring axial play 

tions Manual

R9200 / 11695477 5 - 173
MJFCIFSS
Initials
Check
Comments
tions and damage
Do a visual check of the thermic protection on the exhaust manifold fastening 
hours)
Replace the filter element of the dust filter for the vent valve 
a year)
Change oil in splitterbox 
Replace filter in splitterbox breather 

leaks
Do a detailed check of the engine and the splitterbox rubber buffers (replace if 
necessary and at least every 10000 hours)
and brackets

5 - 174 R9200 / 11695477
MJFCIFSS
Initials
Check
Comments
essary

Every 6000 hours or 2 years, perform a complete Maintenance Echelon given in 


HYDRAULIC SYSTEM
Change hydraulic oil 
Replace filter element of the return filters 
Replace filter element of the leak oil filter 
Replace the hydraulic tank breather filter 
Replace control oil filter element 
Replace swing pumps replenishing oil filter elements 
Replace the control valves high pressure filters, replace filter elements after each 
replacement or repair of a working pump and check the internal surface of the
filter housing
Do a visual check of the oil cooler protection filters, clean or replace if necessary 
Do a detailed check of the oil coolers, clean if necessary 
Do a visual check of the cooling fan blades, replace if necessary 
Check and adjust primary and secondary pressure relief valves 
Do a detailed check of mounting of components (pumps, motors, ...) 

R9200 / 11695477 5 - 175
MJFCIFSS
Initials
Check
Comments
Every 4000 hours (or at least once a year), all hydraulic pumps must be checked 
and adjusted by trained and qualified Liebherr personnel
Every 10000 hours, replace following high pressure (HP) hoses: 

– all HP hoses between work pumps and valve banks,
– all HP hoses of the swing circuit:
• all HP hoses between swing pumps and swing motors,
• all pressure equalizing hoses between swing pump / swing motors circuits,
• all HP pilot hoses of the swing pumps regulation,
– all HP hoses of the oil cooler fan drive circuit, including HP pilot hoses,
– all HP hoses of the water cooler fan drive circuit, including HP pilot hoses.
ELECTRICAL SYSTEM
boxes
once a year)
Do a test of all emergency stops (engine stop only) 

Make sure that the display goes off after each test
CABIN

ment)

5 - 176 R9200 / 11695477
MJFCIFSS
Initials
Check
Comments
Do a visual check of the locks and hinges on doors and windows (lubricate if nec- 
essary)
Do a detailed check of the cabin rubber mounts 
Do a detailed check of the heater exchanger and filter for leaks 
Do a detailed check of the warm water solenoid valve for function and chocking, 
clean it if necessary
Check the condition of the evaporator, clean it if necessary 

operation

operation
eration

tion when starting

R9200 / 11695477 5 - 177
MJFCIFSS
Initials
Check
Comments
starting
stalled
Cabin: Check the heater function (before the cold season) 
Cabin: Check the pressure switch function on the dryer / accumulator unit 

5 - 178 R9200 / 11695477
MJFCIFSS
Initials
Check
Comments
General comments:
Tab. 5-16 2000 hours maintenance schedule - R9200

R9200 / 11695477 5 - 179
MJFCIFSS

5 - 180 R9200 / 11695477
MJFCIFSS
6 Appendix
6.1 Visual check of the hydraulic hoses
6.1.1 Preface
This section describes the procedure for the visual check of the hydraulic hoses.
Note!
These instructions have been written for the maintenance personnel of the ma-
chine.
The activities described in this section may only be carried out by specially trained
personnel.
The instructions are to be read and used carefully by all persons who carry out
work with or on the machine before putting the machine into service for the
first time and later, at regular intervals.
The instructions must be completed by information on current national regulations for
accident prevention and protection. In addition, authorized specialist rules for safe
and correct working procedures are also to be observed.
However, should you require any further explanations or information, LIEBHERR
Danger!
Fluid injection injuries have to be treated immediately!
– Fluid under pressure can cause serious injury. It can be almost invisible when it
escapes from a pinhole and it can go through the skin and contaminate the
blood.
– Do not touch a pressurized hydraulic hose assembly with any part of your body.
– If a fluid-injection accident occurs, medical treatment is necessary immediately.
– Stay out of hazardous areas while testing hose assemblies under pressure. Use
available safety protection.
– Refer to "Isolate machine for hydraulic repair" safe work procedure in the Ser-
vice Manual.

R9200 / 11695477 6-1
MJFCIFSS
Appendix Operating manual
Visual check of the hydraulic hoses
Components description
Fig. 6-1 Hydraulic tube and hose assembly
1 Rubber cover 5 Nipple

2 Reinforcement layer 6 Nipple wire trap area
3 Inside rubber tube 7 Sealing zone
4 Crimp fitting 8 Damping zone
For this document, the terms that follow are available:

– A hose is a hydraulic tube. It is made by:
• the rubber cover 1
• the reinforcement layer 2
• the inside rubber tube 3
– A hose assembly is a hose with fittings attached at the two ends. The fittings are
made by:
• the crimp fitting 4
• the nipple 5
Marking of the components

The hose and the hose assembly are marked with the general data given below.
Hose marking
The hose is marked on the rubber cover with:
– the nominal diameter (DN)
– the manufacturer identification
– the date of production "xQxx" of the hose (i.e. 2Q13 = second quarter of 2013)
– the hose type and quality

6-2 R9200 / 11695477
MJFCIFSS
Operating manual Appendix
Fig. 6-2 Marking of hose
Hose assembly marking

The hose assembly is marked on the fittings with:
– the manufacturer identification
– the date when the hose assembly has been made
– the hose identification number
– the service pressure
Fig. 6-3 Marking of hose assembly

R9200 / 11695477 6-3
MJFCIFSS
Normal conditions of use
Danger!
It is necessary to replace the hydraulic hoses at specified intervals to maintain their
maximum operating performance and to reduce the risk of personal injury and/or
machine damage.
 Obey the replacement intervals given below.
Natural ageing
Hydraulic hoses and hose assemblies undergo a process of natural ageing. Thus,
their service life has a limit:
– When you make a hose assembly, the hose must not be more than four years old.
– The service life of a hose assembly must obey the requirements given in the sec-
tion "Replacement of the hydraulic hoses" of this manual.
Operating stress
The hydraulic hoses must also be regularly replaced because of the operating stress.
 For the replacement intervals given in working hours of the hydraulic hoses, refer
to the section "Control and maintenance chart" of this manual.
Mounting instructions
 Refer to the Operating Manual.
6.1.3 Components functions

This section gives the function of the different main components of a hydraulic hose
assembly.
Inside rubber tube

The inside rubber tube keeps the conveyed fluid in the hose. It is resistant against
the fluid and the temperature of the fluid. Internal damages to this tube can be caused
by contamination of the hydraulic circuit.
The inside rubber seals the hose but it has no pressure stability.
Reinforcement layer
The reinforcement layer, made up of some steel layers with rubber in between, holds
the internal pressure.
The reinforcement layer is the only component of the hose which gives the hose the
pressure stability. The hose has a minimum burst pressure (static) and a maximum
operating pressure (dynamic). The maximum operating pressure is usually at least
four times lower than the minimum burst pressure because dynamic pressures fa-
tigue the reinforcement layer more quickly than static pressures.
The value of the burst pressure and the operating pressure will be lower if the rein-
forcement layer has one of the damages that follow:
– Corrosion of the reinforcement layer.

6-4 R9200 / 11695477
MJFCIFSS
– Rub between the steel layers.

– Damaged rubber in between the steel layers.
The inside rubber can also be damaged if the reinforcement layer moves.
Rubber cover
The rubber cover protects the reinforcement layer from the ambient conditions (UV,
ozone, different liquids) and from mechanical effects (scrubbing, corrosion).
Any rub, cut or rib in the rubber cover means that the protection is no longer satisfac-
tory and the reinforcement layer is subject to a potential destruction.
Nipple
The nipple is necessary to connect a hydraulic hose to another component. The nip-
ple is resistant to all the mechanical forces and bending stress caused by the pres-
sure pulsations in the hose. Thus, it is important to have a good contact between the
nipple and the hose.
Cracks on the nipple cause its fast failure.
Crimp fitting
To make sure that the assembly is correctly sealed, the crimp fitting presses the in-
side rubber tube onto the nipple. In addition, if the hose has a wire trap area, the
crimp fitting clamps the reinforcement layer in between the nipple and the crimp fit-
ting.
If the hose assembly starts to leak at the end of the crimp fitting, the causes that fol-
low are possible:
– The sealing function between rubber hose and nipple is not satisfactory.
– The crimp fitting has not been done 100% correctly.
– The pressure range of the crimp fitting is lower.
6.1.4 Recommendations for hose assembly maintenance
Severity levels
Hose assembly damages can be divided into three severity levels:
– minor damage
– serious damage
– major damage
For each severity level, there are special actions to do at specific intervals.
Checks and recommendations

The sections that follow give:

– the visual checks which are necessary to make an estimate of the damage sever-
ity level
– the recommendations for the related actions and intervals

R9200 / 11695477 6-5
MJFCIFSS
Minor damage
If you find a minor damage:
 Examine the hose assembly. Monitor if the deterioration increases.
Daily  In case of rubbing, move the hose assembly to make sure there is no more
contact.
 Check all necessary conditions for the possible replacement of the defective
part(s) (e.g. part in stock, time of delivery).
Rubber cover is rubbed - Reinforcement layer is not corroded or not rubbed - No sign of oil
Rubber cover has a cut or a crack - Reinforcement layer is not corroded or not cut - No sign of oil
Hose is visually wet near the crimp fitting - Oil does not propagate
There is a small surface of remaining oil which is visually wet but does not result in the formation of drop.
Dry dust collection which does not propagate


6-6 R9200 / 11695477
MJFCIFSS
Serious damage
If you find a serious damage:
 Inform formally the responsible Maintenance Manager about the condition of

Immediately the hose assembly.
 Make sure that you have the correct replacement part in stock.
 Examine the hose assembly. Monitor if the deterioration increases.
Daily  If the deterioration of the hose assembly increases in a small number of days,
refer to next section "Major damage" for the actions to do.
One of the next services,
but not later than 250  Replace the hose assembly.
hours
Rubber cover has many cuts or cracks - Reinforcement layer is not corroded or not cut - No sign of oil
Rubber cover is rubbed - Reinforcement layer is uncovered but not corroded - No sign of oil
Hoses and fittings are visually wet - Oil propagates

There is a surface of remaining oil which is visually wet and results in the formation of non-falling or falling drop.

R9200 / 11695477 6-7
MJFCIFSS
Major damage
If you find a major damage:
Danger!
In this case, the hose assembly must be replaced immediately because it can burst
at any time.
 Obey all safety instructions given in the Operating Manual to avoid accidents
and fires.
 Stop the machine immediately (no exception).

Immediately  Inform formally the responsible Maintenance Manager, or his superior, that the
machine is stopped and about the condition of the hose assembly.
Before restart the machine  Replace the hose assembly.
Oil leakage
The frequency of the drops makes a measurable flow.
Reinforcement layer is cracked, rubbed or corroded
Nipple or crimp fittings are Blisters have formed on the Oil comes out of the cut or
cracked rubber cover cracked rubber cover

6-8 R9200 / 11695477
MJFCIFSS
Cleaning procedure for hydraulic circuits
6.2 Cleaning procedure for hydraulic circuits
This section gives the procedures to drain and clean the different hydraulic circuits
of the machine after a repair and before you put the machine back in operation.
6.2.1 Preface
Note!
These instructions have been written for the maintenance personnel of the ma-
chine.
The activities described in this section may only be carried out by specially trained
personnel.
The instructions are to be read and used carefully by all persons who carry out
work with or on the machine before putting the machine into service for the
first time and later, at regular intervals or after a repair.
The instructions must be completed by information on current national regulations for
accident prevention and protection. In addition, authorized specialist rules for safe
and correct working procedures are also to be observed.
However, should you require any further explanations or information, LIEBHERR
Danger!
Fluid injection injuries have to be treated immediately!
– Fluid under pressure can cause serious injury. It can be almost invisible when it
escapes from a pinhole and it can go through the skin and contaminate the
blood.
– Do not touch a pressurized hydraulic hose assembly with any part of your body.
– If a fluid-injection accident occurs, medical treatment is necessary immediately.
– Stay out of hazardous areas while testing hose assemblies under pressure. Use
available safety protection.
– Refer to "Isolate machine for hydraulic repair" safe work procedure in the Ser-
vice Manual.
6.2.2 General information about hydraulic oil contamination
Hydraulic oil contamination

Hydraulic oil contamination is unwanted liquid or solid material and/or particles in the
hydraulic circuit. It can be caused by:

– the failure of components like pumps, hydraulic motors or cylinders
– too much wear of a component
– material/particles introduced during:
• the general maintenance
• a repair work
– hydraulic circuit not cleaned on previous maintenance work (too much remaining
contamination in the hoses and pipes)

R9200 / 11695477 6-9
MJFCIFSS
Hydraulic oil contamination has a lot of unwanted effects, e.g.:

– corrosion
– internal leaks
– overheating
– wear of the moving part
– damages to other components
– degradation of rubber and elastomer compounds
Metallic contamination of the hydraulic circuit

You can see metallic contamination of the hydraulic circuit through:
– special error codes on the display for working pumps and swing pumps
– the condition of the magnetic rods of return and leak oil filters installed on the hy-
draulic tank
• In normal operation, the magnetic rods are clean:
Fig. 6-4 Clean magnetic rod
• In case of contamination of the hydraulic circuit by metal particles, there is an

important metal collection on the magnetic rods:
Fig. 6-5 Magnetic rod with metal collection
• Because of the set-up of the components, a metal collection on the magnetic

rods is also possible during the initial operation time of the machine.
• Because of the normal wear of pumps and motors, a thin layer of metal on the
magnetic rods is always possible.
 Refer to the Operating Manual for the inspections related to the initial set-up of
the machine.
When you remove the filters, you can also find particles of fibre support bands, O-
ring material or sealant material in the filter element or in the filter housing.
Thus, to prevent damages to the components because of particles contamination in
the hydraulic circuit, you must monitor the hydraulic circuit condition and, when nec-
essary, do all the applicable maintenance tasks.

6 - 10 R9200 / 11695477
MJFCIFSS
6.2.3 General cleaning procedure

 For the complete description about the works to do, also refer to the chapter 2
"Safe Works Procedures" of the Service Manual.
 Always do all the tasks that follow in the order given:
– Step 1: Stop the engine. The attachment must stay on the ground.
– Step 2: Make sure that there is no pressure in the system. Refer to the Operating
Manual.
– Step 3: Drain the hydraulic tank. Refer to the Operating Manual.
– Step 4: Disconnect, drain and clean with applicable tools all of the related hydrau-
lic circuits (hydraulic lines, fittings, oil filters and components). Refer to the sec-
tions below which give all the components of each hydraulic circuit.
Depending on the different assemblies, it is possible that you must disassemble
some components.
– Step 5: Clean the hydraulic tank. Refer to the section "Hydraulic tank" below.
– Step 6: Install all of the hydraulic circuits back. Refer to the Operating Manual for
general installation procedures.
– Step 7: Do the restart procedure before you put the machine in operation. Refer
to the section "Restart the machine" below.
6.2.4 Location of the hydraulic tank filters

Fig. 6-6 Filters on the hydraulic tank
1 Leak oil filter

R9200 / 11695477 6 - 11
MJFCIFSS
2 Return-line filters
6.2.5 Working pumps circuit
Return oil circuit

 Remove the complete return-line filters 2 (refer to section above and Operating
Manual).
 Make sure during removal that contaminated oil does not go into the tank.
 Carefully clean the oil inlet compartment where the filters 2 are installed.
 Carefully clean the filters 2 and the related magnetic rods, or replace if necessary
(refer to the Operating Manual).
Fig. 6-7 Return lines

3 Hydraulic tank 11 Hydraulic hose

4 Oil cooler box 12 Hydraulic hose
5 Oil cooler 13 Hydraulic hose
6 Hydraulic hose 14 Hydraulic hose
8 Hydraulic hose CP2 Control valve collecting pipe
9 Hydraulic hose VB1 Valve block 1

6 - 12 R9200 / 11695477
MJFCIFSS
 Disconnect, drain and clean all the hydraulic hoses.

 Open, drain and clean the collecting pipe CP2.
 Move to next section about the leak oil circuit.
Leak oil circuit
Fig. 6-8 Leak oil circuit of working pumps
3 Hydraulic tank 12 Drain plug

6 Hydraulic pipe 13 Hydraulic block
7 Hydraulic hose CP3 PowerPack collecting pipe
8 Hydraulic hose P1 Working pump 1

 Remove the complete leak oil filter 1 (refer to section above and Operating Man-
ual).
 Carefully clean the oil inlet compartment where the filter 1 is installed.

R9200 / 11695477 6 - 13
MJFCIFSS
 Carefully clean the filter 1 and the related magnetic rod, or replace if necessary
 Disconnect, drain and clean all the hoses and pipe. You can use the drain plug
12 to drain the hydraulic line 6 and 7.
 Move to next section about the high pressure circuit.
High pressure circuit
Fig. 6-9 High pressure hoses between valves blocks and working pumps

HPF1 P1 high pressure filter VB1 Valve block 1
HPF2 P2 high pressure filter VB2 Valve block 2

6 - 14 R9200 / 11695477
MJFCIFSS
HPF3 P3 High pressure filter

HPF4 P4 High pressure filter
 According to the defective pump, remove the related high pressure filter HPFx
 Disconnect, drain and clean the related high pressure hose.
 Install a new high pressure filter.
 Move to next section about the oil intake circuit.
Oil intake circuit
Fig. 6-10 Intake lines of working pumps
3 Hydraulic tank P1 Working pump 1

6 Shutoff valve P2 Working pump 2
7 Compensators (4x) P3 Working pump 3
8 Suction pipes (4x) P4 Working pump 4
SP1 Intake pipe
 Disconnect, drain and clean all the compensators and the intake pipe SP1.
 Clean the shutoff valve 6.
 Clean the hydraulic tank 3 (refer to the related section).
 Do the restart procedure before you put the machine in operation (refer to the re-
lated section).

R9200 / 11695477 6 - 15
MJFCIFSS
6.2.6 Swing circuit
Leak oil circuit
Fig. 6-11 Leak oil hoses of swing pump
6 Hydraulic hose CP3 PowerPack collecting pipe

7 Hydraulic hose P5 Swing pump
a Refer to section "Leak oil circuit of
working pumps"
ual).
 Make sure that, during removal, contaminated oil does not go into the tank.

6 - 16 R9200 / 11695477
MJFCIFSS
Fig. 6-12 Leak oil hoses of swing motors

8 Hydraulic hose 13 Hydraulic pipe
9 Hydraulic hose MSB Rear right swing motor
10 Hydraulic pipe MSF Front right swing motor
11 Hydraulic hose RC Rotary connection
 Disconnect, drain and clean all the hydraulic hoses, blocks and pipes.
 Move to next section about the working pressure circuit.

R9200 / 11695477 6 - 17
MJFCIFSS
Working pressure circuit
Fig. 6-13 Working pressure lines

8 Hydraulic pipe MSB Rear right swing motor
9 Hydraulic hose MSF Front right swing motor
11 Hydraulic hose
 Disconnect, drain and clean all the hydraulic hoses and pipes.
 Disconnect, drain and clean all the distribution blocks.

6 - 18 R9200 / 11695477
MJFCIFSS
Oil intake and oil replenishing circuit
Fig. 6-14 Intake and replenishing lines

7 Hydraulic hose P10 Replenishing oil pump
8 Hydraulic hose SP1 Intake pipe
d Refer to section "Oil intake cir-
cuit" of the working pumps

 Clean the hydraulic tank (refer to the related section).
lated section).

R9200 / 11695477 6 - 19
MJFCIFSS
6.2.7 Cooling pumps circuit
Return oil circuit
Fig. 6-15 Return oil lines of fans motors

7 Hydraulic hose CP2 Control valve collecting pipe
8 Hydraulic pipe MF1 Water fan motor
9 Hydraulic hose MF2 Oil fan motor
 Remove the complete return-line filters 2 (refer to the Operating Manual).

 Carefully clean the oil inlet compartment where the filters 2 are installed.
 Carefully clean the filters 2 and the related magnetic rods, or replace if necessary
 Disconnect, drain and clean all the hydraulic hoses and the pipe.
 Move to next section about the leak oil circuit.

6 - 20 R9200 / 11695477
MJFCIFSS
Leak oil circuit
Fig. 6-16 Leak oil lines of fan motors

6 Hydraulic pipe 12 Hydraulic hose
7 Hydraulic hose MF1 Water fan motor
9 Hydraulic pipe

R9200 / 11695477 6 - 21
MJFCIFSS
Fig. 6-17 Leak oil hose of cooling pumps
13 Hydraulic hose P6.1 Engine cooling pump

d Refer to section "Leak oil circuit P6.2 Oil cooling pump
of working pumps"
CP3 PowerPack collecting pipe
ual).
 Carefully clean the oil inlet compartment where the filter is installed.
 Disconnect, drain and clean all the hydraulic hoses, blocks and pipes.
 Move to next section about the working pressure circuit.

6 - 22 R9200 / 11695477
MJFCIFSS
Fig. 6-18 Working pressure lines of fan motors

7 Hydraulic pipe MF1 Water fan motor
9 Hydraulic pipe P6.1 Engine cooling pump
10 Hydraulic pipe P6.2 Oil cooling pump
11 Hydraulic hose
 Disconnect, drain and clean all the hoses and pipes.


R9200 / 11695477 6 - 23
MJFCIFSS
Oil intake circuit
Fig. 6-19 Intake line of cooling pumps
6 Hydraulic hose P6.1 Engine cooling pump

a Refer to section "Oil intake circuit" of P6.2 Oil cooling pump
the working pumps
SP1 Intake pipe
 Disconnect, drain and clean the suction hydraulic hose 6 and the intake pipe SP1.
 Clean the hydraulic tank 3 (refer to the related section).
lated section).

6 - 24 R9200 / 11695477
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6.2.8 Travel motors circuit
Leak oil circuit
Fig. 6-20 Leak oil circuit of travel motors
6 Hydraulic hose GTL Left travel gear

7 Hydraulic hose GTR Right travel gear
8 Hydraulic hose MTL Left travel motor
9 Hydraulic hose MTR Right travel motor

a Refer to section "Leak oil hoses of RC Rotary connection
swing motors"
UBV Overspeed shutoff valve
ual).
 Make sure that, during removal, contaminated oil does not go into the tank.

R9200 / 11695477 6 - 25
MJFCIFSS
Fig. 6-21 Working pressure circuit on the undercarriage


6 - 26 R9200 / 11695477
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11 Hydraulic hose FBVL Left travel brake valve
12 Hydraulic hose FBVR Right travel brake valve
18 Hydraulic hose
Fig. 6-22 Working pressure circuit on the uppercarriage



 Move to next section about the overspeed pressure circuit.

R9200 / 11695477 6 - 27
MJFCIFSS
Overspeed pressure circuit
Fig. 6-23 Overspeed pressure circuit on the undercarriage


UBV Overspeed shutoff valve

6 - 28 R9200 / 11695477
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Fig. 6-24 Overspeed pressure circuit on the uppercarriage
11 Hydraulic hose
RC Rotary connection
RC-ADD Rotary connection - second part
SU1 Servo oil unit 1

 Clean the hydraulic tank (refer to the related section).
lated section).

R9200 / 11695477 6 - 29
MJFCIFSS
6.2.9 Backhoe cylinders lines
Circuit of bucket tilt cylinders
Fig. 6-25 Hydraulic lines on the uppercarriage

5 Hydraulic pipe VB1 Valve block 1
6 Hydraulic pipe VB2 Valve block 2 LEC/en/Edition: 04 / 2017

6 - 30 R9200 / 11695477
MJFCIFSS
Fig. 6-26 Hydraulic lines on the attachment
11 Hydraulic lines installed on the boom

12 Hydraulic lines installed on the stick and on the bucket cylinders
 Disconnect, drain and clean all the hydraulic hoses, pipes and distribution blocks.
lated section).

R9200 / 11695477 6 - 31
MJFCIFSS
Stick cylinders circuit

7 Hydraulic hose

6 - 32 R9200 / 11695477
MJFCIFSS
Fig. 6-28 Hydraulic lines on the boom

13 Hydraulic pipe installed on the stick cylinders
lated section).

R9200 / 11695477 6 - 33
MJFCIFSS
Boom cylinders circuit

5 Hydraulic pipe 12 Hydraulic pipe

6 - 34 R9200 / 11695477
MJFCIFSS

14 Hydraulic pipe installed on the boom cylinders
lated section).

R9200 / 11695477 6 - 35
MJFCIFSS
6.2.10 Shovel cylinders lines
Circuit of shovel flap cylinders


6 - 36 R9200 / 11695477
MJFCIFSS

6 Hydraulic lines installed on the crowd

R9200 / 11695477 6 - 37
MJFCIFSS
Fig. 6-33 Hydraulic lines on the bucket
7 Hydraulic lines installed on the 10 Hydraulic hose

shovel flap cylinders
9 Hydraulic hose DBF Distribution block for flap cylin-
ders
 Disconnect, drain and clean all the hydraulic hoses, pipes and the distribution
block.
lated section).
Circuit of shovel tilt cylinders

For the hydraulic lines on the uppercarriage:
 Refer to section "Circuit of bucket tilt cylinders" of the machine with the backhoe
attachment.

6 - 38 R9200 / 11695477
MJFCIFSS

2 Hydraulic lines installed on the crowd and on the shovel tilt cylinders
lated section).
Crowd cylinder circuit

 Refer to section "Stick cylinders circuit" of the machine with the backhoe attach-
ment.

R9200 / 11695477 6 - 39
MJFCIFSS
 Disconnect, drain and clean all the hydraulic hoses and pipes.
lated section).
Boom cylinders circuit

 Refer to section "Boom cylinders circuit" of the machine with the backhoe attach-
ment.

6 - 40 R9200 / 11695477
MJFCIFSS

2 Hydraulic pipe installed on the boom cylinders
lated section).

R9200 / 11695477 6 - 41
MJFCIFSS
6.2.11 Clean the hydraulic tank
Fig. 6-37 Hydraulic tank cleaning
1 Access covers of the hydraulic tank

2 Oil inlet compartments
 Remove the access covers 1 from the hydraulic tank.

 Look for particles and unwanted material in the tank and in the internal collecting
pipes.
 Clean the tank manually with lint-free cleaning cloths.
 Flush the tank if necessary.
 Make sure that the oil inlet compartments 2 are clean.
6.2.12 Restart the machine

You must do the procedures below before you restart the machine.
 Make sure that:
– All defective components are replaced or repaired.
– All unwanted material and/or particles are removed from the circuit parts.
– The hydraulic oil filters are cleaned or replaced.
– All the parts you disconnected, drained and cleaned as given above are connect-

6 - 42 R9200 / 11695477
MJFCIFSS
ed back.
 Refill the hydraulic system (refer to the Operating Manual).
 Bleed the hydraulic pumps (refer to the Operating Manual).
 Let the engine idle at the minimum speed during approximately 10 minutes. Do
not operate attachment movements.
 Make sure that no error symbols are shown on the monitoring display (refer to the
Operating Manual).
 Operate the engine at nominal speed.
 Set the auto idle function to off. Refer to the Operating Manual.
Fig. 6-38 Solenoid valves on servo unit
SU1 Servo oil unit

YR3.x Solenoid valves
The servo unit SU1 is located inside the pumps box.

 On the servo oil unit SU1, disconnect the two solenoid valves YR3.1 and YR3.2.
 Do not move the operating and control elements (joystick and pedals) during ap-
proximately 5 minutes.
 Connect the two solenoid valves YR3.1 and YR3.2 back.
 Set the auto idle function to on back.
 Slowly operate all movements that follow. Do not reach the end position of the pis-
ton rods (be careful with the Diesel effect, you can also refer to the Operating
Manual)
– Lift up the attachment.

– Operate each cylinder of the attachment in order below and repeat 10 times be-
fore moving to next cylinders:
• shovel flap cylinders (in case of shovel attachment)
• bucket tilt cylinders
• stick cylinders
• boom cylinders
– Swing clockwise and counterclockwise on approximately 1/2 turn. Repeat 4 times
in each direction.

R9200 / 11695477 6 - 43
MJFCIFSS
Centralized lubrication system
 Make sure again that no error symbols are shown on the monitoring display (refer
to the Operating Manual).
 Only for crawler excavators: start the travel hydraulic circuits forward and back-
ward on approximately 10 meters. Repeat 4 times.
 Stop the engine. The attachment must stay on the ground.
 Release the pressure from the hydraulic system (refer to the Operating Manual).
 Check the return and leak oil filters with related magnetic rods and the high pres-
sure filters.
 Check the machine for leaks.
The machine can now be operated.
6.2.13 Monitor the restarted machine

After you restart the machine, you must monitor the condition of the hydraulic oil fil-
ters as an initial set-up of the machine.
 Clean magnetic rods of the leak oil filter daily during the first 250 hours.
 Clean magnetic rods of all return filters weekly during the first 250 hours.
You can also refer to the Operating Manual.
6.3 Centralized lubrication system

6 - 44 R9200 / 11695477
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MJFCIFSS!
1. Main Screens and Control Buttons
Menu: Used to Enter into Menu List and return to Previous Menu.
Up: Used to move up cursor in the Menu Lists and to increase a Value.
Down: Used to move down cursor in the Menu Lists and to decrease a Value.
The main menu is accessed through the "Menu" button; all the menus are displayed on the right display.
In a given Menu list, you can press the "Up" and "Down" buttons to scroll through menus. Pressing the “Down”
button will then scroll through menus from top of screen to the last menu on screen, but if the “Up” button is
pressed selection will scroll from top to bottom of menus list.
The active line is "inverse video" (white text, black highlighted), use the "Menu" key to get inside the selected
submenu.
The last line of a menu list is always defined as "Back", it is used to move to the previous menu by pressing the
"Menu" button when highlighted.
Within a given Menu where the value can be changed, the change can be made by using the "Up" button to
increase the value and using the "Down" button to decrease the value. Changes are immediately registered in
controller. Pressing the "Menu" button returns you to the previous menu.
Start Cycle P”X”:

The three keys "Start Cycle PX" can be used to start a new lubrication cycle at the corresponding pump.
Description of the software menus

MJFCIFSS!
2. Start Screens
 Left Start Screen:
G r e a s e
C o n t r o l l e r
S t a r t i n g
 Right Start Screen:

I n f o s y s t e m
S y s t em P 1 P 2 P 3M
L ow t emp f e a t u r e
F am 1
Mo d u l e V 1 . 0 0
3. Main Screens
 Left Main Screen:

P 1 O F F
1 2 3 b a r 4 5 6 s e c
P 2 O N S a f e t y
‐ ‐ ‐ b a r 0 s e c
P 3 O N
1 p u l s e 2 0 0 s e c
 Right Main Screen:

L e v e l P 1 1 0 0 %
P 3 9 5 %
P i l o t P 4 2 b a r
B 1 5 0 ‐ 1 ▪
B
P
1 5 0 ‐ 2
2 S a f e t y
▫ s e r v

MJFCIFSS!
4. Architecture of Menus

MJFCIFSS!
5. Menu
I n f o s y s t e m
A c t i v e e r r o r s
S e t P a u s e t i m e
S e t m a x p r e s s
E r r o r h i s t o r y
P s a f e t y s e r v
S e t m a x p r e s s
C h e c k
B a c k ←
 Info System:
I n f o s y s t e m
S y s t em P 1 P 2 P 3M
L ow t emp f e a t u r e
F am 1
Mo d u l e V 1 . 0 0
B a c k ←
 Active Errors:
A c t i v e e r r o r s
G 1 : P r e s s P 1 s t a y l ow
G3 : No f e e dba c k P3 l i ne
G4 : No p r e s s d r op P 1
B a c k ←

MJFCIFSS!
 Set Pause Time:

P1 se t t i ng s 600sec
B a c k ←
P a u s e t i m e P X
▲
2 4 5 s e c
▼
←
 Set max Press:

S e t m a x P r e s s
▲
2 4 0 b a r
▼
←

MJFCIFSS!
 Error History:
G1 : Pr e s s P1 s t a y l ow
G2 : Pr e s s P2 s t a y l ow
G3 : No f e e dba ck P3 l i ne
G4 : No p r e s s dr op P1
G5 : No p r e s s dr op P2
G14 : Le v s en s or P1 NC
G17 : Le v s en s or P3 NCe
G33 : Gr ea s e l ev P 1 l ow
G34 : Gr ea s e l ev P 3 l ow
G36 : P i l o t p r es s l ow n e
G34 :Gre ase l e v P 3 l ow
G36 :P i l ot pre s s l ow n e
G37 : No f eedba ck B150 ‐ 1
G38 : No f eedba ck B150 ‐ 2
B a c k ←
G34 : Gr ea s e l ev P3 l ow
Nb r of occurences
Las t hour 00003
Las t 10 hour s 00015
Tot a l h i s tor i c 01224
B a c k ←
 Safety Function:
P 1
▫
P 2
▫
O F F
▪
B a c k ←

MJFCIFSS!
 Check:
Upon entering the Check menu, the status of the analogue sensors are shown.
B 6 9 O K
B 7 1 O K
B 1 8 4 O K
B 5 0 ‐ 1 O K
B 5 0 ‐ 2 E R R
←
To represent Sensor values in mA, press and hold both "Up" and "Down" arrow buttons for more than three
seconds. This will only apply when a service or inspector dongle is plugged.
B69 1 2 mA B71 3 4 mA
B184 1 6 mA B51 1 2 mA
B50_1 2 1 mA
B50_2 1 9 mA
B150 ‐ 1 9 mA
B150 ‐ 1 9 mA ←
__________________________________________________________________________________
6. Error List
G1 : P r e s s P1 s t ay l ow
G2 : P r e s s P2 s t ay l ow
G3 : No f eedba ck P3 l i ne
G4 : No pres s dr op P1
G5 : No pres s dr op P2
G14 : L ev sensor P1 NC
G17 : L ev sensor P3 NC
G36 : P i l o t pres s l ow
G3 7 : No f eedba ck B150 ‐ 1
G3 8 : No f eedba ck B150 ‐ 2

MJFCIFSS
Operating Manual
en
Operating Manual
Centralized Lubrication Systems
R9200
Product identification
Manufacturer: SKF Lubrication Systems Germany GmbH
Type: R9200
LEC / en / Edition: 04/2017
Type no.: 410
Address
Heinrich-Hertz-Str. 2-8
69190 Walldorf - Germany
R 9200 1
Copyright © Liebherr Mining Equipment Colmar SAS 2017
MJFCIFSS!
Operating Manual
Table of Contents:
1 Guidelines --------------------------------------------------------------------------------------- 4
Explanation of symbols and signs ----------------------------------------------------------------- 5
Illustrations ---------------------------------------------------------------------------------------------- 7
Abbreviations ------------------------------------------------------------------------------------------- 7
Manufacturer and Service addresses ------------------------------------------------------------ 8
Warranty ------------------------------------------------------------------------------------------------- 8
Copyright ------------------------------------------------------------------------------------------------ 8
2 Safety information ----------------------------------------------------------------------------- 9
Disclaimer ----------------------------------------------------------------------------------------------- 9
Emergency stopping of the centralized lubrication system ---------------------------------- 9
Intended use -------------------------------------------------------------------------------------------- 9
Operation of the lubrication system or single components of it ---------------------------- 9
Foreseeable misuse ---------------------------------------------------------------------------------- 9
Unauthorised activities ----------------------------------------------------------------------------- 10
Conversions or modifications --------------------------------------------------------------------- 10
Inspections -------------------------------------------------------------------------------------------- 10
Warning labels on the centralized lubrication pump or system--------------------------- 11
Other applicable documents ---------------------------------------------------------------------- 11
Sources of hazard ----------------------------------------------------------------------------------- 11
Moving or rotating parts ---------------------------------------------------------------------------- 11
Energies ----------------------------------------------------------------------------------------------- 12
Lubricants --------------------------------------------------------------------------------------------- 12
Existing residual risks ------------------------------------------------------------------------------ 12
Persons authorized to operate the pump ------------------------------------------------------ 17
Protection of special groups of persons-------------------------------------------------------- 17
3 Safety recommendations to be complied with ---------------------------------------- 18
General behaviour when handling the system ----------------------------------------------- 18
Explosion protection -------------------------------------------------------------------------------- 18
Transport / installation / maintenance / repairs / servicing -------------------------------- 19
Laying of the lubrication lines--------------------------------------------------------------------- 21
Initial commissioning / daily start-up ------------------------------------------------------------ 22
Cleaning ----------------------------------------------------------------------------------------------- 22
4 Operator obligations ------------------------------------------------------------------------ 23
Determination of hazards -------------------------------------------------------------------------- 23
Provision of necessary information ------------------------------------------------------------- 23

Inspection for correct use-------------------------------------------------------------------------- 23
Briefing of external technicians ------------------------------------------------------------------ 23
Provision of personal protective equipment --------------------------------------------------- 23
Training courses ------------------------------------------------------------------------------------- 23
Inspection of the delivery / returns -------------------------------------------------------------- 24
5 Lubricant --------------------------------------------------------------------------------------- 25
Filling of the reservoir------------------------------------------------------------------------------- 26
2 R 9200
MJFCIFSS!
Operating Manual
Inadvertent filling with incorrect lubricant ------------------------------------------------------ 26

Inspections prior to initial start-up --------------------------------------------------------------- 26
Activation of the pump------------------------------------------------------------------------------ 27
6 Standard operation -------------------------------------------------------------------------- 28
Daily start-up ----------------------------------------------------------------------------------------- 28
Inspections -------------------------------------------------------------------------------------------- 28
Filling of the reservoir during operation -------------------------------------------------------- 28
Cleaning ----------------------------------------------------------------------------------------------- 28
7 Maintenance and repairs ------------------------------------------------------------------ 29
Safety instructions for maintenance and repairs --------------------------------------------- 29
Maintenance of the system ----------------------------------------------------------------------- 29
8 Technical data and operating instructions --------------------------------------------- 30
Operating pressure / operating temperature -------------------------------------------------- 30
Installation position, sound pressure level, weight, dimensions-------------------------- 30
Tightening torques ---------------------------------------------------------------------------------- 30
Output / connections -------------------------------------------------------------------------------- 30
Filling possibilities ----------------------------------------------------------------------------------- 30
Electrical connection (electrically driven products) ------------------------------------------ 30
Air pressure and air quality (air-operated products) ---------------------------------------- 30
9 Lubrication System: Description --------------------------------------------------------- 31
General design --------------------------------------------------------------------------------------- 31
Systems 31
Allocation of the lubrication points ----------------------------------------------------------------------------- 31
Characteristics of lubrication points on the excavator----------------------------------------------------- 33
System P1: Automatic lubrication --------------------------------------------------------------- 34
Configuration 34
Greasing cycle 36
Single-line system ------------------------------------------------------------------------------------------------- 37
Pump station 200L (R9200) ------------------------------------------------------------------------------------- 38
Electronic Controller ----------------------------------------------------------------------------------------------- 40
System P3: Swing ring and swing gear lubrication ------------------------------------------ 42
Grease cycle 42
Pump P3 - Multi-line pump type P203-15XYB -------------------------------------------------------------- 43
10 Operation -------------------------------------------------------------------------------------- 44
Greasing system – Cabin Location ------------------------------------------------------------- 44
System P1: Automatic lubrication --------------------------------------------------------------- 45

Pump P3 ----------------------------------------------------------------------------------------------- 46
11 Inspection and Maintenance -------------------------------------------------------------- 47
12 Troubleshooting ------------------------------------------------------------------------------ 48
R 9200 3
MJFCIFSS!
Operating Manual
1 Guidelines
As you read these instructions, you will notice a number of depictions and symbols which are
to facilitate the navigation and understanding of these instructions.
For reasons of better legibility, in these instructions we mainly use the male form for general
references. Of course, the female form is also always intended.
Please read these instructions thoroughly and heed the warning and safety notes. Please
observe the warning and safety notes and exercise particular caution in these cases.
Inform also other users accordingly.
Text representations Meaning
Bold print Highlighting of particularly important words or

passages
 List 1 Marks lists
o List 2 Marks lists
(parenthesis) Item numbers
 Instructions Instructions to personnel. These always

appear in chronological order.
4 R 9200
MJFCIFSS!
Operating Manual
Explanation of symbols and signs

Activities which generate actual hazards (to life and limb or possible damage to the material)
are marked by warnings. Definitely observe the instructions given in the warnings.
You will find these symbols, which warn of specific dangers to persons, material assets, or the
environment, next to all safety instructions in these operating instructions.
Please read these instructions thoroughly and heed the warning and safety notes. Please
observe the warning and safety notes and exercise particular caution in these cases.
Inform also other users accordingly.
The following warnings are possible.

Warning level Consequence Probability
DANGER Death/ serious injury imminent
WARNING Serious injury possible
CAUTION Minor injury possible
ATTENTION Property damage possible

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Symbol Meaning
General warning
Activities which generate actual hazards (to life and limb or possible
damage to the material)
Warning of suspended load
Risk of explosion
Carry out work on electrical parts only if the atmosphere is not
potentially explosive. Work has to be carried out by a specialist for
maintenance and repairs in potentially explosive atmospheres.
Electrical component hazard, electrical shock hazard

Make sure to disconnect the system or component from the power
supply before carrying out works on electrical parts.
Do not use steam jet or high pressure cleaners for cleaning. Otherwise
electrical components may be damaged. Do not touch cables or
electrical components with wet or damp hands.
Cleaning work on energized components may be carried out by

electrical specialists only.
Risk of fire
Risk of fire and explosion when using inflammable cleaning agents.
Health hazard
Hazard due to spouting lubricant / pressure injection due to a leakage

(defective fitting, too high system pressure or other damages).
Crushing hazard
Slipping hazard
Hot surfaces
Symbol Meaning
Disposal
Environmentally sound disposal and recycling
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Disposal
Environmentally sound disposal of waste electrical and electronic

equipment
Illustrations
The illustrations used refer to a specific product. In the case of other products or product
versions they may have a schematic character only. The basic function, however, does not
change.
Abbreviations
The following abbreviations may be used within these instructions:.
max. maximum Nm Newtonmeter
min. minimum incl. including
min minutes i.e. this means
s seconds rh relative humidity
etc. and so on approx. approximately
poss. possibly Ø diameter
e.g. for example ® registered

trademark
ml millilitre
© Copyright
ccm cubic cm
TM Trademark
mm millimetre
% per cent
°C degrees Celsius
dB (A) sound pressure
°F degrees Fahrenheit level
K Kelvin > greater than

inch inch < less than
etc. et cetera ± plus minus
SW width across flats
kg kilogram
ESD Electrostatic
l litre Discharge
N/A not applicable

mbar millibar
no. Number
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Manufacturer and Service addresses

Manufacturer Customer Service
SKF Lubrication Systems Germany SKF Lubrication Systems Germany GmbH

GmbH Heinrich Hertz Straße 2-8
Heinrich-Hertz-Str. 2-8 DE - 69183 Walldorf
DE - 69190 Walldorf +49 (0)6227-330
SKF Lubrication Systems Germany GmbH

2. Industriestraße 4
DE - 68766 Hockenheim
+49 (0)620527101
SKF Lubrication Systems Germany GmbH

Motzener Straße 35-37
DE - 12277 Berlin
+49 (0)30-720020
Warranty
The installation instructions do not contain any information on the warranty. This can be found
in our general terms and conditions.
Copyright
© Copyright SKF Lubrication Systems Germany GmbH. These installation instructions are
copyright-protected. All rights reserved.
The integration of the content into the manufacturer's installation instructions of the machine,
into which the pump shall be integrated, is expressly allowed.
This also includes the creation of training material for internal, non-commercial purposes. Any
other use without the written consent of the copyright holder - of whatever kind - is prohibited
and is regarded as a violation of copyright.
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2 Safety information
Safety information is to be read and observed by any persons entrusted with works on the
centralized lubrication system or by those persons who supervise or instruct the before-
mentioned group of persons.
It is prohibited to commission or operate the machine, the centralized lubrication system or

single components prior to reading the installation instructions. The installation instructions
must be kept at an accessible location for further use.
Disclaimer
Observation of these installation instructions is the prerequisite for safe operation and the
achievement of product characteristics and performance levels.
The manufacturer shall not be held responsible for damages caused by:
o non appropriate use, faulty assembly, operation, setting, maintenance, repair or accidents
o improper or late response to malfunctions
o unauthorized modifications of the product
o intent or negligence
o Use of non-original SKF spare parts.
Liability for loss or damage resulting from the use of our products is limited to the maximum
purchase price. Liability for consequential damages of whatever kind is excluded.
Emergency stopping of the centralized lubrication system

In case of an emergency stop the centralized lubrication system by:
 switching off the machine, system or vehicle, into which the SKF centralized lubrication
system or its components have been integrated.
 separating the supply of power, compressed air or hydraulic pressure (depending on the
system) to the centralized lubrication system or the corresponding components.
 actuating the emergency-off switch, if any, of the machine, system or vehicle.
Intended use
ATTENTION
All products may be used only for their intended purpose and in accordance with the
instructions.
Intended use is the use of the products to lubricate bearings and friction points with lubricants
within the physical limits that can be found in the relevant product documentation, e. g.
operating instructions and product descriptions, e. g. technical drawings and catalogues.
Operation of the lubrication system or single components of it

Operation is permitted only, if in compliance with:
 All information given in these installation instructions or stated in the referenced

documents.
 All laws and regulations to be complied with by the user.
 Properly and appropriately conducted installation of the system.
Foreseeable misuse
Any other use and purpose of the centralized lubrication system or its components than the
ones described before are strictly prohibited.
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Use is expressly forbidden:

 in a potentially explosive atmosphere, unless the centralized lubrication system or its
components are expressly suitable for it and have been approved accordingly.
 in a working environment or condition that corresponds to the required protection types
IP (International Protection) and Nema (National Electrical Manufacturers Association)
only in parts or not at all.
 to use the CLS to feed, forward, or store hazardous substances and mixtures in
accordance with annex I part 2-5 of the CLP regulation (EC 1272/2008).
 For the supply, transport, stockpiling of gases, liquefied gases, dissolved gases, vapours,
and fluids whose vapour pressure exceeds normal atmospheric pressure (1013 mbar) by
more than 0.5 bar at the maximum admissible operating temperature.
 to use the CLS to feed, forward, or store glycol- or polyglycol based oils and greases.
 to use inadmissible components or components expressly not suitable for the purpose.
Unauthorised activities
The following activities may be carried out by SKF manufacturer specialists or authorized
persons only due to potential sources of faults that may not be visible for the user, or due to
legal regulations:
 Removal, replacement or changes to the centralized lubrication system or components
integrated or connected to it.
 Changes to the control printed circuit board or the power supply board exceeding the
adjustment of lubrication and pause times or the replacement in case of defects.
 Dismantling of individual components of the centralized lubrication system.
 Changes to the power supply or to the admissible input voltage.
 Changes to the admissible or specifically required operating pressure for the supplied
centralized lubrication system.
Conversions or modifications
Unauthorized conversions or modifications may result in unforeseeable impacts on safety and
functionality. Therefore, any unauthorized reconstructions or changes are expressly
prohibited.
Inspections
The following inspections were carried out prior to delivery:
 Electrical inspections following EN 60204-1
(depending on the type of component supplied)
 Tests made in accordance with ATEX
 Safety and functional tests
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Warning labels on the centralized lubrication pump or system

Hand injury warning
During operation of the centralized lubrication system, particularly of
the pump, never remove the lid or the barrel and reach into the
reservoir or the barrel. Risk of trapping or shearing off hands and
fingers!
Electric shock
Connection of 24 V DC components must be provided by a safe
galvanic isolation PELV (Protective Extra Low Voltage) or SELV
(Safety Extra Low Voltage) always.
Other applicable documents

In addition to these installation instructions, the following documents must be observed by
the respective target group:
 Operational instructions and release provisions by the operator.
 Safety data sheet and operating instructions of the lubricant or material used. The
operator must ensure adding them to these installation instructions.
 Operating instructions and technical descriptions of the components used in the
centralized lubrication system.
 Operating instructions and technical descriptions of purchased parts.
Where appropriate:
 Project planning documents.
 Other relevant documents for the integration of the centralized lubrication system into
the superior machine or system.
The owner must supplement these documents by the respective valid national or regional
regulations laid down by the country in which the centralized lubrication system is to be used.
If the centralized lubrication system is sold or transferred, any associated documents must be
passed on to the subsequent operator as well.
Sources of hazard
The centralized lubrication system and the components used have been designed, built and
tested using state-of-the-art technology.
Depending on their version and necessity, they will have left our company only after having
passed stringent safety and reliability tests. Like for all complex machines, also for this system
there may still be involved potential sources of hazard.
Moving or rotating parts

 Drive
 Tooth wheels
 Stirring paddle
 Shovel foot
 Piston
 Guides
 Articulations
 etc.
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Energies
 Electricity
 Temperature (hot or cold surfaces)
 Position energy (raised components)
 Parts subject to pressure (operating pressure, oil pressure,

grease pressure, air pressure, etc.)
 Bursting reservoir if filled by a high-performance pump
 Parts subject to spring tension
Lubricants
 Greases
 Oils
Transport lifecycle
Residual risks Remedy
Tilting or falling of parts during Secure parts against tilting or falling during transport
transport, e.g. over inclines. (e.g. using tapes, belts, ropes, etc.).
Dropping of lifted parts or No people may remain under suspended loads. Keep
tools. unauthorized persons away.
Secure suspended loads using suitable hoisting
equipment (e.g. tapes, belts, ropes, etc.).
Existing residual risks

Installation life cycle
People slipping due to floor Take care when filling. Bind and remove leaked or
contamination with spilled spilled lubricant immediately with a suitable agent.
or leaked lubricant
Follow the operational instructions for handling

lubricants and contaminated parts.
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Installation life cycle

Deviating installation position. Installation of a suitable protective roof over the air
- Foreign objects falling into intake.
the motor air intake or into
other components.
- Borehole for drainage of
Deviating installation position only, if the formation of
condensation water is no
condensation water has been completed. Remove
longer at the lowest point of
condensation with suitable suction device.
the motor.
Tearing or damaging of lines If possible, do not mount onto movable parts. Should
when installed on moving this not be possible, use flexible hose lines of sufficient
machine parts (e.g. pivot arm). length.
Tearing or damaging of lines Use protective pipes or spring coils.

due to installation on chafing
points or installation with too
little bending radius
Falling of parts due to Fix parts only to machine parts with sufficient load
insufficient fixing to the capacity. Observe the weight and the stated tightening
machine. torques.
If no tightening torques are stated, the tightening

torques are to be applied to the screw size for 8.8
screws.
 Literature, see screw manufacturer.

Electric shock through Check the formation of condensation water in the
reduced insulation resistance. motor regularly.
If applicable, drain off condensation water at the drain

plug. Check the insulation resistance regularly.
Electric shock when Prior to connection of electrical components (pump,
connecting the pump. switch cabinet, valves, etc.) de-energize all affected
electrical components. If necessary, please observe
discharge times. The electrical connection may be
carried out by commissioned and qualified electricians
only and in accordance with the connection diagram.
Life cycle - commissioning


Electrical shock due to Before installation and start-up check all cables with
defective connection cable regard to possible damages.
In case of damage, properly replace affected cable.
Immediately switch off the centralized lubrication

system.
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Life cycle - commissioning

Lubricant spraying out due to Tighten all parts with appropriate tightening torques.
incorrect screw connection of Use suitable hydraulic screw connections and lines for
components or lines. the stated pressures.
Check these prior to commissioning for correct

connection and damage.
Contact with corrosive or Wear protective clothes.

toxic substances that may be
set free by a defective
battery.
Ensure sufficient ventilation. Storage and disposal of
defective batteries in accordance with the
corresponding safety data sheets for lithium.
People slipping due to floor Take care when filling. Bind and remove leaked or
contamination with spilled or spilled lubricant immediately with a suitable agent.
leaked lubricant.
Observe the legal or company regulations on dealing

with oils and greases and contaminated parts.
Falling of parts due to Fix parts only to machine parts with sufficient load
insufficient fixing to the capacity. Observe the weight and the stated tightening
machine. torques.
If no tightening torques are stated, the tightening

torques are to be applied to the screw size for 8.8
screws.
 Literature, see screw manufacturer.
Bursting reservoir if filled by a Monitor the filling procedure and stop it when reaching
high-performance pump the max marking of the reservoir
Contact with stirring paddle or Always operate pump with lubricant reservoir or barrel.
shovel foot during "test Do not reach into the stirring paddle, the drive or the
operation" without lubricant supply piston.
reservoir or barrel
Tearing or damaging of lines If possible, do not mount on moveable parts.

when installed on moving
machine parts (e.g. pivot arm).
Should this not be possible, use flexible hose lines of
sufficient lengths.
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Life cycle - operation, maintenance, repair

Contact to the shovel foot Change barrel only with the centralized lubrication
during change of barrel of a system and pump being de-pressurized.
pneumatic, hydraulic or
electric barrel pump. Switch off the pump before changing the barrel and
relieve existing system pressure.
Contact with the stirring Fill preferably via the filling connection.
paddle when filling a reservoir
pump from the top during Filling from the top or changing of barrel in case of
pump operation. barrel pumps only while the pump is idle.
When filling, do not reach into the reservoir.
Electrical shock due to Switch off the centralized lubrication system and
defective connection cable check connection cable for damage.
People slipping due to floor Exercise caution when connecting the system.
contamination with spilled or
leaked lubricant Promptly apply suitable binding agents to remove the
leaked or spilled lubricant.

Tearing or damaging of lines Switch of the centralized lubrication system, check the
routing of the hose lines and optimize or replace
defective hose or line, if necessary.
Should this not be possible, use flexible hose lines of

sufficient lengths.
Fault lifecycle
Too strong heating up of the Switch off the pump and system. Let parts cool down,
motor or other electrical eliminate cause. Replace defective motor or other
components. defective components.
Too strong heating up of Switch of the system or the affected component.

hydraulically driven
components
Ensure proper functioning of the oil cooler.
Strong cooling down and Check the compressor and the drier of the
formation of ice on sound compressed air supply. Reduce the operating speed
absorber and air leakage on of the affected pump.
pneumatically driven pumps
or other components
Shortly switch off the system or heat it, if necessary.
Inadmissible lubricant Switch off the centralized lubrication system and

leakage on components or determine cause. Replace defective lines or
lubricant lines of the components.
centralized lubrication system
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Fault lifecycle
Lubricant spraying out due to Tighten all parts with appropriate tightening torques.
incorrect screw connection of Use suitable hydraulic screw connections and lines for
components or lines. the stated pressures.
Check these prior to commissioning for correct

connection and damage.
Disposal lifecycle
Contamination of the Dispose of the parts following the valid legal and
environment with lubricant company regulations.
and wetted parts
People slipping due to floor Exercise caution when disconnecting the lines.
contamination with spilled or
leaked lubricant. Promptly apply suitable binding agents to remove the
leaked or spilled lubricant.

Contamination of the Dispose of used batteries following the valid legal and
environment due to used company regulations.
batteries on control printed
circuit boards Until disposal, store used battery, e.g. in a closed
polyethylene bag , in order to avoid any damages.
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Persons authorized to operate the pump

Only qualified technical personnel may install, operate, maintain, and repair the products
described in this document. The core principles of these country-specific qualification
requirements for technical personnel cannot be below those of the two standards mentioned
above.
Operator
A person who is qualified by training and experience to carry out the functions and activities
related to normal operation.
This includes avoiding possible hazards that may arise during pump operation.
Specialist for maintenance and repairs

Qualified technical personnel are persons who have been trained, assigned, and instructed by
the operator of the final product. Such persons are familiar with the relevant standards, rules,
accident prevention regulations, and assembly conditions as a result of their training,
experience, and instruction.
They are qualified to carry out the required activities and in doing so recognize and avoid any
potential hazards.
Specialist in electrics
The definition of qualified personnel and the prohibition against employing non-qualified
personnel are laid down in DIN VDE 0105 and IEC 364. Relevant country-specific definitions
of qualified technical personnel apply for countries outside the scope of DIN VDE 0105 or IEC
364.
Protection of special groups of persons

The respective legal employment restrictions do apply.
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3 Safety recommendations to be complied with

General behaviour when handling the system
 The centralized lubrication system, pump or single components may be used only in
awareness of the potential dangers, in proper technical condition, and according to the
information in these installation instructions.
 Familiarize yourself with the functions and operation of the product. The specified
assembly and operating steps and their sequences must be observed.
 Any unclear points regarding proper condition or correct assembly/ operation must be
clarified. Operation is prohibited until issues have been clarified.
 Keep unauthorized persons away from the centralized lubrication system.
 Precautionary operational measures and instructions for the respective work must be
observed.
 Responsibilities for different activities must be clearly defined and observed. Uncertainty
seriously endangers safety.
 Safety-related protective and emergency devices must not be removed, modified or
affected otherwise in their function and are to be checked at regular intervals for
completeness and function.
 Remedy occurring faults in the frame of responsibilities. Immediately inform your
superior in the case of faults beyond your competence.
 Do not reach into the system during operation.
 Wear personal protective equipment always.
 When handling lubricants observe the relevant safety data sheets and operating
instructions by the lubricant manufacturer or supplier.
 Never use parts of the centralized lubrication system or of the machine as standing or
climbing aids.
Explosion protection
 Always behave so that fire and explosion hazards are avoided.
 A written work approval from the operator is required prior to working in potentially
explosive areas.
 There must be no indications that parts of the explosion protection are missing or are
not working. Should such indications become apparent, switch off the machine and
inform a superior without delay. Keep unauthorized persons away.
 Measures for explosion protection must never be deactivated, modified or bypassed.
 It is forbidden to bring in ignition sources such as sparks, open flames and hot surfaces
in potentially explosive areas.
 Check the machine at regular intervals for damage which may represent an ignition risk.
 The ignition temperature of the lubricant must lie at least 50 K over the maximum
admissible surface temperature of the components.
 Only use tools and clothing which are permitted for use in potentially explosive areas
(ESD).
 Transport, installation, repairs and work on electrical components may only be carried
out, if it has been ensured that the atmosphere is not potentially explosive.
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 Repairs or modifications to machines which are protected against explosions may be

carried out only by the manufacturer or by a workshop recognized by a named
institution and confirmed in writing.
If the work is not carried out by the manufacturer, the repairs must be approved by a
named expert and confirmed in writing. The repairs are to be marked by a repair sign on
the machine, stating the following:
o Date
o Executing company
o Type of repair
o If applicable, expert's code
 Transport damages can result in the loss of the explosion protection. If transport
damages can be seen, do not assemble the machine or put it into operation
 All parts of the earthing concept must be correctly available and connected with the
superordinate machine.
 If transport lugs are dismantled after set-up, the threaded bores must be permanently
sealed in accordance with the protection class.
 Handle the materials so that no sparks are generated by tilting, falling, sliding, rubbing,
impacting, etc. If needed, cover materials with suitable means.
 Never disconnect plug-in connections when energized. Secure plug-in connections

against inadvertent manual disconnection with the safety clips included in the delivery.
 The operator must check critically whether operation without a low-level signal might
lead to a new risk potential (e.g. through heat-up of bearing points on the machine in the
area of ignition temperature, poor lubrication or bearing damage). If this cannot be
ascertained, provide a low-level signal or suitable organisational measures for
monitoring of the bearing point temperature.
 Avoid dust accumulation and remove dust immediately. Dust accumulations have a
thermally insulating effect and, if whirled up, generate the formation of a potentially
explosive atmosphere.
 The pump should be integrated into the operator's lightning protection concept.
 All parts are to be checked regularly for corrosion. Replace the affected parts.
 Terminal boxes must be firmly closed and the cable breakthroughs correctly sealed.
 Additional electrical monitoring devices must be firmly connected and correctly adjusted.
 Protect the motor with a motor circuit breaker against inadmissible heating up. When
reaching their nominal life, the motor bearings have to be replaced or inspected to ensure
their suitability for further utilisation.
Transport / installation / maintenance / repairs / servicing

 All relevant persons (e.g., operating personnel, supervisors) must be informed of the
respective activity prior to starting any work. Observe the precautionary operational
measures and work instructions.
 If protective and safety equipment has to be dismantled, it must be reassembled

immediately after finishing the work, and then checked for correct function.
 Ensure through suitable measures that movable or detached parts are immobilized during
the work and that no limbs can be caught in between by inadvertent movements.
 Carry out transport using only suitable hoisting equipment.
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 If transported separately (e. g. repair) lift the motor by means of the transport lugs or eye
bolts. Ensure that transport lugs or eye bolts are firmly seated. Do not carry any further
load on the transport lugs or eye bolts. Do not transport motors on the fan cover.
 Assemble the pumps and other components only outside of the operating range of moving
parts, at an adequate distance from sources of heat or cold.
 Dry wet, slippery surfaces.
 Cover hot or cold surfaces accordingly.
 Prior to performing work, de-energize and depressurize the pump and secure it against
unauthorized switch-on. Work on electrical components must be carried out by electrical
specialists only. Observe any waiting periods for discharging, if necessary.
 Carry out electrical connections only according to the information in the valid wiring
diagram and taking into account the relevant regulations, the local connection conditions
and legal prescriptions (e.g. DIN, VDE). Electrical connections must be done in such way
that no forces are transferred to the product (tension-free connection).
 Do not touch cables or electrical components with wet or damp hands.
 Maintenance and repair work can be subject to restrictions at low or high temperatures
(e.g. changed flow properties of the lubricant). Therefore, where possible, try to carry out
maintenance and repair work at room temperature.
 Carry out all works on electrical components using adequate, voltage insulated and
technically proper tools only.
 Fuses must never be bridged but have to be replaced by the same type of fuse always.
Determine the cause of the failure of the fuse.
 Ensure correct earthing of the electrical system.
 Undertake drilling at non-critical, non-load bearing parts only. Use any available
boreholes. Do not damage lines and cables when drilling. It is essential to observe the
machine manufacturer's installation instructions and to consult the machine designer in
case of doubts.
 Observe possible abrasion points. Protect the parts accordingly.
 Other units of the machine or vehicle must not be damaged or impaired in their function
by the installation of the centralized lubrication system.
 All components used must be designed for:

o maximum operating pressure
o lubricant to be supplied
o maximum/ minimum temperature
o corresponding supply voltage available on site
o operating and ambient conditions at the location of use

o required lubricant volume
 Parts of the centralized lubrication system must never be subjected to torsion, shearing
or bending.
 Check all parts prior to use for contamination and clean, if necessary. Lubricant lines
should be primed with lubricant prior to installation. This makes the subsequent ventilation
and commissioning of the system easier.
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 Observe the specified tightening torques. When tightening, use a calibrated torque
wrench.
 When working with heavy parts use suitable lifting tools. If need be, consult the
responsible safety officer.
 Avoid mixing up or wrong assembly of dismantled parts. Mark these parts accordingly.
Laying of the lubrication lines

When laying the lubrication lines, observe the following information in order to warrant trouble-
free function of the entire centralized lubrication system.
CAUTION
Environmental pollution
Lubrication lines must be absolutely leakproof. Lubricants may pollute ground
and waters. Lubricants have to be handled and disposed of properly. Observe all
applicable prescriptions and laws regarding disposal of lubricants as well as the
relevant safety data sheets.
Slipping hazard
Centralized lubrication systems must be absolutely leakproof. Leaking lubricant
is hazardous due to the risk of slipping and injury. During assembly, operation,
maintenance and repair of centralized lubrication systems watch out for leaking
lubricant. Leaks must be sealed immediately.
 Dimension the lubrication line according to the maximum pressure and the output volume
of the pump unit used.
 Starting from the pump unit the main lubrication line should be laid preferably rising with
a possibility to vent it at the highest point of the lubrication line system.
 Mount the lubricant metering devices at the end of the main lubrication line in such way
that the outlets of the lubricant metering devices show upwards. If lubricant metering
devices have to be mounted below the main lubrication line, then this should not be done
at the end of the main lubrication line.
 The tube lines, hoses, shut-off and way valves, fittings, etc. have to be laid out according
to the maximum operating pressure of the pump unit, the admissible temperatures and
the lubricants to be supplied. Furthermore, the lubrication line system must be protected
against inadmissibly high pressure.
 Before the assembly thoroughly clean all components of the lubrication line system like
tube lines, hoses, shut-off and way valves, fittings, etc. In the lubrication line system no
seals should protrude towards the inside, as the lubricant flow could be impeded and
contaminations could enter the lubrication line system.
 Lubrication lines shall generally be laid in such way that there can never be created air
pockets at any point. Avoid changing the cross sections of the lubrication line from smaller
to larger cross sections in the lubricant flow direction. Design cross section transitions as
smooth as possible.
 The lubricant flow in the lubrication lines should not be impeded by the installation of
sharp elbows, angle valves and check valves. Provide unavoidable changes of the cross
sections in the lubrication lines with as smooth transitions as possible. Avoid sudden
changes of direction, if possible.
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Initial commissioning / daily start-up

Ensure that:
 The machine manufacturer's instructions regarding the lubricants to be used are
observed.
 All safety devices are completely available and functional.
 All connections are correctly connected.
 All parts are correctly installed.
 All warning labels on the centralized lubrication system are completely
available, highly visible and undamaged.
 Illegible or missing warning labels are to be replaced without delay.
 The system pressure specified for proper operation is adhered to and neither exceeding
nor falling below specification.
Cleaning
 Risk of fire and explosion when using inflammable cleaning agents. Only use non-
flammable cleaning agents suitable for the purpose.
 Do not use any aggressive cleaning agents.
 Do not use steam jet or high pressure cleaners. Otherwise electrical components may be
damaged. Observe the protection classes, e.g. IP (International Protection) and NEMA
(National Electrical Manufacturers Association), required for proper operation.
 Cleaning work on energized components may be carried out by electrical specialists
only.
 Do not touch cables or electrical components with wet or damp hands.
 Mark damp areas accordingly.
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4 Operator obligations
Determination of hazards
The operator must determine all hazards resulting from the integration of the pump into the
superordinate machine and the hazards at the location of operation of the machine, and
carry out the measures necessary to ensure safety and health protection.
Provision of necessary information

The operator must make the installation instructions required for the respective activity
accessible to all people commissioned with operation, maintenance and repairs.
He must ensure that these people have read and understood the necessary installation
instructions.
The same applies for all relevant safety data sheets, company instructions, accident
prevention regulations, instructions from suppliers of purchase parts and utilities.
Depending on the business organization, the relevant installation instructions may have to be
made accessible to other people and departments.
Inspection for correct use

The operator must check at regular intervals through suitable measures that the centralized
lubrication system is being used according to its intended purpose, that no conversions or
manipulations have been made to the centralized lubrication system or to single components
and that all parts are fully functional.
Briefing of external technicians

Prior to commencing the activities, external technicians must be informed by the operator of
the company safety provisions, the applicable accident prevention regulations to be
maintained, and the functions of the centralized lubrication system and protective devices.
Provision of personal protective equipment

The operator must provide suitable personal protective equipment for the respective location
of operation and the purpose of operation.
Training courses
In order to provide a maximum of safety and economic viability, SKF carries out detailed
product training courses. It is recommended that the training courses are attended. Please
contact SKF Customer Service for information.
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Inspection of the delivery / returns

The delivery must be inspected for completeness based on the delivery papers. Transport
damages must be reported to the forwarder immediately. Keep the packaging material until
any discrepancies are resolved.
Returns
Clean all parts and pack them properly, i.e. following the regulations of the recipient country,
before returning them. Mark returns on the packaging as follows;
Do not burden / this side up!

Protect against moisture!
Handle with care!
Fragile, do not throw!
Disposal
At the end of their service life, the

centralized lubrication system and its
components must be dismantled and
disposed of according to the respective
valid provisions in an environmentally
friendly manner. It is forbidden to use parts of a
centralized lubrication system that is to be disposed
of or to assemble these parts to build a new system.
In case of a final shutdown follow the applicable rules and regulations on the disposal of
contaminated parts or means of operation. The product can also be returned to SKF for proper
disposal, in which case the customer is responsible for reimbursing the costs incurred. The
parts are recyclable.
CAUTION
Lubricants may pollute ground and waters. Lubricants have to be handled and
disposed of properly.
Observe the instructions by the machine manufacturer regarding the lubricants to be

used.
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5 Lubricant
For lubricant information, refer to chapter 5.3 “Lubricants and operating fluids” of the Liebherr
Operating Manual
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Filling of the reservoir
WARNING
Risk of hand injuries caused by the stirring paddle or shovel foot
 Fill lubricant via the lid only when pump is idle. Never reach into
the reservoir or grease barrel while the pump is running.
Inadvertent filling with incorrect lubricant

Should incorrect lubricant have been filled, please proceed as follows:
 Switch off the pump or centralized lubrication system and secure it against being
switched on.
 Remove lubricant.
 Clean the entire centralized lubrication system (lubricant reservoir, pump housing,
metering devices and line systems).
 Fill in lubricant of correct specification.
 Switch the system or pump on.
 Vent lubrication system.
 Inform your superior to ensure that the error won't occur again.
Inspections prior to initial start-up

ATTENTION
Risk of damage to the machine

Fill the feed lines and bearing housings with lubricant to specification and lubricate the
lubrication points by hand. Otherwise the bearing points may become damaged due to
a lack of lubricant.
Check the entire system for accordance with the intended purpose and the planning
documentation. Ensure that all parameters, characteristic values and means of
operation are present and have been correctly adjusted. If deviations are detected,
they must be remedied without delay.
In order to warrant safety and function, a person assigned by the operator must inspect certain
areas of the central lubrication system prior to initial commissioning. Report any detected
deficiencies immediately to your superior and remedy them. Deficiencies may be remedied by
an authorized and qualified specialist only.
Check the following points prior to initial commissioning.

Electrics:
 Electrical connections carried out correctly.
 Cable entries sealed correctly.
 The voltage and frequency of the power network correspond to the information on the
type identification plate of the motor.
 Monitoring devices and additional equipment (e.g. motor circuit breaker) are correctly
connected and adjusted.
 All parts such as lines, cables, metering devices, etc. have been correctly installed and
are undamaged.
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Mechanics:
 No loose or missing parts remaining (e.g. pressure relief valves, feed lines).
 No damages, deformations, cracks, burnt and smoky points.
 No discolorations, contaminations and/or corrosion.
 No unusual humidity accumulations, odours, vibrations, or sounds.
 No leakages of lubricant at connections and from lines.
Activation of the pump

Depending on the version the centralized lubrication system or pump is activated:
 By installing it into a machine
 By switching on the machine contact
 By a control provided by the customer
 By manual activation
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6 Standard operation
Daily start-up
Below find the activities to be carried out in case of standard operation.
Inspections
With regard to the actions listed below "Inspections prior to commissioning" the operator has
to determine adequate control intervals depending on the respective operating situation of the
pump or centralized lubrication system.
Filling of the reservoir during operation

Fill the reservoir as described in chapter "Installation and commissioning".
Cleaning
Execution, required protective clothes, cleaning agents and devices following the valid
operational regulations of the operator.
DANGER
Danger to life
Risk of fire and explosion when using inflammable cleaning agents.
Do not use steam jet or high pressure cleaners. Electrical components
may be damaged. Do not touch cables or electrical components with
wet or damp hands. Cleaning work on energized components may be
carried out by electrical specialists only. Wear personal protective
equipment always.
Exterior cleaning
 Thorough cleaning of all surfaces.
 Mark and secure wet areas.
Interior cleaning
 Normally, interior cleaning is not required.
ATTENTION
Risk of damage to the machine
If using solvents for cleaning, ensure compatibility with plastic parts and painting. Do not
use polar organic solvents such as alcohol, methanol or acetone.
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7 Maintenance and repairs

Safety instructions for maintenance and repairs
WARNING
Electric shock
Make sure to disconnect the pump from the power supply before
carrying out works on electrical parts.
Risk of injury
Before carrying out any maintenance or repair work, take at least the
following safety measures:
o Keep unauthorized persons away.
o Mark and secure work area.
o Depressurize the product.
o Disconnect the product from the power supply and secure it
against being switched on.
o Verify that no power is being applied.
o Earth and short-circuit the product.
o Where needed, cover neighbouring units that are live.
Maintenance of the system

Depending on the version our centralized lubrication systems require virtually no maintenance.
However, the following parts should be inspected and, if necessary, replaced by new parts at
regular intervals:
 Pressure relief valves
 Check valves
 Pump elements
Pressure relief valve tolerance +5 %/ -10 %

If this tolerance is exceeded, the pressure relief valves must be replaced.
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8 Technical data and operating instructions

Operating pressure / operating temperature
All system components must be designed for the maximum operating pressure and must be
secured by an adequate pressure relief valve against too high system pressures. For details
see operating or installation instructions and data sheets of the respective product.
Installation position, sound pressure level, weight, dimensions

For details see operating or installation instructions and data sheets of the respective
product.
Tightening torques
product.
Output / connections
For details see operating or installation instructions and data sheets of the respective product.
Deviating conditions such as NLGI class, temperature and counter pressure may lead to a
deviation in the flow rate. This should be taken into account when designing the lubrication
points.
Filling possibilities
product.
Electrical connection (electrically driven products)

Following the respective applicable installation prescriptions for electrical systems. For
details see operating or installation instructions and data sheets of the respective product.
IP type of protection
Motor and system:
For IP or NEMA protective class see type identification plate of motor or system respectively
the Technical Data chapter of the individual components. For details see operating or
installation instructions and data sheets of the respective product.
Air pressure and air quality (air-operated products)

Filtered and oiled air according to DIN ISO 8573-1 not higher than class 5
Inlet air pressure 5.5 – 7 bar
Maximum particle density 10 mg / m3
Water content (pressure dew point) + 7 °C
Oil content (maximum oil concentration) 25 mg / m3

Please follow the instructions of the respective product.
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9 Lubrication System: Description

General design
Systems
The lubrication system of the R9200 excavator which provide lubricant to the lubrication points are
supplied by two independent centralized lubrication systems:
 System P1, to lubricate the swing gear bearing and the attachment bushes (and options)
 System P3, to lubricate the swing ring teeth and the swing gear centering seat
Allocation of the lubrication points

The lubrication points of the R9200 excavator described below are dispatched as follows:
Backhoe attachment:
Fig. 1 Position of lubrication points

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Shovel attachment:
Fig. 2 Position of lubrication points
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Characteristics of lubrication points on the excavator
All the necessary information regarding the greasing points and quantities are available in chapter 21
of the Liebherr Service Manual.
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System P1: Automatic lubrication

In the automatic system, a central lubrication pump provides lubricant to each lubrication point through
a single line via injectors model LM5 and subsequent metering devices model SSV.
Configuration
Injector model LM5 supplies lubricant to the progressive metering devices model SSV which distributes
the lubricant to each lubrication point evenly. A control unit commands and monitors the entire system.
Legend:
Equipment:
Uppercarriage:
Fig. 3 Automatically operated single-line system with LM5 and subsequent progressive divider
valve for backhoe attachment
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Fig. 4 Automatically operated single-line system with LM5 and subsequent progressive divider
valve for shovel attachment
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Greasing cycle
When the pause time has lapsed, the pump starts operating and supplies the lubricant via the main
line to the LM5 injectors. The pistons inside the injectors are operated via lubricant pressure. A pre-
metered amount of lubricant is dispensed to the connected SSV.
After all injectors have operated, the pressure in the main line rises until the preset pressure on the
pump is reached 240 bar. The control unit stops the pump via the pressure switch B69. The pump
stops running and the relief valve is deactivated at the same time. The compressed lubricant in the
main line can flow back into the reservoir, the pressure drops. When the pressure has fallen below 80
bar the pistons inside the LM5 injectors return to their initial positions by means of spring force and
reload the adjustable amount of lubricant by this action.
The pause time can start and the system is now ready for another lubrication cycle.
Fig. 5 Cycle: Equipment and uppercarriage
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Single-line system
The single-line system consists of a pump to supply lubricant under pressure to the injector metering
devices via the supply line. The injector metering devices deliver lubricant to a secondary
(progressive) metering device or to the bearing through feed lines.
The lubrication cycle is initiated by an automated pump. The injectors have indicator stems, which
move in and out to indicate that they have been cycled.
A controller will control the automated system.
The time between on cycles and the length of off cycles is adjustable. The controller includes the
timer function above with a monitor function and alarm capability. A pressure switch is used to
indicate when system pressure has been reached to turn off the pump and verify that a lube cycle
has been completed. If the pressure switch does not detect full pressure within a preset period of
time, the controller goes into alarm state.
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Pump station 200L (R9200)

1 Solenoid Y34_1 (pump
control)
2 Hydaulic relief (vent) valve
3 Grease reservoir 200L for
FlowMaster II-pump
4 Lubricant filter, refilling
5 Check valve
6 Filtering unit
Central lubrication pump 200L (complete view)
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7 Overflow pipe
8 Level sensor
9 High-level sensor
10 Pressure switch
11 Dip stick (grease reservoir)
12 Dip stick (pump gear)
13 Pump P1 – Model
FlowMaster II
Central lubrication pump 200L (top)
For information and descriptions of the components, refer to chapter 13.

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Electronic Controller
For more details:
 Operating elements
 Functions
Refer to Manual 93EN-98002-A11_OpInst_LIEBHERR-LFR_Mining_664-36957-7_...
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Fault signals
Each time a fault arises, an acoustic signal will be given by the controller (buzzer) and the two
flashing lights on the pump stations will be activated. Buzzer and flashing lights can be deactivated
by pressing the ENTER key.
In two cases this will not be possible:
- very low grease level in the barrel (LL)

- both sensors for monitoring the lubrication of the slewing rim are defective
In these cases, buzzer and flashing lights will be deactivated when switching off the motor, however,
will be activated again when starting the motor.
Adjusted values
For service personnel with PC, corresponding software and authorization:
adjustable max. value
adjustable min. value
adjusted value
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System P3: Swing ring and swing gear lubrication

In the automatic system P3, the central lubrication pump provides lubricant to the Progressive Metering
Device (Progressive System) which distributes the lubricant to each lubrication point evenly (swing
ring teeth and the swing gear centering seat).
Fig. 6 Schematic of lubrication: Swing ring teeth and swing box centering
Grease cycle
Fig. 7 Grease cycle
When the pause time has lapsed, the pump P3 supplies lubricant to the connected progressive
metering device. A progressive metering device type SSV 6 is provided with the proximity switch B51
for control and monitoring purposes. After three cycles of the SSV 6, which correspond to a full
lubrication cycle, the pump P3 is switched off thanks to the proximity switch B51.
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Pump P3 - Multi-line pump type P203-15XYB
1 Reservoir 15 liters
2 Level sensor
3 High level sensor “Full”
4 Overflow pipe
5 Pump housing with integrated motor
Fig. 8 P203-15XYB
The pump is a compact multiline pump consisting of the following components:
· Reservoir with stirring paddle

· Printed circuit board
· Pump element
· Pressure relief valve
· Filling nipple
· Electrical connection parts
· Operates according to lubrication cycles (pause and operating times)
· Designed for the delivery of greases up to NLGI 2
· Can be used at low temperatures down to -40 °C.
· During the operating time the pump dispenses lubricant to the connected lubrication points
via one device.
Number of outlets: 1
Piston diameter: 7 mm
Lubricant output: approx. 4 cm³/min
Reservoir capacity: 15 liters
For more details:
 Description
 Mode of operation
 Maintenance
 Troubleshooting
 Technical data
Refer to Technical Description: 21EN-30001-xxx; 20EN-20003-xxx; 26A-20003-xxx
For information and descriptions of the components, refer to chapter 13.
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10 Operation
Greasing system – Cabin Location
Fig. 9 Cabin location
For more details:
 Information regarding the operation of the control unit are available in the respective manual.
Refer to Data Sheet 93EN-98002-xxx for the Electronic Controller
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System P1: Automatic lubrication
CAUTION!
Operation by authorized and instructed personnel only!

Never exceed the admissible system pressures!
Refill clean lubricant on time!
CAUTION!
Do not interrupt the power supply (main switch of battery) while the pump is
operating.
When starting the excavator, the centralized lubrication systems are connected to the power supply
automatically. Each lubrication pump then starts a full lubrication cycle and is stopped during the preset
pause time only, etc.
The pump P1 delivers lubricant via a single-line system to the lubrication points according to Chapter
9.2 Configuration.
Regarding the control and monitoring of the system refer to: Chapter 9.2. Cabin greasing module U4-
1 or Electronic Controller
If required, the operator can force the greasing cycle: for details refer to the respective data sheets.
See the characteristics of each lubrication points: Characteristics of lubrication points on the excavator.
For more details:
 Chapter 9.2 Greasing cycle

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Pump P3
CAUTION!
Operation by authorized and instructed personnel only!

Never exceed the admissible system pressures!
Refill clean lubricant on time!
CAUTION!
Do not interrupt the power supply (main switch of battery) while the pump is
operating.
When starting the excavator, the centralized lubrication systems are connected to the power supply
automatically. The lubrication pump starts a full lubrication cycle and stops during the preset pause
time only, etc.
The pause time is factory-set to 6 minutes.
In normal working condition, no actions are required from the operator.
The only useful information is the low level quantity of the pump P3 reservoir.
If required, the operator can force the greasing cycle: for details refer to the respective data sheets.
NOTE!
DAILY: DO A VISUAL CHECK OF THE RESERVOIR FOR GREASE LEVEL
For more details:
 Chapter 9.3 Greasing cycle
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11 Inspection and Maintenance

DANGER!
DANGER!
– Do not carry out any repair works while the system is pressurized
– Grease: Relieve system from pressure by carefully opening a fitting
and/or the manual vent valve(s) if installed (option)
– Hydraulic Oil: Relieve hydraulic system from pressure as described in
the Operator Manual
– Warning: Lubricant may spurt out while system is under pressure.
NOTE!
Regular inspection and maintenance intervals are prerequisites for the

proper functioning of the centralized lubrication system over a longer
period of time. Any claim for warranty or liability will be null and void, if the
prescribed maintenance intervals are not adhered to.
Please observe the following regular inspections and maintenance works:
Daily:
 Visually check the lubrication points with regard to leaking lubricant

 Visually check the hose connections with regard to leaks and abrasions
 Check movement of indicator pins: During the lubrication time the pins have to retract, in the
pause time all pins have to be extracted.
Weekly:
 Visually check of tube fittings with regard to leaks

 Determine the time required for one lubrication cycle. If the determined time deviates much
from the usual lubrication time, check each single component (pumps, metering devices, tube
lines).
Every 1000 operating hours:
 Clean or replace strainer assembly

 Clean or replace lubricant filter (refilling)
 Check the oil level in the crankcase of the pump model FlowMaster (if applicable) at the dip
stick
Every 2000 operating hours:
 Change the oil in the crankcase of the pump model FlowMaster.

Use SAE 10W30 motor oil in all units used in an ambient temperature between –40° to 65°C.
For ambient temperatures between 10° to 21°C uses Mobil Aero HFA low temperature oil.
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12 Troubleshooting
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
Injectors leaky or worn See Troubleshooting: Injectors
Malfunction: No pressure relief or too slow pressure relief in the main line (automatic
option only)
Cause: Remedy:
Pressure control device faulty Replace pressure control device, check electric
cable
Hydraulic vent valve faulty Replace valve, check fluid supply
Grease too hard or not suitable for low Change lubricant

temperatures
Motor of pump does not run
Possible cause Visible Remedy
Fault in the superior No pump noise Check the electrical lines

machine or external control and the external control unit
unit.
Check the motor circuit

Motor circuit breaker has breaker
tripped
Motor runs, but pump does not supply lubricant
Possible cause Visible Remedy
Reservoir empty Visual check Refill

Air pockets in the lubricant Air bubbles in the lubricant Vent
Suction bore of pump After disassembling the Disassemble and clean the
element is clogged. pump element pump elements.
Defective or dirty system After disassembly of the

Replace check valve.
check valve check valve
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Check pump element and

Worn pump element Little pressurization
replace, if necessary.
Defective pressure relief Determine cause.

Lubricant leaking from the
valve or fault at the Replace pressure relief
pressure relief valve
lubrication point valve
Blockade in the
Grease leaking from the Determine cause and
downstream lubrication
pressure relief valve eliminate it.
system
If the fault cannot be determined and remedied, contact our Customer Service.
Please follow the instructions of the respective product.
For more details:
 Regarding error codes (fault indications)
Refer to 4.4DE_EN-68610-xxx
or
Refer to 93EN-98002-xxx
Fault indications (error codes)

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Conversion factors
Pressure: 1 bar = 14.5 PSI
1 PSI = 0.0690 bar
Length: 1 mm = 0.03937 inch

1 cm = 0.3937 inch
1 m = 39.37 inch
1 inch = 25.40 mm
1 foot = 0.3048 m
Volume: 1 liter = 0.2642 US gallon

1 liter = 2.113 pint
1 liter = 1.057 quart
1 US gallon = 3.785 liter
1 cm3 = 0.06102 cubic inch
1 m3 = 1.3079 cubic yard
Torque: 1 Kpm = 7.23 ft.lbs

1 Nm = 0.7375 ft.lbs
1 ft.lbs = 0.138 Kpm
1 ft.lbs = 1.358 Nm
Weight: 1 kg = 2.2046 lbs

1 metric ton = 1.102 short ton
1 metric ton = 2204.6 lbs
1 lbs = 0.4536 kg
1 lbs = 0.000454 metric ton
Temperature: Temp (°F) = Temp (°C) x 1.8 + 32

Temp (°C) = [Temp(°F) - 32] / 1.8
0 °C =32 °F
100 °C = 212 °F
MJFCIFSS

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from serial number 40001

copyright © Liebherr-Mining Equipment Colmar SAS 2017

Vehicle ident. number:

copyright © Liebherr-Mining Equipment Colmar SAS 2017

copyright © Liebherr-Mining Equipment Colmar SAS 2017

Modifications, conditions, copyright

copyright © Liebherr-Mining Equipment Colmar SAS 2017

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

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

3.3.2 Starting aids (optional) ........................................................................................................... 3-78

copyright © Liebherr-Mining Equipment Colmar SAS 2017

3.5 General working methods .................................................................................................................. 3-122

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

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

5.6 Diesel engine ....................................................................................................................................... 5-39

copyright © Liebherr-Mining Equipment Colmar SAS 2017

5.7.2 Elastic bedding ....................................................................................................................... 5-48

5.14.1 Notes on the electrical system ............................................................................................. 5-108

copyright © Liebherr-Mining Equipment Colmar SAS 2017

5.15.5 Additional cab heater (optional) ............................................................................................ 5-122

6.2.7 Cooling pumps circuit ............................................................................................................. 6-20

copyright © Liebherr-Mining Equipment Colmar SAS 2017

1.1 Assembly - overview

1.1.1 Machine and construction equipment

Fig. 1-1 Machine and construction equipment

copyright © Liebherr-Mining Equipment Colmar SAS 2017

100 Uppercarriage 320 Hydraulic cylinder

Fig. 1-2 Uppercarriage

20 Swing gear installation 80 Covering

copyright © Liebherr-Mining Equipment Colmar SAS 2017

75 Rotating deck 125 Emergency ladder

Fig. 1-3 Undercarriage

208 Idler 1000 Rotary connection

1.2 Vibration emissions

copyright © Liebherr-Mining Equipment Colmar SAS 2017

Weighted effective vibration in m/s²

Machine type Typical working cycles

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

copyright © Liebherr-Mining Equipment Colmar SAS 2017

1.3 EC Declaration of Conformity

Fig. 1-4 Sample EC Declaration of Conformity

copyright © Liebherr-Mining Equipment Colmar SAS 2017

1.4 Technical data

1.4.1 Working technical data

1.4.2 Technical description

copyright © Liebherr-Mining Equipment Colmar SAS 2017

Operating Weight with

Easy Machine Control

Single Exclusive Ergonomic

Advanced Central High Performance

Quality Liebherr Strengthened

International Service Organization Reduced Costs and Investment Performance

Troubleshoot Repair and Easy Access

Protecting Your Most

Safety-First Cab Design Protection Against Fire Ignition

Secure Maintenance Automatic Fire Suppression System

Improved Accessibility Working Commitment to

Optimized Energy Consumption, Fewer Emissions Certiﬁed Environment Management Systems

Engine Swing Drive