Operating Manual 9400 Liebherr

en
Operating manual
Hydraulic excavator
R9400
from serial number 26377
Document identification
ORIGINAL MANUAL
Order number: 11000047
Edition: 06 / 2012
Valid for: R9400 from serial number 26377
Author: LEC - Technical documentation department
Product identification
Manufacturer: Liebherr-Mining Equipment Colmar SAS
Type: R9400
Type no.: 1257
Conformity: CE
LEC/en/Edition: 06 / 2012
Address
Liebherr-Mining Equipment Colmar SAS
49 rue Frédéric Hartmann
CS 50038, F-68025 Colmar Cedex
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 . . . . . ZK . . . . . .
Construction year:
. . . .
First start-up date:
. . / . . / . .
0-2 R9400 / 11000047

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
service 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. Place a copy in an easily
reached position on the cab storage shelf.
The operating and maintenance instructions must be completed by information on
current national regulations for accident prevention and protection. In addition to the
operating instructions and legally binding regulations on accident prevention which
apply in the user country and at point of use, authorized specialist rules for safe and
correct working procedures are also to be observed.
These operating and maintenance instructions contain all the information required
for operating and maintaining your machine.
– Some illustrations in these operating instructions may depict details and working
devices which differ to your machine.
– In some illustrations, protective devices and covers have been removed in the 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
technical documentation, sales school and customer service departments are avail-
MJFCIFSS
Operating manual
able for your convenience.

You will appreciate that LIEBHERR warranty claims made on the basis of improper
operation, unsatisfactory maintenance, use of unauthorized operating materials or
non-adherence to safety regulations cannot be recognized.
LIEBHERR will annul any and all obligations incurred by LIEBHERR and / or its 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
Operating manual
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 Signs on the machine .......................................................................................................................... 2-20
2.4.1 Introduction............................................................................................................................. 2-20
2.4.2 Arrangement of signs ............................................................................................................. 2-22
2.4.3 Meaning of the 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 joystick ............................................................................................................ 3-3
3.1.3 Keyboard .................................................................................................................................. 3-4
3.1.4 Control board............................................................................................................................ 3-8
3.1.5 Monitoring display .................................................................................................................. 3-10
3.1.6 Main screen ............................................................................................................................ 3-12
3.1.7 Monitoring cameras ................................................................................................................ 3-30
3.2 The access and the outfit of the cab.................................................................................................... 3-32
3.2.1 Entering or leaving the cab..................................................................................................... 3-33
3.2.2 Safety lever ............................................................................................................................ 3-37
3.2.3 Operator’s seat ....................................................................................................................... 3-38
3.2.4 Adjusting of the auxiliary seat................................................................................................. 3-41
3.2.5 Sunshade ............................................................................................................................... 3-42
3.2.6 Emergency exit....................................................................................................................... 3-43
3.2.7 Interior lightings ...................................................................................................................... 3-44
3.2.8 Fire extinguisher ..................................................................................................................... 3-44
3.2.9 Windscreen wiper ................................................................................................................... 3-45
3.2.10 Field of view ........................................................................................................................... 3-47
3.2.11 Lighting ................................................................................................................................... 3-49
3.2.12 Heating/air conditioning system ............................................................................................. 3-50
3.3 Setting the machine into operation ...................................................................................................... 3-54
3.3.1 Bringing the machine safely into service ................................................................................ 3-54
3.3.2 Starting / stopping the machine .............................................................................................. 3-56
3.3.3 Starting aids (optional) ........................................................................................................... 3-63
3.3.4 Jump start procedure ............................................................................................................. 3-67
3.3.5 Emergency operations ........................................................................................................... 3-68

3.3.6 Board E52 for safety mode of Diesel engine and servo control ............................................. 3-70
3.3.7 Driving .................................................................................................................................... 3-73
3.4 Working with the machine.................................................................................................................... 3-76
3.4.1 The uppercarriage swing movements .................................................................................... 3-81
3.4.2 Working position ..................................................................................................................... 3-83
3.4.3 Joystick functions when setting up the machine .................................................................... 3-83
3.4.4 Lowering the work equipment when the engine is not running .............................................. 3-87
3.5 General working methods.................................................................................................................... 3-88
3.5.1 Minimum impact working methods for your machine ............................................................. 3-88
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Operating manual
3.5.2 Preparatory activities .............................................................................................................. 3-89

3.5.3 Positioning of the machine ..................................................................................................... 3-90
3.5.4 Working with the backhoe bucket ........................................................................................... 3-90
3.5.5 Working with the Shovel bucket ............................................................................................. 3-93
3.6 Transport.............................................................................................................................................. 3-95
3.6.1 Travelling procedures for mining machine.............................................................................. 3-95
3.6.2 Excavator lifting and lashing operations ................................................................................. 3-97
4 Malfunctions ................................................................................................................................................... 4-1

4.1 Error code charts ................................................................................................................................... 4-2
4.1.1 Sensors .................................................................................................................................... 4-2
4.1.2 Regulating circuit ...................................................................................................................... 4-3
4.1.3 Keyboard .................................................................................................................................. 4-3
4.1.4 Display ...................................................................................................................................... 4-4
4.1.5 Coding error.............................................................................................................................. 4-4
4.1.6 Connection box pump transmitters ........................................................................................... 4-4
4.1.7 Joysticks ................................................................................................................................... 4-4
4.1.8 Error due to warning symbols in SY field.................................................................................. 4-5
4.1.9 Heating/air conditioning system................................................................................................ 4-7
4.2 Faults and remedies .............................................................................................................................. 4-8
4.2.1 Diesel engine and fuel system.................................................................................................. 4-8
4.2.2 Hydraulic system ...................................................................................................................... 4-9
4.2.3 Transmission ............................................................................................................................ 4-9
4.2.4 Electrical system..................................................................................................................... 4-10
4.2.5 Heating/air-conditioning system ............................................................................................. 4-10
4.2.6 Work equipment ..................................................................................................................... 4-10
4.3 Fuses and relays.................................................................................................................................. 4-11
4.3.1 Power electrical box E1003 .................................................................................................... 4-11
4.3.2 Cabin electrical box E1005 ..................................................................................................... 4-13
4.3.3 Heating / air-conditioning electrical box E1006 ...................................................................... 4-14
5 Maintenance ................................................................................................................................................... 5-1

5.1 Servicing the machine safely ................................................................................................................. 5-1
5.2 Maintenance 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 ............................................................................................................................ 5-14
5.3.7 Location of oil sample points .................................................................................................. 5-16
5.4 Lubricating and operating material specifications ................................................................................ 5-17
5.4.1 Lubrication oil for the diesel engine ........................................................................................ 5-17
5.4.2 Fuel......................................................................................................................................... 5-17
5.4.3 Hydraulic oil specifications for LIEBHERR Mining excavators ............................................... 5-17
5.4.4 Swing and travel gear oils ...................................................................................................... 5-23
5.4.5 Splitterbox oil .......................................................................................................................... 5-24
5.4.6 Lube oil for elastic coupling .................................................................................................... 5-24

5.4.7 Lubricating grease and other lubricants ................................................................................. 5-25
5.4.8 Coolant ................................................................................................................................... 5-26
5.4.9 Lubricants specifications for -40°C ......................................................................................... 5-26
5.5 Diesel engine ....................................................................................................................................... 5-27
5.5.1 Diesel engine oil level check .................................................................................................. 5-27
5.5.2 Diesel engine oil change ........................................................................................................ 5-28
5.5.3 Engine oil sump refilling.......................................................................................................... 5-30
5.5.4 Engine oil sampling ................................................................................................................ 5-31
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Operating manual
5.5.5 Mounting screws .................................................................................................................... 5-32

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

5.13.4 Swing gears and travel gears flushing ................................................................................... 5-80
5.13.5 Oil level check on idler (ITT idler only) ................................................................................... 5-81
5.13.6 Splitterbox – oil change .......................................................................................................... 5-82
5.13.7 Coupling – oil change ............................................................................................................. 5-83
5.14 Rotary connection (from SN 28066) .................................................................................................... 5-85
5.15 Track components ............................................................................................................................... 5-86
5.15.1 Track components mountings check ...................................................................................... 5-87
5.15.2 Monitoring the track tension ................................................................................................... 5-89
5.15.3 Track tensioning system......................................................................................................... 5-90
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Operating manual
5.15.4 Cleaning the track components .............................................................................................. 5-91

5.16 Electrical system .................................................................................................................................. 5-91
5.16.1 Notes on the electrical system................................................................................................ 5-91
5.16.2 Principal batteries switches and ECM connectors.................................................................. 5-92
5.16.3 Battery care ............................................................................................................................ 5-93
5.16.4 Electrical components location ............................................................................................... 5-94
5.16.5 Electrical boxes and cab pressurization ................................................................................. 5-95
5.17 Heating/air conditioning system ........................................................................................................... 5-95
5.17.1 Heating system ....................................................................................................................... 5-96
5.17.2 Air-conditioning system .......................................................................................................... 5-97
5.17.3 Dual air-conditioning system (optional)................................................................................. 5-100
5.17.4 Additional maintenance operations ...................................................................................... 5-100
5.18 Check mounting bolts for tightness.................................................................................................... 5-101
5.18.1 Counterweight mounting bolts .............................................................................................. 5-102
5.18.2 Swing ring mounting bolts .................................................................................................... 5-103
5.18.3 Fuel tank mounting bolts ...................................................................................................... 5-104
5.18.4 Hydraulic tank mounting bolts .............................................................................................. 5-105
5.18.5 PowerPack mounting bolts ................................................................................................... 5-106
5.18.6 Swing gears and swing motors mounting bolts .................................................................... 5-107
5.18.7 Hydraulic pumps mounting bolts .......................................................................................... 5-108
5.18.8 Side frames mounting bolts .................................................................................................. 5-109
5.18.9 Cabin elevation mounting bolts ............................................................................................ 5-110
5.18.10 Driver’s cabin mounting bolts ............................................................................................... 5-111
5.19 Drive unit brakes and swing gear brakes........................................................................................... 5-111
5.20 General maintenance points .............................................................................................................. 5-112
5.20.1 Replacing working parts ....................................................................................................... 5-112
5.20.2 Welding work on the machine .............................................................................................. 5-112
5.21 Control and maintenance chart.......................................................................................................... 5-113
5.22 Centralized lubrication system ........................................................................................................... 5-120
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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
100 Uppercarriage 320 Hydraulic cylinder

200 Undercarriage 330 Stick
310 Boom 350 Bucket
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MJFCIFSS
Product description Operating manual
Assembly - overview
1.1.2 Uppercarriage
Fig. 1-2 Uppercarriage
20 Swing gear installation 77 Cab elevation

25 Swing ring installation 80 Covering
40 Service trap 85 Lower covering
50 PowerPack 90 Cab
60 Hydraulic tank installation 95 Catwalk and handrail
65 Oil radiator installation 110 Fuel tank
70 Control valve installation 115 Counterweight installation
75 Rotating deck
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Operating manual Product description
Vibration emissions
1.1.3 Undercarriage
Fig. 1-3 Undercarriage
208 Idler 1000 Rotary connection

400 Track chain 4500 Travel gear with sprocket
1.2 Vibration emissions
The operator seat built into the machine by the manufacturer conforms to ISO
7096:2000, EM 6. When replacing the seat, ensure that the new seat also conforms
to this standard.
Hand-arm vibration
If the machine is operated according to the manufacturer instructions, the weighted
(frequency-rated) effective hand-arm vibration is below 2.5 m/s² according to ISO
5349-1:2001.
Whole-body vibration
If the machine is operated according to the manufacturer instructions, the weighted
(frequency-rated) effective vibration shown for specific machine applications in the
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MJFCIFSS
Vibration emissions
table below apply. These values conform to the specifications in the technical report
ISO/TR 25398:2006 "Earth-moving machinery – Guidelines for assessment of expo-
sure to whole-body vibration of ride-on machines – Use of harmonized data measu-
red by international institutes, organizations and manufacturers". The method of
assessment conforms to ISO 2631-1:1997. The effective values in the table for re-
presentable 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 who-
le-body vibration to which the operator is exposed can only be estimated. For a more
detailed assessment of the daily exposure of the operator across an 8-hour shift,
please refer to the LIEBHERR brochure on whole-body vibration and the software
designed for the assessment. This document and software are available from the
LIEBHERR dealer and are included as standard on the documentation CD (Lipart)
shipped with new machines.
For instructions how to reduce whole-body vibration during operation of mobile cons-
truction machinery, please refer to chapter "Control, operation / working with machi-
ne / 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. LEC/en/Edition: 06 / 2012
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Operating manual Product description
EC Declaration of Conformity
1.3 EC Declaration of Conformity
Fig. 1-4 Sample EC Declaration of Conformity (from year of manufacture 2010)

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Technical data
1.4 Technical data
1.4.1 Working technical data
Backhoe Shovel
Maximum working slope* (22 m3) 4,0° - 7,0% 4,0° - 7,0%
Maximum travelling angle (350 t) 22,1° - 40,6% 22,1° - 40,6%
Maximum tilt angle of diesel engine 30° 30°
Working ambient temperature range -12°C to +55°C -12°C to +55°C
Noise emission**
LpA (inside cab) with: 78dB(A) 78dB(A)
- water and hydraulic oil fans at 70%,
- air conditioning fan at 60%.
Tab. 1-1 Working technical data
* The maximum working slope has been determined for a hydraulic excavator in
standard configuration (with bucket volume as given in the table above) with a 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 slo-
pe 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 measu-
rement uncertainty is defined in the above standard.
1.4.2 Technical description

This should be taken from the accompanying technical description.
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Mining Excavator R 9400
Operating Weight with Backhoe Attachment: 345,500 kg / 760,594 lb
Operating Weight with Shovel Attachment: 353,000 kg / 778,230 lb
Engine Output: 1,250 kW / 1,675 HP
Bucket Capacity: 18.00 – 24.00 m3 / 23.5 – 31.5 yd3
Shovel Capacity: 18.00 – 24.00 m3 / 23.5 – 31.5 yd3
Technical Data
Engine Hydraulic Controls
1 Cummins diesel engine Servo circuit �� independant, electric over hydraulic
Rating per proportional controls of each function
SAE J 1995 �� 1,250 kW/1,675 HP at 1,800 rpm Emergency control �� via accumulator for all attachment func-
Model �� QSK50 (USA/EPA Tier 2) tions with stopped engine
Type �� 16 cylinder turbocharged V-engine Power distribution �� via monoblock control valves with inte
after-cooler grated primary relief valves and flanged on
two separate water cooling circuits secondary valves
common rail Flow summation �� to attachment and travel drive
Displacement �� 50 l/3,067 in3 Control functions
Bore/Stroke �� 159/159 mm / 6.26/6.26 in Attachment and
Engine cooling system �� fans driven via hydraulic piston motor swing �� proportional via joystick levers
Air cleaner �� dry-type air cleaner with pre-cleaner, with Travel �� proportional via foot pedals or hand levers
automatic dust ejector, primary and safety Bottom dump bucket �� proportional via foot pedals
elements
Fuel tank �� 6,908 l/1,825 gal
Electrical system
Voltage �� 24 V Electric System
Batteries �� 4 (+ 2) x 170 Ah/12 V
Alternator �� 24 V/260 Amp Electric isolation �� easy accessible battery isolations
Engine idling �� sensor controlled Working lights �� high brightness halogen lights:
Electronic engine – 2 on working attachment
power management �� engine power and speed sensing over the – 1 on RHS of uppercarriage
entire engine rpm range – 3 on LHS of uppercarriage
– 2 on counterweight
Xenon lights in option
Emergency stop switches �� at ground level, in hydraulic compartment,
Electric Motor (optional) in engine compartment and in operator cab
Electrical wiring �� heavy duty execution in IP 65 standard for
1 electric motor operating conditions of – 50 °C to 100 °C/
Power output �� 1,350 kW/1,810 HP – 58 °F to 212 °F
Type �� 3 phase AC squirrel cage motor
Voltage �� 6,000 V, other voltage on request
Frequency �� 50 Hz (or 60 Hz – dependent on country)
Revolutions �� 1,500 rpm or 1,800 rpm Swing Drive
Motor cooling �� integrated air-to-air heat exchanger
Starting method �� reduction of inrush current Hydraulic motor �� 2 Liebherr axial piston motors
Swing gear �� 2 Liebherr planetary reduction gears
Swing ring �� Liebherr, sealed triple roller swing ring,
internal teeth
Hydraulic System Swing speed �� 0 – 3.9 rpm
Swing-holding brake �� hydraulically released, maintenance-free,
Hydraulic pumps multi-disc brakes integrated in each swing
for attachment and gear
travel drive �� 4 variable flow axial piston pumps
Max. flow �� 4 x 751 l/min. / 4 x 198 gpm
Max. hydr. pressure �� 320 bar/4,640 psi
Hydraulic pump Uppercarriage
for swing drive �� 2 reversible swash plate pumps, closed-
loop circuit Design �� torque resistant designed upper frame in
Max. flow �� 2 x 390 l/min. / 2 x 103 gpm box type construction for superior strength
Max. hydr. pressure �� 350 bar/5,076 psi and durability
Pump management �� electronically controlled pressure and flow Attachment mounting �� parallel longitudinal main girders in box-
management with oil flow optimisation section construction
Hydraulic tank capacity �� 2,200 l/581 gal Machine access �� 45° access system with handrails on the
Hydraulic system cab side of the uppercarriage. Full con-
capacity �� 4,200 l/1,110 gal trolled descent in case of emergency stop.
Hydraulic oil filter �� 1 high pressure safety filter after each high Additional emergency ladder fitted near the
pressure pump + fine filtration of entire cab
return flow
Hydraulic oil cooler �� 2 separate coolers, 2 temperature
controlled fans driven via hydraulic piston
motor Service Flap
Design �� hydraulically actuated service flap, with
lighting easily accessible from ground level
to allow:
– fuel fast refill
– hydraulic oil refill
– engine oil quick change
– splitterbox oil quick change
– swing gearbox oil quick change
– swing ring teeth grease barrel refilling via
grease filter
– attachment/swing ring bearing grease
barrel refilling via grease filter
– windshield wash water refilling
Quick couplers on request
2 R 9400
Technical Data
Operator’s Cab Central Lubrication System
Design �� resiliently mounted, sound insulated, Type �� Lincoln Centromatic lubrication system for
large windows for all around visibility, the entire attachment/swing ring bearing
integrated falling object protection FOPS and teeth
Operator’s seat �� suspended, body-contoured with shock Grease pumps �� Lincoln Powermaster pump plus separate
absorber, adjustable to operator’s weight pump for swing ring teeth
Cabin windows �� 20.5 mm/0.8 in tinted armored glass for Capacity �� 200 l/53 gal bulk container for attachment/
front window and right hand side windows, swing ring bearing, separated 80 l/21 gal
all other windows in tinted safety glass, container for swing ring teeth
high pressure windshield-washer system Refill �� via the service flap for both containers, fill
75 l/20 gal watertank, lines with grease filter
aluminium sun louvers on all windows
Heating system/
Air conditioning �� 1 heating system + air conditioning (double
unit optionally available) fully automatic Attachment
Cabin pressurization �� ventilation with filter
Controls �� joystick levers integrated into armrest of Design �� box-type structure with large steel castings
seat in all high-stress areas
Monitoring �� via LCD-Display, data memory Pivots �� sealed with double side centering with
Rear vision system �� camera installation on counterweight and 1 single floating pin per side, all bearings
right-hand side of the uppercarriage dis with wear resistant steel bushings, bolts
played over an additional LCD-display hardened and chrominium-plated
Automatic engine Hydraulic cylinder �� Liebherr design and made, all cylinders
shut off �� engine self-controlled shut off located in well protected areas
Destroking of main Hydraulic connections �� pipes and hoses equipped with SAE split-
pumps �� in case of low hydraulic oil level flange connections
Safety functions �� aditional gauges with constant display for: Kinematics �� Liebherr parallel face shovel attachment
engine speed, hourmeter, voltmeter, safety geometry, backhoe bucket pivoting angle
mode for engine speed control and pump 150°, electronic controlled end-cushioning
regulation
Noise level (ISO 6396) �� LpA (inside cab) = 77 dB(A)
with oil/water fans at 100 % and AC fan at
65 %
Undercarriage
Design �� 3-piece undercarriage, box type structures
for center piece and side frames (stress
relieved steel work component as a stand
ard)
Hydraulic motor �� 2 axial piston motors per side frame
Travel gear �� Liebherr planetery reduction gear
Travel speed �� 0 – 2.7 km/h / 0 – 1.67 mph
Parking brake �� spring engaged, hydraulically pressure
released external wet multi-disc brakes for
each travel motor, maintenance-free
Track components �� maintenance-free,
forged double grouser pad, tractor-type
chain, optional maintenance-free dual pin
cast link and pad combined
Track rollers/
Carrier rollers �� 9/2
Automatic track
tensioner �� pressurized hydraulic cylinder with accu-
mulator
Transport �� undercarriage side frames are removable
R 9400 3
Dimensions
F E A2
D A1
A
OEL H3
W1 H2 C
W H1
H
K P
Q
L N
U S
Z B
V G
X
mm/ft in mm/ft in
A 6,405/21’ P 2,494/ 8’ 2”
A1 7,184/23’ 6” Q 1,187/ 3’10”
A2 7,900/25’10” S 5,516/18’ 1”
C 7,957/26’ 1” U 8,825/28’11”
D 6,400/20’11” Z 10,657/34’11”
E 6,665/21’10” N 1,000/ 3’ 3”
F 3,100/10’ 2” B 6,516/21’ 4”
H 5,664/18’ 6” G 6,926/22’ 8”
H1 6,653/21’ 9” V 13,279/43’ 6”
H2 7,227/23’ 8” W 8,421/27’ 7”
H3 8,343/27’ 4” W1 9,243/30’ 3”
K 2,434/ 7’11” X 18,560/60’10”
L 6,645/21’ 9” OEL Operator’s Eye Level 6,740/22’ 1”
4 R 9400
Dimensions
F E A2
D A1
A
OEL
H3
W1 H2 C
W H1
H
K P
Q
L N
U S
Z B
V G
X
mm/ft in mm/ft in
A 6,405/21’ P 2,494/ 8’ 2”
A1 7,184/23’ 6” Q 1,187/ 3’10”
A2 7,900/25’10” S 5,516/18’ 1”
C 7,957/26’ 1” U 8,825/28’11”
D 6,400/20’11” Z 10,657/34’11”
E 6,665/21’10” N 1,000/ 3’ 3”
F 3,100/10’ 2” B 6,516/21’ 4”
H 5,664/18’ 6” G 6,926/22’ 8”
H1 6,653/21’ 9” V 16,400/53’ 9”
H2 7,227/23’ 8” W 6,800/22’ 3”
H3 8,343/27’ 4” W1 8,100/26’ 6”
K 2,434/ 7’11” X 20,600/67’ 6”
L 6,645/21’ 9” OEL Operator’s Eye Level 6,740/22’ 1”
R 9400 5
Backhoe Attachment
with Gooseneck Boom 9.30 m/30’6”
ft m
55 Digging Envelope
16
50 Stick length 4.20 m/13’ 9”
45 14
40 R 3750 Max. reach at ground level 16.30 m/53’ 5”

12
Max. teeth height 15.50 m/50’10”
35 Max. dump height 10.50 m/34’ 5”
10
30 Max. digging depth 9.50 m/31’ 1”
25 8
Max. digging force (ISO) 1000 kN/224,809 lbf
20 6
Max. breakout force (ISO) 1050 kN/236,049 lbf
15
4
10
2
5
0 0 Operating Weight
-5
-2
and Ground Pressure
-10
-4 The operating weight includes the basic machine with backhoe
-15 attachment and a 22.00 m3/28.78 yd3 bucket.
-20 -6
Pad width mm/ft in 1,000/3’3”
-25 -8 Weight kg/lb 345,500/760,594
-30 Ground pressure kg/cm2 / psi 2.60/36.98
-10
20 18 16 14 12 10 8 6 4 2 0 m
65 60 55 50 45 40 35 30 25 20 15 10 5 0 ft
Buckets
For materials classe
according to VOB, Section C, DIN 18300 < 5 5 – 6 5 – 6 5 – 6 7 – 8 7–8
Typical operation
according to VOB, Section C, DIN 18300 GP HD HD HD XHD XHD
Capacity ISO 7451 m 3 24.00 18.00 22.00 24.00 18.00 20.00
yd3 31.39 23.54 28.78 31.39 23.54 26.16
Suitable for material up to a specific weight of t/m3 1.7 2.2 1.8 1.6 2.0 1.8
lb/yd3 2,867 3,710 3,035 2,698 3,373 3,035
Cutting width mm 3,900 3,400 3,700 3,900 3,400 3,700
ft in 12’9” 11’1” 12’1” 12’9” 11’1” 12’1”
Weight kg 22,000 23,000 23,000 23,800 24,500 25,000
lb 48,502 50,706 50,706 52,470 54,013 55,116
GP: General purpose bucket
HD: Heavy-duty bucket
XHD: Heavy-duty rock bucket
6 R 9400
Shovel Attachment
with Shovel Boom 6.75 m/22’1”
ft m
18 Digging Envelope
55 17
16 Stick length 4.30 m/14’ 1”
50 15
45 14 Max. reach at ground level 14.00 m/45’11”
13 Max. dump height 11.20 m/36’ 8”
40 12 Max. crowd length 4.50 m/14’ 9”
35 11 Bucket opening width T 2.50 m/ 8’ 2”
T
10
30 9 Crowd force at ground level (ISO) 1195 kN/268,647 lbf
25
8 Max. crowd force (ISO) 1610 kN/361,942 lbf
7 Max. breakout force (ISO) 1290 kN/290,004 lbf
20 6
5
15
4
10 3
2
Operating Weight
5
2 and Ground Pressure
0 0
-1 The operating weight includes the basic machine with shovel attach-
-5 ment and a 22.00 m3/28.78 yd3 bucket.
-2
-10 -3 Pad width mm/in 1,000/3’3”
-4 Weight kg/lb 353,000/778,230
-15
-5 Ground pressure kg/cm2 / psi 2.66/37.83
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 m
50 45 40 35 30 25 20 15 10 5 0 ft
Bottom Dump Buckets

For materials classe
according to VOB, Section C, DIN 18300 < 5 < 5 5 – 6 5 – 6 7 – 8 7–8
Typical operation
according to VOB, Section C, DIN 18300 GP GP HD HD XHD XHD
Capacity ISO 7546 m3 24.00 22.00 18.00 22.00 18.00 19.00
yd3 31.39 28.78 23.54 28.78 23.54 24.85
Suitable for material up to a specific weight of t/m3 1.6 1.8 2.2 1.8 2.1 1.9
lb/yd3 2,698 3,035 3,710 3,035 3,541 3,204
Cutting width mm 4,250 4,250 4,250 4,250 4,250 4,250
ft in 13’11” 13’11” 13’11” 13’11” 13’11” 13’11”
Weight kg 36,700 35,400 35,400 35,400 37,500 38,500
lb 80,910 78,044 78,044 78,044 82,673 84,878
Wear kit level I I II II III III
GP: General purpose bucket
HD: Heavy-duty bucket
XHD: Heavy-duty rock bucket
Level I: For non-abrasive materials, such as limestone, without flint inclusion, shot material or easily breakable rock, i.e., deteriorated rock, soft
limestone, shale, etc.
Level II: For preblasted heavy rock, or deteriorated, cracked material (classification 5 to 6, according to DIN 18300)
Level III: For highly-abrasive materials such as rock with a high silica content, sandstone etc.
All illustrations and data may differ from standard equipment. Subject to change without notice. All indicated loads are based in accordance with ISO 9248.
R 9400 7
The Liebherr Group of Companies
Wide Product Range State-of-the-art Technology

The Liebherr Group is one of the largest construction To provide consistent, top quality products, Liebherr
equipment manufacturers in the world. Liebherr’s high- attaches great importance to each product area, its
value products and services enjoy a high reputation in components and core technologies. Important modules
many other fields, too. The wide range includes domes and components are developed and manufactured in-
tic appliances, aerospace and transportation systems, house, for instance the entire drive and control techno
machine tools and maritime cranes. logy for construction equipment.
Exceptional Customer Benefit Worldwide and Independent

Every product line provides a complete range of models Hans Liebherr founded the Liebherr family company in
in many different versions. With both their technical excel 1949. Since that time, the enterprise has steadily grown
lence and acknowledged quality, Liebherr products offer to a group of more than 120 companies with nearly
a maximum of customer benefits in practical application. 33,000 employees located on all continents. The corporate
headquarters of the Group is Liebherr-International AG
in Bulle, Switzerland. The Liebherr family is the sole owner
of the company.
www.liebherr.com
Printed in Germany by Typodruck RG-BK-RP LEC/SP 11003238-1-07.11_enGB-US
Liebherr-Mining Equipment Colmar SAS

49 rue Frédéric Hartmann, F-68025 Colmar Cedex
 +33 369 49 20 00, Fax +33 369 49 23 18
www.liebherr.com, E-Mail: info.lec@liebherr.com
2 Safety instructions
Working with the machine holds dangers to which you as the owner, machine ope-
rator or maintenance expert could be exposed. If you regularly read and note the sa-
fety 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
informations in these operating instructions. These safety informations describe
various dangers which are emphasized by the terms Danger, Caution and Note.
These terms are identified by symbols in the operating instructions and have the
following meaning:
Danger!
Warning relating to a danger that carries with it a high risk of death or serious injury
if the appropriate preventative measures are not taken.
Caution!
Warning relating to dangers that could 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
precondition described, i e. the machine must be brought into a particular work
position in order to be able to carry out the actions subsequently described.
 This symbol identifies an action.
The machine operator or the maintenance personnel should be active at this
location and carry out the action described.
 This symbol means “Carry out an activity".
copyright by
R9400 / 11000047 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
additional rules and guidelines!
Additional points that should be noted are:
– the safety regulations which apply on site,
– statutory road traffic regulations,
– the guidelines provided by professional associations.
2.2 Use in accordance with the regulations
– The hydraulic excavator is a machine with work equipment (eg. hoe type bucket,
grab, bucket attachment) designed to detach, lift, transport and shake off earth,
stones and other materials, while the 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 devi-
ces. 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 re-
gulations. The manufacturer is not liable for any damage resulting from this
action. The user is solely responsible for the risk incurred.
– Observing the operating instructions and the inspection / maintenance 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 repai-
ring the machine. Give personnel the power to refuse to carry out unsafe instruc-
tions. This also applies in relation to traffic regulations.
copyright by
2-2 R9400 / 11000047
MJFCIFSS
Operating manual Safety instructions
Safety Instructions
– Only permit apprentices and personnel who are in training or who have only ge-
neral 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 wor-
king 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 chec-
king whether any warning signs are missing or illegible.
– Respect all danger and safety instructions.
– For special applications the machine must be equiped with specific safety 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 forbiden to repair the structure of the cab.
– Not original equipment and component parts or such kind, wich has generaly not
been validated by LIEBHERR for installation or extension, has not to be installed
or added onto the excavator without previous written agreement of LIEBHERR.
Wherefore the necessary technical documentations has to be at LIEBHERR’s dis-
posal.
copyright by
R9400 / 11000047 2-3
MJFCIFSS
Safety Instructions
Avoidance of crushing and burns

– Do not work beneath the equipment if it is not safely positioned on the ground or
supported.
– Do not use any damaged or insufficient load-bearing take-up materials, such as
ropes or chains.
– Wear adapted work gloves when working with wire cables.
– When working on the equipment, never use your fingers to locate bores; use the
correct punch for the procedure.
– Ensure that no objects enter the fans when the engine is on. The fan will eject or
destroy these objects and will itself be damaged.
– Near operating temperature, the parts of the engine cooling system, of the 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 coo-
led 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 purpo-
se.
– Never lay under the machine if it is raised with work equipment 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 char-
ging 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.
copyright by
2-4 R9400 / 11000047
MJFCIFSS
Safety Instructions
– All doors, covers and boxes locks have to be unlocked before operation in order
to facilitate firefighting in case of fire. Only electrical boxes from and over 50V
must remain locked during operation.
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 faci-
litate 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 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 particulary vigilant to realise the climbing
and descent from the cab with the best safety conditions, and do or give the ins-
tuctions to the execution of prior preparations to be accomplished, as enunciated
above, in order to displace yourself safely.

– Be particulary vigilant with those prerequisites conditions.
– For cab 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.
copyright by
R9400 / 11000047 2-5
MJFCIFSS
Safety Instructions
If unavailable, let it be instaled before working with the door open.

– For cab with a rear door:
• Now continue to climb up, still using the three-point support and close the door
as soon as you enter the cab.
• Sit down in the operator’s seat and fasten the safety belt (if available) before til-
ting 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 ins-
tructions.
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 equipment is operating correctly.
– Move the machine carefully to an open area and then check the function of the
running and slewing gear brakes, the steering and the signaling and lighting de-
vices.
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.
copyright by
2-6 R9400 / 11000047
MJFCIFSS
Safety Instructions
– Use the stop bolts to secure the upper structure facing the undercarriage, if
available.
– Lower the equipment and anchor the grab lightly in the ground.
– Position every control lever into neutral position and depress the parking and
slewing brakes.
– Stop the engine in accordance with the operating instructions and tilt the safety
lever up before leaving the cab.
– Lock the machine, included hoods and compartments, retire every keys and se-
cure the machine against unpermited use and vandalis.
Safely getting down

to instal 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 ali-
gned 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 parti-
cular care when working near them. If necessary, inform the responsible authori-
ties.
– Maintain a safe distance from electrical aerial lines. Do not allow the equipment
to come near cables when working near electrical aerial lines. Risk of fatality! 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 equipment,
• do not leave the driver’s cab,

• warn any personnel in the vicinity not to come close to the excavator and
not to touch 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.
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Safety Instructions
– 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 re-
gulations beforehand.
– Always turn on the lights in conditions of poor visibility or darkness.
– Do not permit any passengers in the machine.
– Only work when seated properly and with the safety belt securely fastened (if
available).
– Report all function faults and ensure that all necessary repairs are carried out 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 equipment; this applies particularly when using the grab.
– Position the upper structure in the longitudinal direction when moving and hold
the load as close to the ground as possible.
EXCEPTION : excavators used for loading and unloading, see the part "Safe use
when loading and unloading (particularly when loading and unloading wood)" on
page 10.
– Adjust your driving speed to suit local conditions.
– Avoid any working movements which may tip the machine. Should the machine
start to tip or slide sideways, however, turn the upper structure to face downhill
and lower the equipment at the same time.
– As far as possible, work downhill or uphill and not side on to the slope.
– Drive safely on stony, sleepery or inclined ground
– Only drive downhill at the permitted speed or you could lose control of the machi-
ne.
– Always shift down to a lower running step before a slope. When doing this, the
diesel engine must run at maximal speed and the speed may only be reduced
using the foot pedals.
– Load an occupied truck only if all safety requirements are fulfilled, notably in order
to protect the truck operator.
– For demolition work, digging and crane operations etc., always use protective 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 equipment 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 equipment parts. The greatest degree of care must be taken to
avoid damage.
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Safety Instructions

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.
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
applications are required.
– Do not attach too large bucket or bucket with side cutters or that are during ope-
rations with rocky material. This would prolong the work cycles and may lead to
damage to the bucket as well as further machine components.
– With the 2x45° offset articulation, the offset position may only be employed if the
working tool or the attachment does not touch the material.
– Operation of the offset articulation to drill into the material is not permitted.
– Do not lift the machine during operation. Should this happen, lower the machine
slowly back to the ground.
– Do not let the machine fall heavily on the ground and do not hold it back with the
hydraulics. This would damage the machine.
– During operation with the attachment it is forbidden to raise the machine with the
dozing blade (e.g. carving at the ceiling when tunnelling).
– Do not dig under the undercarriage. Take all necessary measures to prevent
ground collapse under the machine.
– The practice of following working methods is forbidden:
• Batter pulling, also known as Scaling or Ripping,
• Double benching, also known as Split benching or Double flitching.
The practice of these methods will result in increased stresses to steel structu-
res and components of Liebherr Mining Machines. It may significantly reduce
the expected life of structures and/or components.
Liebherr does not condone and does not approve the operation of Liebherr Mi-
ning Machines in this manner.
Safe use with a hydraulic hammer

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

ding and unloading wood)
– According to use, it can be necessary when working with a grab to move with the
equipment raised and the load lifted up; this applies, for example, when loading
and unloading wood.
– Here, the centre of gravity of the machine will be displaced upwards in the vertical
direction. The driving characteristics of the machine will thus be influenced 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-
rection.
• Only rotate the upper structure when the undercarriage is stationary.
• Only rotate the upper structure after you have picked up the load.
• Only move the machine when you have picked up and lifted the load and rota-
ted the upper structure to the driving position.
• There is a danger of possible swinging movement and dropping of the load
when the equipment is raised.
• A protective grid (FOPS) in accordance with ISO 10262 must be attached to the
cab.
• A protective roof (FOPS) in accordance with ISO 10262 must be attached if the-
re 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 pro-
duct, such as moisture, must be noted.
– Working procedures when using machines with grabs require the machine ope-
rator to receive special instruction and training.
– Use as part of the work process is only permitted when the machine operator has
sufficient training and practical experience.
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Safety Instructions
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 upper structure is
over the centre of the undercarriage, which reduces the risk of tilting.
– The machine can still sway and tilt despite being aligned!
When moving the machine:
• Rotate the upper structure parallel to the undercarriage (transport position).
• Draw the equipment as close as possible to the machine.
• Only at this point may the support feet be retracted and the machine moved.
• Moving with loads is not permitted.
• Check the terrain to be covered to ensure that the ground is solid and even. Po-
tholes 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
(slewing) the upper structure out of the transport position.
• It is imperative that you check the contact surface of the support (load carrying
capacity of the substrate). A support subsiding would have disastrous conse-
quences!
• Carry out all movements with increased care.
• To slew the load, move the equipment as close as possible to the machine
(Caution! swinging grab)and hold the load close to the undercarriage and
above the substrate.
• Avoid braking or accelerating the equipment or upper structure abruptly.
• Do not lift any loads which are heavier than those given in the load chart.
Protection from vibration

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

– To a large extent, the machine operator determines the vibrational loads since he
selects the speed, gearbox ratio, working method and route himself.
This means that there is a wide range of different vibrational loads for the same
machine type.
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Safety Instructions
Whole-body vibrational load for the machine operator can be reduced if the following
recommendations are observed:
– Select suitable machines, equipment parts and auxiliary devices for each part of
the job.
– Use a machine that has a suitable seat (i.e. for earth-moving machinery such as
hydraulic excavators, this should be a seat which corresponds with EN ISO
7096).
tructions.
– 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 equip-
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.
– 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 ope-
rating instructions.
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Safety Instructions
Attaching and removing equipment 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
installed or attached to the machine without LIEBHERR’s prior written consent.
– LIEBHERR must be provided with the appropriate technical documentation ne-
cessary for this purpose.
– Before carrying out any major repair work on the equipment, position the machine
on level, firm ground.
– Do not work beneath the equipment if it is not safely positioned on the ground or
supported with appropriate supports.
– Before loosening lines or unscrewing bolts, you must store the equipment, switch
off the engine and press the start key to the contact position and both joysticks
and the pushbuttons to “Turn grapple” in order to reduce the pressure in the 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 equipment: switch off the engine and keep the safety lever
tilted up. Never use your fingers to locate bores; use the correct punch for the 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 equipment 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 equipment pins safely

– If possible, always use a hydraulic bolt press to press out the equipment’s bolts.
– If you have to remove a bolt using a sledge-hammer, a driving punch and a bore
hole conductor held by another person must be used.
– To drive in a bolt, screw the drive screws provided in the toolbox if provided 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.
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 equipment 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.
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Safety Instructions
– Attach the hand lever for fine-tune driving (crawler excavator) onto the accelerator
pedals.
– Ensure that a spotter gives the machine operator the required signal.
– Prepare the placing block to ensure against rolling back when the machine is dri-
ving 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 throu-
gh 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.
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
available in order to carry out maintenance work.
– The inspection and maintenance schedule given at the end of these operating
instructions defines precisely who is required / permitted to carry out what work.
Jobs listed as daily / weekly work may be carried out by the machine's driver or
maintenance personnel when they have received appropriate instruction.
The remaining work may only be carried out by specialist personnel with appro-
priate training.
– Replacement parts must correspond to the technical requirements determined by
the manufacturer. Original replacement parts are always guaranteed to meet the-
se 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.
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Safety Instructions
– 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 maintenan-
ce 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 uppercarria-
ge’s access when the excavator is in this configuration.
– Pull out the ignition key and shut off the main battery switch.
– Always tighten any loose screw connections during maintenance and repair work.
– The mounting bolts of the main components, of the hydraulic hoses and of the
counterweight must be replaced after every removal.
– If safety devices have to be dismantled during set-up, maintenance and repair
work, they must be immediately reinstalled and checked at the end of the work.
– When carrying out repair work, particularly when working under the machine,
hang a “Do not start” warning sign in a clearly visible position on the control panel.
Pull out the start key and shut off the main battery switch.
– Operate combustion motors and fuel operated heaters only in well ventilated
areas. Before operating these units, check ventilation.
– In addition, always follow applicable local regulations.
Cleaning
– Clean oil, fuel or care products off the machine before starting maintenance or 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 machi-
ne for the first two months after initial set-up of the machine (or after repainting).
– Do not use combustible liquids to clean the machine.
– Before cleaning the machine with water or steam jets (high pressure cleaner) or
other cleaning materials:
• lubricate all bearing points, bolt connections and the rim bearing to prevent 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.
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Safety Instructions
– If you use a high pressure cleaner with steam or hot water to clean the machine,
observe following recommendations :
• the distance between the nozzle and the surface to be cleaned must be no
lower than 20 inches
• the water temperature should not exceed 60°c (140°F)
• limit the water pressure to 80 bar maximum (11500 PSI)
• if you employ cleaning fluid, only use neutral cleaning agents such as customa-
ry car shampoos diluted to 2 or 3 percent maximum
– After cleaning:
• remove all covers completely.
• check all fuel, engine oil and hydraulic lines for leakage, loosened connections,
chafing and damage.
• rectify any defects found immediately.
• lubricate all bearing points, bolt connections and the rim bearing to displace any
water or cleaning products that may have entered.
Field of view
– Mirrors and cameras, which were possibly removed for the transport, must be ine-
vitably 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, du-
ring operation or when travelling.
– Mirrors are installed on the machine:
• on the left to check the left side of the machine.
• on the front to check the front side of the machine.
• on the right to check the right side of the machine.
• above the counterweight to check the rear side of the machine.
– On some machines, some mirrors may be replaced with cameras.
– At each extension, construction or change on the machine, the sight conditions
must be maintained. These conditions must otherwise be checked according to
ISO 5006.
– Mirrors must be cleaned at least at daily intervals.
– Damaged mirrors and cameras must be immediately replaced.
– The site has to be organised so that the 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 maintenan-
ce plan:
• every 250 operating hours by the machine owner’s maintenance personnel.
• every 500 operating hours by authorised specialist personnel.
– It is advisable to carry out these tests: supported, on firm, horizontal substrate,
with the equipment in longitudinal and cross direction for variable loads. Current
accident prevention regulations must be adhered to.
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Safety Instructions
– Especially check the supporting components, in particular :

• framed construction undercarriage with axle and gearbox storage, support
outriger, lower slewing ring support with tower and slewing ring.
• framed construction uppercarriage with bearing for boom and hoist cylinder, 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 chan-
ge 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 pe-
netration test should be carried out as a crack test on areas which do not have
good visibility, such as the ring bearing support, in order to increase testing safety.
– Any damage found must be rectified immediately. Welding work on load-bearing
parts of the earth-moving machinery, loading devices and transport devices may
only be carried out by trained specialist personnel and only in accordance with the
accepted rules of welding engineering. In case of doubt, contact the LIEBHERR
customer support service to discuss suitable remedies.
Welding, drilling, firing and grinding work

– Any welding on structural parts (as undercarriage, uppercarriage, equipment
parts,…) may only be done the manufacturer, or authorized official dealer. If this
rule is neglected, the warranty is voided.
– Only carry out welding, drilling, firing and grinding work on the machine with 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 the swing ring, joints, gears,
bushings, rubber parts and 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 them so that they do not
present a risk. Only use suitable and correctly functioning lifting devices and load
take-up devices with adequate load capacity.
Do not stand or work under swinging loads.
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Safety Instructions
– Do not use lifting devices which are damaged or do not have sufficient load
carrying capacity.
Wear work gloves when working with wire cables.
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
purpose.
When working at height, wear a harness to prevent falling.
Ensure that all grips, steps, rails, platforms and ladders are free of dirt, snow and
ice.
– Pneumatic cylinders do not have to be used as handles. Open doors and covers
carefully, so that pneumatic cylinders do not hit their stops, because this could
cause mechanical damages.
– Make sure the equipment on which you will operate is securely supported before
working (e.g. replacing teeth). Prevent metal touching metal when doing this.
– For safety reasons, never open and remove a track chain unless having previous-
ly totally released the pretension of the chain tensioning unit.
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 equi-
pment.
– 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 swit-
ching off the engine, with the start key in contact position and with the safety lever
down into its lowest position, you must operate all pilot control devices (joystick
and pedals) in all directions in order to reduce the actuating and dynamic pressu-
res in the work circuits. You must then reduce the internal tank pressure as des-
cribed 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.
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Safety Instructions
– 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 vol-
tage, 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 the-
se 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 vi-
sible damage and any possible damage must be immediately checked for leaka-
ge.
– 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.
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Signs on the machine
– 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 pertai-
ning 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 proper-
ly fastened. Doing this will prevent vibration and damage during operation.
• Install the lines and hoses in such a way that they cannot chafe on other lines,
hoses or parts.
• A minimum distance from other parts of approx. half the exterior diameter of the
hose is recommended. The distance should not, however, be less than 10 to
15 mm.
• When replacing the lines or hoses on moving parts (e.g. from the boom to the
stay), check before initial start-up that there are no chafing areas in the entire
area of movement.
2.4 Signs on the machine

2.4.1 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.
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– 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 le-
gible.
 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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2.4.2 Arrangement of signs
Fig. 2-1 Arrangement of signs on uppercarriage
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Fig. 2-2 Arrangement of signs on PowerPack
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1 Typeplate Liebherr France "CE" 65 Crush hazard label

2 Typeplate Liebherr America 70 Maximum charge label
3 Typeplate Liebherr France 75 Ladder manual unlock label
10 Danger signal label 76 Ladder accu. depressurization
15 Banning label 80 Crush hazard label
20 Emergency ladder label 90 Filling volumes label
25 Emergency stop label 91 Lubricating chart label
30 Explosion hazard label 94 Control symbols label (backhoe)
35 Emergency exit label 95 Control symbols label (shovel)
40 Rotation blade hazard label 96 Safety lever label
45 Hydraulic valve position label 97 Safety belt label
50 Hydraulic tank pressure label 98 Hydraulic tank shut-off valve label
55 Oil injection hazard label 99 External starting label
60 Burn hazard label 100 Instruction manual warning label
2.4.3 Meaning of the signs
Plate 1: Typeplate LFR (Liebherr France) "CE"

This typeplate displays the following information:
– Product identification number
– Type
– Construction year
– Nominal engine power
– Max. speed
– Operating mass*
Plate 2: Nameplate LAM (Liebherr America)
This nameplate displays the following information:
– Type
Plate 3: Typeplate LFR (Liebherr France)

This typeplate displays the following information:
– Type
– Construction year
– Nominal engine power
– Max. speed
– Operating mass*
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Plate 10: Danger signal label

Indicates to stay out of the surrounding operating area in order to avoid severe injury.
Plate 15: Banning label

Indicates that the concerned element may only be opened when the engine is swit-
ched off.
Plate 20: Emergency ladder label

Indicates the emergency ladder.
Plate 25: Emergency stop label

Indicates an emergency stop.
Plate 30: Explosion hazard label

Indicates explosion risk and gives associated safety instructions.
Plate 35: Emergency exit label

Indicates the direction of an emergency exit.
Plate 40: Rotation blade hazard label

Indicates risks due to rotating blades and gives associated safety instructions.
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Plate 45: Hydraulic valve position label

Indicates how to open and close the hydraulic valve.
Plate 50: Hydraulic tank pressure ON/OFF label

Indicates how to switch hydraulic tank pressure on and off.
Plate 55: Oil injection hazard label

Indicates risks due to oil discharge and gives associated safety instructions.
Plate 60: Burn hazard label

Indicates risks due to hot surfaces and gives associated safety instructions.
Plate 65: Crush hazard label

Indicates risks due to moving railings and gives associated safety instructions.
Plate 70: Maximum charge label

Indicates the maximum allowable charge on the access ladder.
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Plate 75: Ladder manual unlock label

Indicates how to manually unlock the access ladder.
Plate 76: Ladder accumulator depressurization

Indicates how to depressurize the acces ladder accumulator.
Plate 80: Crush hazard label

Indicates risks due to belts and gives associated safety instructions.
Plate 90: Filling volumes label

Indicates volume of lubricant and operation fluids to fill via the service trap.
Plate 91: Lubricating chart label

Indicates the different fluid change and analysis intervals to observe.
Plate 94: Control symbols label (backhoe attachment)

Indicates the functions associated with the control units.
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Plate 95: Control symbols label (shovel attachment)

Indicates the functions associated with the control units.
Plate 96: Safety lever label

Indicates precaution to be taken before leaving the driver seat.
Plate 97: Safety belt label

Indicates to always seat belt while operating the excavator.
Plate 98: Hydraulic tank shut-off valves label

Indicates precaution to be taken before starting the excavator.
Plate 99: External starting label

Indicates precautions to be taken before removing starting cables. LEC/en/Edition: 06 / 2012
Plate 100: Instruction manual warning label

Indicates that informations in the operating instructions must be carefully noted.
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Plate 101: Lashing point label

Indicates the location of lashing points on the excavator.
Plate 102: Stop-lift point label

Indicates the location of stop-lift points on the excavator.
* Estimated mass of the machine in its standard version (without optional equipment)
according to its configuration: Diesel, electric, backhoe, shovel or pontoon.
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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
8 Heater vent S6 Switch / float position attachment

15 Control board S7 Safety lever
A2 Radio S100_1 Emergency stop
E14 Cigarette lighter U13 Display for monitoring cameras
E52 Control board for safety operation U15 Greasing module
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Control and operation Operating manual
Operating and control elements
H1 Monitoring display U20 Shovel flap pedal

H9 Buzzer U21 Left joystick
P5 Hourmeter U22 Right joystick
S1 Ignition key U23 Right travel pedal
S2 Control keyboard U24 Left travel pedal
S5 Switch / horn U103_1 AC / heater control unit
Fig. 3-2 Standing position from operator’s point of view
E14 Cigarette lighter S5 Switch / horn

H1 Monitoring screen S6 Switch / float position attachment
S1 Ignition switch U21 Left joystick

S2 Control keyboard U22 Right joystick
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Operating manual Control and operation
3.1.2 Arrangement of joystick
Fig. 3-3 Joystick, right (3) and left (4)
Standard control
The left joystick (4) controls the stick and slewing movements.
– Direction of movement a and b: Stick is drawn in or out.
– Direction of movement c and d: Uppercarriage is rotated to the left or to the right.
The right joystick (3) controls the boom or bucket and grab movements.
– Direction of movement e and f: Bucket will be tilted up or down, grab will close or
open.
– Direction of movement g and h: Boom will be raised or lowered.
Note !
From delivery, the machine is equipped with the standard control system correpon-
ding to the norm ISO. Nevertheless, the machine can be equipped with a commu-
tation circuit allowing the use of a special control system (for example LIEBHERR
control system).
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3.1.3 Keyboard
Fig. 3-4 Excavator keyboard
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S10 – Working light / attachment floodlights

 Press button.
 Working light on the uppercarriage is activated.
 LED 1 in the button illuminates.
 Press button again.
 Working light is disabled.
 LED 1 in the button goes out.
 Attachment floodlights are activated.
 Working light and attachment floodlights are activated.
 LEDs 1 and 2 in the button illuminate.
 Working light and attachment floodlights are desabled.
 LEDs 1 and 2 in the button go out.
S11 – Windshield washer
 Press and hold button.
 Washing water will be sprayed onto the windshield through the outlet nozzles.
 The windshield washer runs continuously.
 Release the button.
 Washing water will be stopped.
 Windshield washer will run continuously for approx. another 3 seconds.
S12 – No function
S14 – Windshield wiper

 Press button.
 Intermittent setting is activated.
 LED I in the button illuminates.
 Continuous operation is activated.
 LED C in the button illuminates.
 LED I in the button goes out.
 Windshield wiper is switched off.
 LED C in the button goes out.
In addition, the break time for the intermittent setting can be adjusted:
 Select the intermittent setting and keep the button depressed.
 After a few seconds, LED I in the button will start blinking rapidly.
 Release the button when the blinking duration has reached the desired break ti-
me. Adjustment is possible between 2 and 9 seconds.
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S17 – Swing brake

 Press button.
 Swing brake is engaged.
 Uppercarriage is locked.
 LED in the button illuminates.
 Swing brake is released.
 LED in the button goes out.
S18 – Overload warning device (optional)
 Press button.
 Overload warning device is activated.
 Overload warning device is disabled.
 No overload warning device is built in.
 Press button.
 The symbol for "No overload warning device is present" appears on the moni-
toring screen.

 The symbol for "No overload warning device is present" goes out.
S19 – No function
S20 – Automatic idling

 Press button.
 Automatic idling is activated.
 Automatic idling is deactivated.
S21 – High speed gear
 Press button.
 Transfer from normal drive to fast drive is activated.
While driving, the machine will automatically transfer from normal drive to fast drive.
LED 2 illuminates after transfer to fast drive.
 Transfer from normal drive to fast drive is disabled.
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S22 – Counterweight floodlights

 Press button.
 Counterweight floodlights are activated.
 Counterweight floodlights are disabled.
S36 – Special function 1 (optional)
Configuration and activation according to kit.
S41 – Dome light

 Press button.
 The interior lights are activated.
 The interior lights are disabled.
S56 – No function
S86 – Mode selection, speed adjustment

Three different modes can be selected by pressing the switch. The currently active
mode will be displayed under the letter on the LED.
– L: LIFT mode (speed level 5)
– F: not used
– E: ECO mode (speed level 8)
– P: POWER mode (speed level 10)
P4 – Engine RPM display
The speed range of the diesel engine is displayed in 10 levels.
S228 – Engine RPM increase

 Press button.
 Speed will be increased by one level.
 A second LED to the right illuminates in engine RPM display.
S229 – Engine RPM decrease
 Press button.
 Speed will be decreased by one level.
 A second LED from the right goes out in engine RPM display.
S354 – Travel brake
 Press button.
 Travel brake is engaged.
 Undercarriage is locked.
 Travel brake is disabled.
 Undercarriage is unlocked.
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3.1.4 Control board
Fig. 3-5 Control board
Standard functions Quantum engine monitoring system

S100_1 Emergency stop H60 Quantum STOP indicator
S122 Disable ladder or trap control lock H61 Quantum WARNING indicator
H38 Greasing system alarm H62 Quantum PROTECTION indicator
S82_1 Diagnostic increment
H81 Hydraulic valve closed S82_2 Diagnostic decrement
H91 Power reduced S85 Quantum monitoring ON/OFF
H92 Fire alarm
H94 Fuel valve closed Safety operation engine
S149 Ether control (cold starting aid) S23 Engine safety operation ON
P4 Engine RPM indicator R6 Engine RPM adjustment
P8 Service batteries voltmeter S178 Engine stop after running
P9 Principal batteries voltmeter
H6 Clock Safety operation hydraulic pumps
S73 POWER pump control
H93 Water in fuel indicator S74 FLOW pump control
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S126 Additional cabin lighting
Optional functions
H103 Preheating indicator
S12-1 Side wiper
S12-2 Back wiper
S26 Dual air conditioning
Disable ladder or trap control lock

 For further information about correct use of this function, refer to § "Access lad-
der" in section "Entering or leaving the cab" of this manual.
Quantum engine monitoring system

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

 For further information about correct use of these functions, refer to section
"Emergency operations" of this manual.
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3.1.5 Monitoring display
Fig. 3-6 Monitoring display
A Analog indicator H24 No function

B Check display P2 Coolant temperature display
C Main screen P2.1 Coolant temperature display red
area
D Menu control, screen P3 Fuel level display
H2 Indicator light, engine oil pressure P3.1 Fuel level display red area
H12 Indicator light, battery S349 Back button
H19 No function S350 Down button
H20 No function S351 Up button
H23 No function S352 Menu button
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Area A: Diesel engine monitoring
P2 –Diesel engine coolant temperature display

The display must be in the green area when operating the machine.
In the event of overheating (over 98 ºC = 204°F), the red LEDs P2.1 at the end of
indicator P2 will flash.
The buzzer in the cab also sounds.
When this Indicator light illuminates, the error will be saved as error code E 503.
 The red indicator protection H62 on the control board will light up.
 The Quantum system will cause an engine shutdown.
 Find and rectify the cause of the problem.
P3 – Fuel level display
The LED indicator lights show the fuel level. When the both red light P3.1 light up,
about 10% to 20% fuel are left in the tank as reserves.
Area B :Indicator lights
H2 –Indicator light, low engine oil pressure

The Indicator light illuminates if the engine oil pressure drops below a given value
when the machine is operating.
The buzzer in the cab also sounds.
When this Indicator light illuminates, the error will be saved as error code E 501.
 The red indicator protection H62 on the control board will light up.
 The Quantum system will cause an engine shutdown.
 Find and rectify the cause of the problem.
H12 –Indicator light, battery charge
The Indicator light illuminates if the ignition key is placed in the contact position.
The Indicator light goes out as soon as the engine is started.
When the machine is operating, this Indicator light illuminates if the V-belt alternators
or the electrical charging system are defective.
 Bring the engine to a low idle immediately.
 Allow the engine to idle for approximately 5 seconds.
 Switch off the engine.
 Rectify the error.
H19 – No function
H20 –No function
H23 – No function
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H24 – No function
Area D: Menu control for screen
Fig. 3-7 Screen menu control
The screen can be operated using the following 4 buttons:

– S349: Back button
– S350: Down button
– S351: Up button
– S352: Menu* button
* = Change from main to submenus
These buttons can be used to jump from the operator’s menu to the submenus or to
move from page to page.
Area C: Screen
To change the screen contrast:

 Press button Menu and arrow button Up (higher contrast) or Down (lower con-
trast) simultaneously.
 The value set will be saved.
To alter the brightness of the main screen:

 Press button Back and arrow button Up (brighter) or Down (darker) simulta-
neously.
 The value set will be saved.
Note!
A light sensor built in to the top left of the monitoring screen controls the illumination
on the main screen, dependent on the brightness of the environment. Tracking is
carried out using the buttons and originating from the basic setting. Illumination will
be automatically reduced in conditions of low environmental brightness.
To change the brightness and the contrast setting to the works setting:
 Turn off the ignition.
 Press and hold the Up and Down buttons simultaneously.
 Turn on the ignition again.

 Release the buttons once the automatic check is completed.
3.1.6 Main screen

The main screen appears when the machine has been switched on and remains on
display until the screen is changed over to the menu selection screen using the Menu
button.
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Fig. 3-8 Main screen
EC Cable error display SY Symbols

INF Information TI Time
Main screen design
SY field
The uper field of the monitor shows, on the one hand warning and indicator symbols,
on the other hand a clock, if no more than 4 warning symbols are shown. Should
more than two symbols be shown, so the clock is no more displayed and up to four
symbols can be diplayed simultaneously in the field SY.
If more than 4 symbols must be displayed, the symbols will be shift to the left by one
symbol every 10 seconds (see section "Warning symbols in the SY field" further in
this chapter).
EC field
The EC window displays the error codes for electrical faults which occur in the exca-
vator's electronics system (line errors, sensor errors etc.). A maximum of 7 error co-
des are displayed simultaneously. If there are more than these 7 errors present, an
arrow which points to where the other error codes are located will be displayed next
to the error code window.
 Press the Up or Down button.
 The error code window will be shifted in the direction selected in the error code
list.
INF field
The INF field displays information temporarily, in both text and graphic form.
If more than 3 symbols are to be displayed, the symbols will shift one symbol to the
left approx. every 10 seconds.
The information is displayed in graphic or text form and indicates specific operating
states on the machine. (see section "Information symbols in the INF field" further in
this chapter).
TI field
The machine operating hours and the daily operating hours counter are displayed
bottom right in this field.
The ® symbol indicates that a quantity limitation is active for the pumps (see section
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"Status of hydraulic pumps and electrical inputs and outputs menu" further in this
chapter).
Menu navigation in the event of an error display

If an error is recognized as “new” in the SY field, the user is returned to the main
screen. The relevant error display is activated.
Depending on the error (level of urgency), the buzzer will sound either continuously
or in short consecutive bursts. This symbol will be displayed in the INF field.
Danger!
If the error displayed is not rectified immediately, this could lead to persons sustai-
ning injury or the machine being damaged.
 Rectify / have the error rectified immediately.
 To switch off the buzzer, press the Back button.
 The error will be acknowledged and stored.
Warning symbols in the SY field

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

This symbol appears as long as the engine coolant temperature is below a preset va-
lue.
 Avoid starting the Diesel engine and operating the excavator under these condi-
tions if the excavator doesn’t have an optional preheating system.
 If the excavator has an optional preheating system, operate the preheating sys-
tem first until the symbol goes off.
 If you start the Diesel engine while the symbol is on, error code E 495 will be
stored.
E 501 – Low engine oil pressure
This symbol appears if the engine oil pressure drops below a preset value.
 Indicator light H2 lights up and buzzer sounds simultaneously.
 The Quantum system will cause an engine shutdown.
 Find and rectify the problem.
 See also Cummins Operation and Maintenance manual.
E 502 – Coolant low
This symbol appears if the coolant level drops below the minimum level.
 The buzzer sounds simultaneously.

 Bring the engine to a low idle immediately.
 Switch the engine off as quickly as possible.
 Localise the leak and carry out repairs.
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Caution!
This monitoring device acts as an increased level of security in case of larger
amounts of water loss (eg. hose rupture). It does not relieve the operator or mainte-
nance personnel from the responsibility of regularly checking the coolant level in the
equalizing reservoir.
2963 / E 503 – Engine coolant overheat (low / moderate or high)
This symbol appears simultaneously with the P2 coolant temperature display.
E 540 – Engine coolant pressure

This symbol appears simultaneously with the red indicator protection H62 if the coo-
lant pressure is too low.
 See Cummins Operation and Maintenance manual.
 Locate the reason for the trouble and get it repaired.
E 597 – Manifold overheat
This symbol appears simultaneously with the red indicator protection H62 if the ma-
nifold temperature is too high (above 104°C=220°F).
 See Cummins Operation Maintenance manual.
E 506 – Oil in splitterbox is overheating
This symbol appears if the oil temperature in the splitterbox exceeds 85°C (185°F).
 Turn the engine off.
 Find and correct the problem (splitterbox cooler dirty, ...).
E 562 – Low oil level in splitterbox
This symbol appears if the oil level drops below the minimum level.
 Find and repair a possible leak.
 Add oil until the level is correct.
E 564 – High oil level in splitterbox
This symbol appears if the oil level in the splitterbox is above the maximum level.
 Find and repair the problem.
It is possible that too much oil has been added, or the oil level might have increased
due to hydraulic oil entering via a defective pump shaft seal.
E 591 – Splitterbox oil pressure low
This symbol appears if the splitterbox oil pressure drops below 0.2 bar.
 Stop operation and turn the engine off.
 Find and correct the problem.
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Servo pressure low

This symbol appears if the servo pressure drops below 20 bar.
E 504 – Low hydraulic oil level
This symbol appears if the oil level in the hydraulic tank drops below the minimum
level. At the same time, the pump are automatically returned to minimum flow.
 Find and repair the cause of the oil loss.
 Add hydraulic oil via the service flap or via one of the return filters.
Hydraulic oil warm-up procedure on
This symbol appears as long as the warm-up procedure is on, i.e. as long as the hy-
draulic oil temperature is below a preset value.
 During the warm-up procedure, the main pumps displacement is limited to
50% in order to prevent damage to components.
E 505 – Hydraulic oil overheat
This symbol appears if the hydraulic oil temperature in the tank exceeds a preset va-
lue.
 Stop operation.
 Continue to let the engine run in high idle and wait until the symbol disappears.
If necessary.
 Find and correct the problem (oil cooler dirty, blower or thermostat defective, ...).
Main pumps power reduction on
This symbol appears as long as the hydraulic oil temperature is in a preset high tem-
perature range.
 Main pumps power is reduced progressively as long as the hydraulic oil tem-
perature is in this range.
 Main pumps output is set to zero if the hydraulic oil reaches the overheating
temperature.
 Allow the hydraulic oil to cool down to be able to operate the excavator then cor-
rectly.
E 590 – Low hydraulic tank pressure
This symbol appears if the hydraulic tank pressurization drops below 0,15 bar.
 Find and correct the problem (check the air pressure system).
E 566 - E 567 - E 568 - E 569 – Main pumps are contaminated
This symbol appears if metallic particles have been deposited on the contamination
switch of one of the main pumps (the pump number appears in the top corner of the
symbol).
 Notify the maintenance personnel.
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E 572 - E 573 – Swing pumps are contaminated

This symbol appears if metallic particles have been deposited on the contamination
switch of one of the swing pumps (the pump number appears in the top corner of the
symbol).
 Notify the maintenance personnel.
E 578 - E 579 - E 580 - E 581 – Main pumps overheat
This symbol appears if the temperature on one of the main pumps exceeds a preset
value (the pump number appears in the top corner of the symbol).
E 584 - E 585 – Swing pumps overheat
This symbol appears if the temperature on one of the swing pumps exceeds a preset
value (the pump number appears in the top corner of the symbol).
E 592 – Low oil level in the Centinel System (optional)
This symbol appears if the oil level in the Centinal tank drops below the minimum le-
vel.
 Fill the Centinel tank as soon as possible.
E 593 – High fuel temperature
This symbol appears simultaneously with the red indicator protection H62 if the fuel
temperature is too high (above 104°C=220°F).
E 594 – High fuel rail pressure
This symbol appears simultaneously with the red indicator protection H62 if the fuel
rail pressure exceeds a normal limit.
E 595 – High blow-by pressure
This symbol appears simultaneously with the red indicator protection H62 if the blow-
by pressure exceeds a normal limit .
 Stop engine.

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E 596 – Low engine oil level

This symbol appears simultaneously with the red indicator protection H62 if the en-
gine oil level drops below the minimum level.
 Full the engine oil tank.
E 598 – Oil change required
This symbol appears simultaneously with the red indicator protection H62 if an engi-
ne oil change is required.
 Do it as soon as possible.
E 543 – Dual Lifetime sealing oil level low
This symbol appears if the oil level in the Lifetime sealing drops below minimal level.
 Add oil until correct level is reached.
E 544 – External swing teeth greasing
This symbol appears if the swing teeth greasing system is defect.
 See also Lincoln servicing manual.
E 545 – Grease level low
This symbol appears if the grease level drops below minimum level.
 The bucket will be blocked.
 Add grease until correct level is reached.
 See also Lincoln servicing manual.
D 421 – Engine oil temperature high
This symbol appears if the engine oil reaches high temperature.
 The Quantum system will cause engine torque derate.
 Stop operation.
 Continue to let the engine run in high idle and wait until the symbol disappears.
If necessary.
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D 421 – Engine oil overheating

This symbol appears if the engine oil reaches maximum temperature.
 The Quantum system will cause engine torque derate.
 Stop operation.
D 418 – Water in fuel
This symbol appears if what is detected in fuel with moderate quantity.
 Drain fuel filters.
1852 – Water in fuel high level
This symbol appears if what is detected in fuel with high quantity.
 Drain fuel filters.
D 441 – Battery voltage low
This symbol appears if the battery voltage drops below minimum value.
D 442 – Battery voltage high
This symbol appears if the battery voltage exceeds maximum value.
D 449 – Rail overpressure
This symbol appears if the fuel rail pressure exceeds maximum value.
 Engine will undergo power and/or speed derate.
1362 – Engine oil filter differential pressure

This symbol appears if the engine oil filter is defective.
 Engine will derate and/or stop.
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E 460 – Exhaust gas temperature deviation

This symbol appears if the exhaust gas temperature deviates from normal range.
E 464 – Exhaust gas temperature too high
This symbol appears if the exhaust gas exceeds maximum temperature.
Error detected on ECM
 See also § "Error code charts".
Information symbols in the INF field
Service due
This symbol appears if a service interval is due.
 Switch on the ignition.
 The service interval to be carried out will be displayed for approx. 10 seconds
in place of the overall operating hours.
Acknowledge error
This symbol appears if a machine error (E 5xx) has occurred and the buzzer sounds
simultaneously.
Getting information from the operator’s menu on the main

screen
Main screen menu selection

Fig. 3-9 Main screen
 To change to the operator’s menu, the main screen must be visible.

 Press the Menu button on the main screen.
 The list of accessible menus is displayed.
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Fig. 3-10 Menu selection in the operator’s menu.
To select the operator’s menu:

 Press arrow key Down or Up.
 The following or previous operator’s menu will be displayed on screen with a
black background.
 The selected menu is displayed with a black background, the Reset daily opera-
ting hours menu is used here as an example.
 Press the Menu button again.
 The submenu for the function selected is displayed.
 Press the Back button again.
 The submenu will be aborted.
Symbol Description
Reset daily operating hours counter
Confirm service interval
Select quantity limitation relating to attachments (eg. hammer)
Operating hours and device data
Status of hydraulic pumps and electrical inputs and outputs
Recorded and stored errors
Immobilizer
(must be activated by LIEBHERR customer service using a

service connector)
Tab. 3-1
Tab. 3-2 Overview of menu options
Reset daily operating hours counter menu

The daily operating hours counter can be reset to 0 using this menu.
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Fig. 3-11 Resetting the daily operating hours counter
To set the daily operating hours counter to 0:

 Press the Up arrow key.
 The OK which is not crossed out will be displayed with a black background.
 Press the Menu* button.
 The operating hours will be reset to 0.
 The arrow key symbols Up and Down and the Menu symbol will no longer be
displayed.
To exit the menu:

 Press the Back button.
Confirm service interval menu

This menu is used for information on service intervals and to confirm service work
which has been carried out.
Fig. 3-12 Service intervals menu
The operating hours of the next service interval (in this example, “500 Hrs”) and the
current operating hours (“478 Hrs”) are displayed in the menu.
A pending service interval can be confirmed a maximum of 50 operating hours before
the service interval is due.

When this time period has been reached a query will appear to ask whether the ser-
vice work has been carried out.
 Service work carried out.
 Press the Up arrow key.
 The OK which is not crossed out will be displayed with a black background.
 Press the Menu button.
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 The current operating hour will be confirmed as the last service interval carried
out.
 Service work not carried out.
Allocation of quantity limitation options to external input I1 menu

(Kit input; for example, activation of the hammer pedal)
Predefined quantity limitations have been assigned in this menu.
The arrow opposite the symbol represents the current selection.
In the example (see Fig. 3-13), quantity 2 is active if the specified attachment is ser-
viced.
Fig. 3-13 Work equipment quantity limitation menu
 Press the Up or Down arrow key.

 A different, predefined quantity (1-4) can be assigned (e g. when work equip-
ment is changed).
 The selection is confirmed. The arrow displays the current selection.
To exit the menu:

Operating hours menu

Pages 1 to 2 provide an overview of the operating hours of individual units, proces-
ses and operating types.
Fig. 3-14 Engine service life menu (example)
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Page 1 provides the service life in hours for:

– Diesel engine
– Diesel engine in P mode (RPM stage 10)
– Diesel engine in E mode (RPM stage 8)
– Hydraulic operation
– Swing movements
– Travel movements
– Diesel at low idle
Fig. 3-15 Operating hours menu

 Page 2 is displayed.
The screen (page 2/3) indicates the operating hours for :
– Pontoon operation
– Safety operation for pump power control
– Safety operation for pump flow control
Fig. 3-16 Technical data

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

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Status of hydraulic pumps and electrical inputs and outputs menu
Fig. 3-17 Quantum system menu
Page 1 provides information from the Quantum system of the engine.
Fig. 3-18 Quantity limitation menu

This screen gives information about the operating position of the hydraulic pumps. It
gives the following indications for each working pumps :
 If the flow limitation is activated for the pump. If it occurs, the symbol "R" is dis-
played in the field TI, see main screen. The screen 2/7 shows an example with
the flow limitation M1 activated, which limits the pump P2 to 34% of the maximum
flow. Should several flow limitations be actuated at the same time, so the one with
the smallest flow value has priority.
 The graphic bar with electric current value indicates for the pump the amount of
the momentary flow control signal.
Fig. 3-19 LR magnet menu
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The present LR solenoid current (current value for power control) is showed on
screen 3.
Fig. 3-20 Fan speed current values menu

The screen 4 indicates for the fan pumps the amount of the momentary flow control
signal.
Fig. 3-21 Electrical inputs


Pages 5, 6 and 7 provide an overview of the status of different electrical inputs.
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A“ ” means "Input not active".

A“ ”means "Input active".
An “NC” beneath the terminal designation means that the software for the relevant
input has been deactivated.
The status of the inputs can be changed using the menu "set data" - "set E-code".
The screen 5 indicates the status of the inputs for the different movements.
The screen 6 indicates the status of the flow limitation. M1, M2, ... correspond to ma-
chine specific (internal) oil flow limitations. I1, I2, ... correspond to predefined oil flow
limitations (see also menu "set option").
The screen 7 indicates the status other inputs. For the frequency inputs B53 and
B12, the signs “ ” means that a significant frequency is recognised by the system
B12 Engine RPM sensor B53 Swing motor sensor
S7 Safety lever servo control S57 Swing brake
To exit the menu:

Error menu (operating errors and electrical system errors)
Fig. 3-22 Recorded errors menu
There are 3 selection options in this menu:

– By selecting list Exxx, machine errors recorded by the sensors are listed.
– By selecting list E-elec, all main screen cable errors stored when operating are
listed.
– By selecting list S-Exxx, all errors which appeared when the service connector
was connected are listed.
To select the desired error type:

 Press the Down or Up arrow key.
 The following or preceding error type will be displayed with a black bac-
kground.
 The submenu on a black background will be displayed.
 If more than 6 error codes are present, arrow key Down or Up can be used to
scroll to the next page.
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Machine error list Exxx:
Fig. 3-23 Error list (Fig. left) and Error occurrence (Fig. right) menu
 Select list Exxx.

 The first page of the submenu appears.
All errors and their error codes are listed on the first page.
 Use the Down or Up arrow key to select the error code desired.
 The second page of the submenu appears.
Operating hours and the duration of the first and last ten occurrences of the error se-
lected will be listed on the second page.
 The first page of the submenu appears.
 Press the Back button again to select another error type or press the Down or Up
arrow key to select a new error code.
s*: Error was indicated by a buzzer and was acknowledged using the Back button.
The duration is given in seconds.
m*: Error was indicated by a buzzer and was acknowledged using the Back button.
The duration is given in minutes.
Note!
Only operating errors with an error code E 5xx will be displayed in the list Exxx me-
nu.
Cable error list E-elec.:

Fig. 3-24 Occurrence of electrical error (Fig. left) and Error statistics (Fig. right)
 Select Cable error list E-elec.:
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 The submenu appears.
The column "Sum" shows the number of all errors that were ever noted.
The column "Test" shows the number of errors occurred since the last deletion of this
test error memory listing.
The operating hours above the test column show the operating hour when the last
test memory was deleted (reset).
Press the Back button.
 A different error type may be selected.
Other errors list S-Exxx:
Fig. 3-25 Call up service operation error list menu
Selecting "list S-Exxx" also shows the errors according to the list in pages (see sec-
tion "Warning symbols in the SY field" previously in this chapter), but this time only
the errors that occurred during "service operation".
For each error, an overview can be shown and paged in just like for the "list-Exxx"
selection. The column "Sum" shows the number of all errors that were ever noted.
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3.1.7 Monitoring cameras
Fig. 3-26 Display for monitoring cameras
1 Field for camera 1 (opposite side) F1 F1 button (full screen camera 1)

2 Field for camera 2 (counterweight) F2 F2 button (full screen camera 2)
F8 F8 button (return)
System description
Monitoring cameras are installed on the excavator as follows in order to extend the
operator’s field of view with the operating environment:
– camera 1: on the opposite side of the cab,
– camera 2: on the counterweight.
Display
The inputs from the different cameras are transmitted to the display located on the
front right of the cab and divided on the screen as described above (see Fig. 3-26).
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Full screen
Fig. 3-27 Full screen display
The input from one camera can be switched to full screen (with the input from the
other camera remaining simultaneously displayed with normal size).
To switch a camera to full screen:

 Press F1.
 Camera 1 is switched to full screen while camera 2 remains displayed with
normal size.
 Press F2.
 Camera 2 is switched to full screen while camera 1 remains displayed with
normal size.
To switch back to standard display:

 Press F8.
 Screen turns back to standard display.
Note!
Additional cameras can be installed as optional feature. In this case, the additional
inputs will be displayed on the screen on the remaining free fields and full screen
display will be possible via corresponding Fx button.
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The access and the outfit of the cab
3.2 The access and the outfit of the cab
Safely getting up
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 particulary vigilant to realise the climbing
and descent from the cab with the best safety conditions, and do or give the ins-
tuctions to the execution of prior preparations to be accomplished, as enunciated
above, in order to displace yourself safely.
– Be particulary vigilant with those prerequisites conditions.
– For cab 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 instaled before working with the door open.
– For cab with a rear door:
• Now continue to climb up, still using the three-point support and close the door
as soon as you enter the cab.
• Sit down in the operator’s seat and fasten the safety belt (if available) before til-
ting down the safety lever, and start the machine.
Safely getting down

to instal 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 ali-
gned with each other.
– Open and lock the door. Be sure of it’s locking. Take care of weather conditions !
Unfasten the safety belt.
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– Position yourself with your face toward the machine when getting out and use
three-point support, i.e. two hands and one foot or two feet and one hand must
always be in contact with the access system at the same time. Climb down until
you can close the doors safely. Always use your hand for control when closing the
doors. Lock the door.
– Now climb down to the ground.
3.2.1 Entering or leaving the cab
Climbing up
Caution!
Entering or leaving the cab incorrectly could lead to injury.
 Proceed with the same attention on exit or entry of the cab, as while climbing the
machine.
 Ensure that the safety lever is always in its highest position when entering or lea-
ving the cab.
 Always use the handholds provided for the purpose when 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. 3-28 Access ladder
Getting in
If the access ladder is in its lowest position and the excavator isn’t running, you can
climb up on the machine.
 Climb in with the access ladders and with your face towards the ladders and use
the provided handholds.

 On the cabin catwalk, open the door.
 Go in the cabin and sit in the operator’s seat
 Adjust the seat if necessary.
Getting out
 Switch off the machine and push the safety lever up.
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 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
Fig. 3-29 E1022-1 Access ladder control box
H67 Control light red / ladder not up S155 Push-button / access ladder up
H68 Not used S156 Not used
S125 Switch / lighting of cab access S157 Not used
S141 Switch / lighting of main ladder S158 Push-button / access ladder down
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Fig. 3-30 S122 on control board
The access ladder can be brought either to lower position to permit access to the up-
percarriage or to upper position during operation.
Before operating the machine, the ladder must be fully raised to the uppercarriage
and locked in place.
The ladder can be extended and retracted from the uppercarriage via the control box
E1022-1, which is installed on the catwalk next to upper ladder section leading to the
cab.
Danger!
Never actuate the ladder if you or a third person are on or in immediate proximity of
the ladder.
To bring the ladder into lower position:

 Push the switch S158 to swing the ladder until it has reached the lowest position.
To bring the ladder into upper position (working position):

 Push the switch S155 until the ladder has reached its top position.
 When the top position is reached, the ladder is locked and control light H67
goes out.
Caution!
For safety reason, the excavator can only be operated if the ladder is locked in its
top position. Otherwise, the red indicator light goes on. This means that the swing
and travel movements remain locked.
This safety measure can be momentarily by-passed by pushing and holding the
button S122 on the control board.
Note!
The ladder can only be swung up with the Diesel engine running.
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To bring the ladder into lower position in case of emergency:
In case of defect (service batteries out of order, defective solenoid valve or wiring...)
avoiding the regular lowering procedure of the ladder,
 Open valves V1 and V2 to lower the ladder.
3.2.2 Safety lever
Fig. 3-31 Safety lever
For safety purposes, the left control panel is provided with a safety lever.
Caution!
The safety lever must always be pushed up into its highest position (see arrow)
when entering or exiting the cab.
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 joys-
tick or foot pedals, are operated.
– The slewing gear brake is locked (LED in switch S17 illuminates).
– It is not possible to release the slewing gear brake using switch S17.
When the safety lever is pushed (push up / push down) to its lowest position, the
slewing gear brake and the LED in switch S17 will return to their original states and
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the pilot control devices will be active.

 Before the operator starts working, he must push the safety lever down into its
lowest position while seated in the operator’s seat.
3.2.3 Operator’s seat
Fig. 3-32 Standard operator’ seat
1 Set horizontal, upper 4a Set seat inclination, 7 Set lumbar support

front
2 Set horizontal, lower 4b Set seat inclination, 8 Seat heating
rear
3 Adjust armrests 6 Set lumbar support 10 Set backrest
The operator’s seat should be set up before starting the machine; this means that:
– The diesel engine may not be started.
– The safety lever must be pushed up.
This will avoid unexpected movement of the machine.
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Setting the armrests
Fig. 3-33 Setting the armrests
 Turn the knurled head screw 3 on the armrest in direction a.

 The armrests incline upwards.
 Turn the knurled head screw 3 on the armrest in direction b.
 The armrests incline downwards.
Setting the seat and backrest

Fig. 3-34 Setting the seat and backrest
 Rear seat inclination: Pull lever 4a up, set the inclination and release the lever.
 Front seat inclination: Pull lever 4b up, set the inclination and release the lever.
 Backrest: Pull lever 10 up, set the inclination and release the lever.
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Setting the horizontal seat position
Fig. 3-35 Setting the horizontal
 Pull up the lever 1 to push the operator's seat in the horizontal direction.
 Pull up the lever 2 to push the operator's seat and control panels in the horizontal
direction.
Setting the vibration damping and lumbar support, swit-

ching on the seat heating (air-cushioned operator’s seat, op-
tional extras)
Fig. 3-36 Switch bar on the air-cushioned operator’s seat
To set the vibration damping:

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

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

 Use switch 8 to switch the seat heating on or off.
The seat heating switches off automatically when the temperature set is reached.
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Putting on / releasing the safety belt
Fig. 3-37 Safety belt
The safety belt is automatic. It is not necessary to adjust the length of the belt.
 Pull the belt and buckle 2 out of the roller mount 1.
 If pulled out of the roller mount sharply, the belt may lock.
 Push the buckle into the belt lock 3 until it fastens.
Danger!
The safety belt is designed to protect the operator.
 Before starting the machine, always fasten the safety belt.
 Ensure that the safety belt is not twisted when it is fastened.
 To ensure your safety, check the condition, function and fastening of the belt re-
gularly and replace any damaged parts without delay.
 To open lock 4, push down on the belt lock using your thumbs.
 The safety belt will slide automatically back into the roller mount 1.
3.2.4 Adjusting of the auxiliary seat

Fig. 3-38 Auxiliary seat
The lever 1 serves to lock the auxiliary seat into position either beside the operator’s
seat or against the cab’s wall.
To rotate the seat,
 Pull the lever 1.
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To seat,
 Pull down the seating.
Note
When there is no one on this auxiliary seat, the seating must be pulled up and the
seat in position lock against the cab’s wall.
3.2.5 Sunshade
Fig. 3-39 Windscreen and side windows sunshade
The cab is provided with three sunshades, located on the windscreen and on the two
side windows.
Windscreen
 Pull the sunshade down using the cross strut on the sunshade 1.
 The sunshade can be set for individual use.
 Pull out on the string 2.
 The sunshade rolls itself up.
Side windows
 Pull the sunshade down using the cross strut on the sunshade 1.
 The sunshade can be set for individual use.

 Pull out on the string 2.
 The sunshade rolls itself up.
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3.2.6 Emergency exit
rear door
Fig. 3-40 Emergency exit – rear door
By pulling the handle 1 on the interior of the inferior window of the cabin door, the
rubber weatherstrip can be released and removed.
 In case of emergency, pull the rubber weatherstrip out of the entire area of the
window and push out the window.
Side window
The rear left window is equipped with the same system as the rear door.
 By pulling the handle on the interior of the rear left window, the rubber weathers-
trip can be released and removed.

 In case of emergency, pull the rubber weatherstrip out of the entire area of the
window and push out the window.
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3.2.7 Interior lightings
Fig. 3-41 Interior lightings
The interior lightings are switched on using the switch S41 on the Keypad.
 Press the switch S41.
 The lights E7 are switched on.
 Press the switch S41 again.
 Interior lighting E7 are switched off.
3.2.8 Fire extinguisher

The interior of the cab is fitted with fixing points allowing the mounting of a fire extin-
guisher. These fixing points are on the right side wall of the cab, on the frame
between the two windows.
Fig. 3-42 Fire extinguisher fixing location
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Note!
It is the responsibility of the owner of the machine to decide if it must be fitted with
a fire extinguisher or not, considering the operating conditions and the regulations
which apply in the country and at the point of use of the machine.
Caution!
If your machine is fitted with a fire extinguisher:
 Always comply with the operating guide on the body of the extinguisher,
 Make sure, all the inspections of the fire extinguisher which are prescribed by
the regulations applicable to the operating place of the machine are accom-
plished.
3.2.9 Windscreen wiper
Windscreen wiper
When the ignition is switched on, pressing switch S14 will activate the windscreen
wiper.
 Press switch.
 Intermittent switching
 LED I in the switch illuminates.
 Press switch again.
 Continuous operation.
 LED C in the switch illuminates.
 LED I in the switch goes out.
 Press switch again.
 Windscreen wiper is switched off.
 LED C in the switch goes out.
Setting the interval time for the intermittent switching
The interval time can be set when the ignition is on by pressing switch S14.
 Press the switch until the windscreen wiper is switched off (LED I in switch goes
out)
 Press and hold switch.
 LED I in the switch flashes.
 Release the switch when the desired interval time has been reached.
 The interval time can be set to between 2 and 10 seconds.
Windshield washer installation

When the ignition is switched on, pressing button S11 will activate the electric winds-
creen washer installation.
 Press and hold button.
 Washing water will be sprayed onto the windscreen through the outlet nozzles.
 The windshield washer runs continuously.
 Release the button.
 Washing water will be stopped.
 Windshield washer will run continuously for approx. another 3 seconds.
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Windscreen washing fluid container
Fig. 3-43 Windscreen washing fluid container
The container for the windscreen washing fluid is located under the cabin in the cab
elevation.
The container can be refilled via the service trap with ordinary windscreen washing
fluid.
Volume: see lubricant chart
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3.2.10 Field of view
Fig. 3-44 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 stan-
ding out of the hatched area illustrated on the fig. above.
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Danger!
Before using the excavator, make sure that the cameras and the outside mirrors are
correctly adjusted.
 Regularly check mirrors for condition and correct adjustment.

 Regularly check cameras for condition and correct adjustment. If necessary,
clean using a soft, dry tissue.
 Replace damaged mirrors and cameras immediately.
To cover the 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 definied by the four checkpoints given on the fig.
above.
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3.2.11 Lighting
Fig. 3-45 Arrangement of floodlights
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E1_1Fuel tank floodlight E8_1Counterweight floodlight (optional,

E1_2Fuel tank floodlight (optional, not not represented)
represented) E8_2Counterweight floodlight (optional,
not represented)
E2 Attachment floodlight E18_1Counterweight floodlight
E3 Attachment floodlight E18_2Counterweight floodlight
E4 Attachment floodlight (optional, not E23_1Counterweight floodlight (optio-
represented) nal, not represented)
E5 Attachment floodlight (optional, not E23_2Counterweight floodlight (optio-
represented) nal, not represented)
E6_1Hydraulic tank floodlight E58_1Top of cabin floodlight
E6_2Hydraulic tank floodlight (optional, E58_2Top of cabin floodlight
not represented)
Working light and attachment floodlights

Floodlights E1_1, E2, E3, E6_1, E58_1 and E58_2 as well as optional floodlights
E1_2, E4, E5 and E6_2 can be activated using button S10 on the control keyboard.
E1_1, E1_2, E6_1, E6_2, E58_1 and E58_2 constitute working light.
E2, E3, E4 and E5 are attachment floodlights.
 Press button.
 Working light is activated.
 Working light is deactivated.
 Attachment floodlights are activated.
 Working light and attachment floodlights are switched on.
 LEDs 1 and 2 in the button illuminate.
 Working light and attachment floodlights are switched off.
 LEDs 1 and 2 in the button go out.
Counterweight floodlights
Floodlights E18_1 and E18_2 as well as optional floodlights E23_1, E23_2, E8_1
and E8_2 can be activated using button S22 on the control keyboard.
 Press button.
 Counterweight floodlights are switched on.
 LED in button illuminates.

 Counterweight floodlights are switched off.
3.2.12 Heating/air conditioning system

A heater and an air conditioner are installed in the cab as standard equipment.
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The heater is installed on the cab floor. The evaporator for the air conditioning sys-
tem is integrated in the roof of the cab, and the condenser is installed on the Diesel
engine radiator.
Control unit front panel
Fig. 3-46 Front panel of the heating/air conditioning control unit
Control keys Indication on the LCD Display
1 Air conditioning ON/OFF 9 Recirculated air mode indicator

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

In order to achieve a quick dehumification of the cab when setting the machine into
operation, it may be advisable to briefly turn on the air conditioning operation when
the heater is already operative.
 Press button 6.
 Reheat mode is activated.

 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.
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Note!
To avoid overloading the starter motor and the batteries, turn on the air conditioning
mode and the reheat mode only after the diesel engine is running.
Reheat mode is automatically limited on 10 minutes.

 If the machine is used for a longer period of time without using the air conditio-
ner, press the reheat button 6 about every 2 weeks so to turn on the compressor.
Setting the evaporator blower speed manually

 Press button 5.
 Blower speed manual setting is activated.
 Indication bar 13 appears on display 19 and indicates currently set blower
speed.
 Automatic mode symbol 12 disappears from display 19.
 Manual blower mode symbol 14 blinks on display 19 for 5 seconds.
 During these 5 seconds, evaporator blower speed can be increased with button 2
or decreased with button 3 in steps of 10%.
 Press button 5 twice.
 Manual mode is deactivated.
 Symbols 13 and 14 disappear from display 19.
 Automatic mode is reactivated.
 Symbol 12 reappear on display 19.
Note!
Lowest possible evaporator blower speed is 30% (3 bars are indicated on symbol
13).
Switching ON/OFF the heating mode

 Press button 7.
 Heating mode is activated.
 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.
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MJFCIFSS
Setting the machine into operation
Switching the temperature unit from °Celcius to °Fahrenheit

 Press and hold button 8.
 Press button 3 additionally.
 Temperature unit indication 18 switches over into °Fahrenheit.
 Repeat same procedure to switch back temperature unit indication to °Celcius.
Dual air conditioning (optional equipment)

When you switch the excavator on, the automatic dual air conditioning system is ac-
tivated by default. The two air conditioning units are working alternately every 6
hours.
 Press "Dual air conditioning" button S26 on control board (see § "Control board").
 Automatic air conditioning mode is deactivated.
 First air conditioning unit is activated.
 Second air conditioning unit is deactivated.
 First air conditioning unit is deactivated.
 Second air conditioning unit is activated.
 Automatic air conditioning mode is reactivated.
3.3 Setting the machine into operation
3.3.1 Bringing the machine safely into service

– Carry out a careful inspection tour around the machine each time before starting
it.
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– 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 faci-
litate 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

tructions.
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 equipment is operating correctly.
– Move the machine carefully to an open area and then check the function of the
running and slewing gear brakes, the steering and the signaling and lighting de-
vices.
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Stopping the machine safely

– Only stop the machine on level, firm ground.
– If the machine has to be stopped on an incline, chocks should be used to secure
it from rolling away.
– Before stopping the machine, each time it is possible, align the uppercarriage with
the undercarriage so that the sprockets locate at the back-end. This is the only
one position which enables a secured access to every maintenance locations on
the uppercarriage.
– Use the stop bolts to secure the upper structure facing the undercarriage, if
available.
– Lower the equipment and anchor the grab lightly in the ground.
– Position every control lever into neutral position and depress the parking and
slewing brakes.
– Stop the engine in accordance with the operating instructions and tilt the safety
lever up before leaving the cab.
– Lock the machine, included hoods and compartments, retire every keys and se-
cure the machine against unpermited use and vandalis.
3.3.2 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
Caution!
The activities referred below involve scald or burn hazards due to the high tempe-
rature of the coolant or of the oil when the machine is at operating temperature.
 Please read first the maintenance chapter in order to get informations about
carrying out these activities.
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 Before starting the machine, the following activities should be carried out on a
daily basis:
– Check air filters for contamination*.
– Check the oil level in the engine*.
– Check the coolant level in the diesel engine*.
– Check fuel system and fuel level.
– Check the oil in the hydraulic system.
– Check that the cameras and the outside mirrors are correctly adjusted.
– If required, remove any ice and snow from the engine hood in the area of the coo-
ling and combustion air intake.
* Refer to the maintenance chapter for further informations about the procedure to follow.
Turning on the electrical system
Ignition key switching positions
Fig. 3-48 Ignition key S1
P Parking position 2 Not used

0 Off 3 Start position
1 Contact position
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Switching on the electrical system
Fig. 3-49 Batteries switches
 The batteries switches S9_1 and S9_2 must be in position "on". These are instal-
led in an electrical box located on the top of the catwalk above access ladder.
 Turn the ignition key S1 to contact position 1.
 Immediately after turning the system on, the display and the control unit will
run through a selft test.
 Make sure all indicators function properly after turning the electrical system on,
i.e. the light emitting diodes (indicator lights and gauges) turn on for a short time
then the complete field of the LCD screen 200 turns momentarily black (the matrix
indicator is energised completely for a short time).
 Only the LED in button S22 doesn’t turn on on that time.
Fig. 3-50 S22 on control keyboard
Note!
If no automatic check of the keyboard and monitoring display is carried out when
the ignition key is in the contact position, check that the main batteries are switched
on.
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Service interval display
Fig. 3-51 Service interval request
After the automatic check, any service interval that may be due will be indicated by
a graphic symbol.
In place of the operating hours information, the number of hours relating to the
service interval required will now be displayed.
The service interval request will go out after approx. 8 seconds.
Starting the engine
Note!
 Only operate the starter motor when the diesel engine is off.
 Operate the starter motor continuously for no longer than 10 seconds.
 If the engine does not start, turn the ignition key back to contact position 0,
before restarting the engine.
 And repeat the starting procedure at 20 seconds intervals to allow the starter
motor to cool off.
Starting procedure when the exterior temperature is above 0 °C (32 °F)

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

 Maintain the key on this position during the prelub time.
 As soon as the engine is running, release the key.
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Cold start aid for exterior temperature below 0 °C (32 °F) (optional)
A cold start system can be installed on the engine, which makes it easier to start at
low temperatures.
To actuate the cold start system:

 Press the cold starting aid button S149 on the control board.
 If the engine will not start, or at the beginning of a starting procedure.
 Push this button for a few seconds to spray starter fluid into the intake
manifold.
 As soon as the engine turns over, release the button (once the engine is turning,
the button is automatically locked).
Note!
Do not preheat an engine which is at operating temperature.
Starting procedure when the exterior temperature is below -18 °C (-

0.4°F)
For starting at temperatures below -18 °C, it is recommended to equip the machine
with a preheating system in accordance with LIEBHERR.
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Engine speed adjustment and mode functions
Fig. 3-53 Speed adjustment and mode functions
The previously selected engine speed will be displayed on the LED chain P4. It is
divided into 10 speed levels.
 To adjust the engine speed, press arrow keys S228 or S229.
- or -
Press the mode selection button S86.
Speed selection with arrow keys S228 and S229
To increase the speed:

 Press switch S228.
 Speed will be increased by one level.
 A second LED to the right illuminates in the P4 display.
To reduce the speed:

 Speed will be decreased by one level.
 A second LED from the right goes out in display P4.
Speed selection with mode selection button S86

Three different modes can be selected by pressing switch S86. Depressing hte
button causes to change from a pre-selected mode to the next, in the following order:
L, E, P, L and so on (mode F unavailable).
– L: LIFT mode (speed level 1 – sensitive lifting of loads)
– F: not used
– E: ECO mode (speed level 8 – economical work)
– P: POWER mode (speed level 10)
 Press the mode switch S86.
 The mode selected will be used, with the corresponding speed and power.
 The appropriate LED will illuminate permanently.
The currently active mode will be displayed under the letter on the LED. The mode
selected will be saved when the engine is switched off and will be displayed by a
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flashing LED above switch S86 the next time the engine is started.
If the engine speed is changed via the arrow keys to the engine speed for mode L,
E or P, then it jumps automatically to the corresponding mode.
If the engine speed does not correspond to the preselected mode (either because
the engine speed has been changed via the arrow keys or lowered via the low idle
automatic), the LED blinks to indicate the mode selected before.
Warm-up phase for diesel engine and hydraulic circuit

When engines are running, indicator lights H2 (engine oil pressure) and H12 (charge)
on the display must turn off.
Fig. 3-54 H2 ,H12 and P2 on display
 Let the engine idle at approximately 1000 RPM during the first 3 to 5 minutes, but
at least until warning symbols for low hydraulic tank pressurization and for low
servo pressure turn off on the LCD screen.
 Slowly increase the engine load until the coolant temperature reaches 40°C, i.e.
second green lighting diode goes on on the temperature gauge P2.
Note!
Idling for an extended period of time damages the engine.
 Switch off the diesel engine if the machine is not being used.
As long as the hydraulic oil temperature is below a preset value, the warm-up symbol
is displayed on the SY field of the main screen.
During the warm-up procedure, the main pumps displacement is limited to 50% in or-
der to prevent damage to components.
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.
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Caution!
 Bring the engine and hydraulic oil up to operating temperature. The controls
operate sluggishly at low oil temperatures.
 Move the machine carefully in an open space to test the function of the travel
and swing brakes.
 Check that the equipment is operating perfectly.
Switching off the diesel engine
Caution!
The engine could be damaged.
 Do not switch the engine off suddenly from full throttle.
 Reduce engine RPM to low idle via the arrow key S229 and let the engine run for
3 to 5 minutes so as to lower the temperature.
 Then turn the ignition key to position 0 in order to switch off the engine.
 Remove the ignition key.
3.3.3 Starting aids (optional)
Functional description
The excavator can be fitted with an optional preheating kit (required according to the
ambient temperature of the work environment) supplied by an external electric power
supply.
Preheating devices are installed on different components of the excavator. These de-
vices are supplied by 2 electric modules (see § "Preheating components").
These 2 modules are installed in an additional electric cabinet in the cabin elevation.
In order to be supplied externally, this cabin elevation has a socket for a generator
set (Gen-Set).
 The Gen-Set must provide at least 21kVA, 400V, 50Hz.
When the Get-Set is connected, the 2 modules are supplied one after the other (see
§ "Preheating procedure").
Caution!
The Diesel engine can be started during the preheating but travel and swing move-
ments are not allowed.
The preheaters are monitored and a warning light H104 on the control board will
come up if a default is detected.
A warning symbol on the Display stays on during the preheating cycle until the Diesel
engine can be started.
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Preheating components
-30°C (-22°F) low temperature kit

 This kit must be activated every time the excavator is standing with external tem-
perature between -30°C and 0°C (-22°F and 32°F) and weekend or service and
maintenance day.
Module 1 supplies following components:
– engine cooling water equipment,
– engine oil immersion heaters,
– hydraulic oil immersion heaters in suction pipe,
– splitterbox immersion heaters,
– battery heating blankets,
– electrical box preheater.
Module 2 supplies following components:
– hydraulic oil immersion heaters in hydraulic tank.
-40°C (-40°F) low temperature kit

 This kit must be activated every time the excavator is standing with external tem-
perature between -40°C and 0°C (-40°F and 32°F) and weekend or service and
maintenance day.
Additionally to the -30°C kit devices, module 2 supplies the following added compo-
nents:
– windshield defrosting unit,
– electric cabin heater.
Optional components
Following devices can be installed in addition to the previous kits:
– grease tank heating blanket (supplied by module 1),
– fuel heater,
– ether start aid,
– thermal insulation kit (including louvers, lower covering, insulated PowerPack
doors and fire protection sheets),
– preheating pedal plate and footrests,
– connections for external heating air hose,
– snow protection for air filter (see description below).
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Snow protection for air filter (optional)
Fig. 3-55 Snow protection for air filters
A Summer setting 25 Cover

B Winter setting 26 Screw
To set summer position A

 Set cover 25 on bottom position.
 Fresh air comes exclusively from outside.
To set winter position B

 Before starting the engine at ambient temperature below 0°C, the air inlet of the
engine air filter must be switched in winter position B.
 Unscrew the screws 26.
 Move up cover 25 and install screws 26 on top position.
 The air is a mixture between outside air and PowerPack compartment air (war-
med up).
Preheating procedure
Note!
If the excavator is turned off but the ambient air temperature won’t be lower than -
10°C (14°F), or if the excavator is turned off less than one hour and the ambient air
temperature is lower than -10°C (14°F) (for daily maintenance for example):
 Follow standard procedure to park the excavator (no need to connect the Gen-
Set, i.e. to use the preheating kit).
 Then, start the excavator by following the standard start procedure.
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Measures to be taken after engine stop or prior to start preheating (in

any case)
Fig. 3-56 Backhoe (left) and shovel (right) attachments position during preheating
 Lay down the attachment on the ground, so that a maximum quantity of oil is in
the hydraulic tank: stick and bucket cylinders fully raisin in, bucket on the ground.
 Shut louvers for hydraulic oil coolers and engine coolers as well as PowerPack
insulation doors (if installed).
 Use the snow protection for air filter as described in § "Snow protection for air fil-
ter" previously in this section.
To preheat the excavator

 Plug Gen-Set into socket for module 1 and 2 on the cabin elevation:
 Power supply indicator light comes on on the electric cabinet.
 Preheating cycle for module 1 starts.
 Indicator light for module 1 comes on on the electric cabinet.
 When preheating cycle for module 1 is completed:
 Indicator light for module 1 goes off.
 Preheating cycle for module 2 starts.
 When preheating cycle for module 2 is completed:
 Indicator light for module 2 goes off.
 Preheating cycle for module 1 starts again.
 etc...
To operate the excavator

 Make sure that the warning symbol for low coolant temperature is no longer dis-
played.
 Start the Diesel engine.
 At this step, no travel or swing movement are possible. Attachment move-
ments are limited.
 Turn on the windshield defrosting unit and the electric cabin heater (if installed).
 Make sure that the hydraulic oil temperature has reached at least +10°C (+50°F).
 Open louvers (if installed).

 Operate all attachment movements at reduced speed:
– Lift up the boom very slowly and bring it down very slowly, repeat these opera-
tions 5 times.
– Do the same operations for each cylinder of the attachment by repeating them 5
times.
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Note!
 If the attachment is equipped with bypass valves and if the ambient temperature
is below -30°C (-22°F):
 Open these valves to bypass the cylinders in order to heat up oil in the attach-
ment pipes and hoses
 Operate all attachment as described above.
 As the bypass valves are open, there is no movement of the attachment.
 After these operations, close all bypass valves.
 The excavator can now be operated.
To stop the preheating

 Unplug Gen-Set from socket on electric cabinet for module 1 and 2.
 Power supply indicator light on the electric cabinet goes off.
3.3.4 Jump start procedure
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.
Connecting 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.
Disconnecting the batteries

 First remove the cable from the negative terminal (-) of the exterior battery and
then from the negative terminal (-) of the flat battery.
 Remove the second cable from the positive terminal (+) of the exterior battery and
then from the positive terminal (+) of the flat battery.
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 Check the electrical function of the machine.

For battery care and maintenance, see the chapter “Battery care”.
3.3.5 Emergency operations
Emergency shutdown
Fig. 3-57 S100-1 on control board
To execute an emergency shutdown:

 Turn the starter key to the "0" position or push one of the emergency stop buttons
S100_1, S100_2, S100_3, S100_4 or S100_5.
 This action will shut down the diesel engine and disconnect the electrical system.
Caution!
Only use this shutdown method in case of emergency. After an emergency shu-
tdown, it is very important to let the engine run again for a short time at low idle on
next restart.
Using the emergency stop buttons will cause the hydraulic tank to be depressurized
quickly.
 After a shutdown via an emergency stop button, the button must be unlocked be-
fore attempting to restart.
Caution!
You must wait at least 10 minutes after an emergency shutdown before attempting
to restart.
Emergency operations of the diesel engine

If the engine cannot be started, monitored or operated safely due to a function pro-
blem in the control electronic of the excavator, diesel engines operation can be con-
tinued via the emergency control function.
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Fig. 3-58 Emergency operation on control board
Starting the diesel engine

 Press button S23 to turn on the emergency control circuit for Diesel engine.
 Indicator light in the button illuminates.
 Turn the speed control rotary knob R6 fully counterclockwise to low idle RPM.
 The starting procedure is the same as during the normal starting procedure (see
§ "Starting the engine" in this manual).
 Release the ignition key as soon as the engine starts.
Caution!
 Operate the starter motor continuously for no longer than 10 seconds.
 Wait 20 seconds before trying the starting procedure again to allow the starter
motor to cool off.
Adjusting the diesel engine speed

To adjust engine speed with emergency control:
 Turn the speed control rotary knob R6 counterclockwise to reduce engine speed.
 Turn the speed control rotary knob R6 clockwise to increase engine speed.
Note!
When the emergency control circuit is turned on, the engine control buttons S20,
S228, S229 and S86 of the keyboard are not functioning.
All remaining buttons on the control panel remains fully functional, if they are not
affected by the existing problem.
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Monitoring the engine speed

In emergency function, the speed dial indicator P4 remains fully functional and must
be monitored regularly and carefully, because all remaining indicators and warning
symbols may no longer be reliable or fully functional (depending on the problem).
Turning the diesel engine off
Caution!
Do not suddenly turn the engine off when it’s running at high idle.
To turn off the engine with emergency control:

 Reduce the engine speed via the speed control rotary knob R6 to low idle.
 Continue to run the engine at low idle for 3-5 minutes to lower the temperature.
 Turn the ignition key to position 0 to turn the engine off and remove the key.
Emergency control of the hydraulic pumps

During normal operation of the excavator, the electronic horsepower control conti-
nuously adjusts the pump flow to the pressure level of the working circuits. If a trouble
occurs in the circuit of the regulator, the pumps are swivelled back to minimal flow.
However it remains possible in this case to carry on the working with the machine
(with somewhat reduced power) by pushing the button S73.
3.3.6 Board E52 for safety mode of Diesel engine and servo con-
trol
Thanks to this printed board, the excavator can, in case of a failure in the main elec-
tronic circuit, be maintained operating temporarily and with some restrictions.
Fig. 3-59 Control board for safety operation E52
E52 Printed board for safety operation S71 Switch / engine start in safety
mode
H11 Warning light / Diesel engine in S72 Switch / RPM selection in safety
safety mode mode
H60 Warning light / operating error on S73 Switch / servo pressure circuit in
Diesel engine with safety mode safety mode
turned on
Starting the Diesel engine in safety mode

In normal operation, the engine is started via the main electronic circuit when the ig-
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nition key is turned to start position.

In case the engine can no longer be started or kept running due to troubles in the
control electronics, it can be started in safety operation via the starting switch S71.
 Turn the ignition key in start position and at the same time push the safety start
switch S71 to the right.
 Keep the switch pushed to the right until the engine starts
 The warning light H11 turns on.
 The symbol S71a is displayed on the screen.
 The engine is now operating in safety mode.
Safety operation of the Diesel engine

The engine can also be switched into safety operation automatically, as an example
consecutively to a communication default in the control system.
In safety operation, the engine works with reduced output in comparison with the nor-
mal operation.
In safety operation the stop of the Diesel engine is achieved just like in normal oper-
ation, while turning back the ignition key to the "off" position.
It is not possible to return to normal operation when the engine is running, the rocker
switch S71 must be tilted back from safety operation into normal operation (position
"AUTO") only when the excavator is turned off.
Note!
In safety operation, the communication between the electronic control box of the
engine and the main circuit of the excavator may be no longer possible.
The engine operating error codes are in this case no longer displayed on the
screen.
The occurence of an operating error of the engine is then indicated as follows:

• the red warning light H60 lights on,
• a buzzer in the cab beginns to sound.
• the error code E525 appears on the monitoring display.
Caution!
In case the warning light H60 lights up, the operator must shut the engine down as
soon as possible and recognize which error has occurred.
It's the operator's own responsibility to decide if the machine can be maintained
operating or not!
In safety operation the following functionss remain available:

• the automatic engine power reduction in case of overheating of the engine cool-
ant or of the charge air.
• the memorization of the occurring engine faults into the inner error memory of
the control box of the engine.
At the opposite, the following functions are no longer operative:

• the automatic engine shutdown in case of low lube oil pressure.
• the automatic engine shutdown when the maximum permitted coolant or char-
ging air temperature has been exceeded.
Diesel engine RPM adjustment in safety mode

In normal operation, the desired value for the engine RPM is entered via the buttons
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S86, S228 and S229, and the engine speed is controlled in consequence by the
electronic system of the machine.
If the engine has been started in safety mode via the rocker switch S71 so it can be
operated only with two different RPM values. The commutation between the two val-
ues is achieved via the switch S72.
Fig. 3-60 Emergency control of the engine RPM
 Manually choose one of the values:

• with the switch S72 tilted to the left, the engine runs at the lower safety RPM.
• with the switch S72 tilted to the right, the engine runs at the upper safety RPM..
Note!
When the engine is switched automatically into safety operation, the current engine
speed is maintained as long as the engine is not shutdown.
Safety operation of the servo control circuits

During normal operation, the servo pressure supply to the swing brake and to the joy-
sticks and pedals is controlled over the electronic circuit of the machine.
While tilting the switch S73 in safety position, this servo pressure supply can be en-
forced, and is maintained even in case of a trouble in the normal control circuit.
Fig. 3-61 Safety mode of servo circuits - Safety switch and symbols at the display
 Tilt the safety lever down.

 Commute the switch S73 into safety position (tilt to the right).
 the three indicator symbols S73a, S73b and S73c appear on the display.
 the joysticks and pedals are supplied with servo pressure.
 the swing brake is released.
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Danger!
The safety mode must be turned on only temporarily and in order to move the ma-
chine for emergency reasons and when, due to a trouble in the normal control cir-
cuit, releasing the swing brake or supplying the pilot controls is hindered.
In safety mode, the swing brake will be released as soon as the ignition key is tur-
ned to contact position, and the normal brake control is out of function.
 Inform all personnel involved in the operation or maintenance of the machine
that the safety mode has been turned on and that, by the fact, the control of the
swing brake is modified.
 Locate the trouble which makes the operation in safety mode necessary and get
it repaired as quickly as possible.
Note!
 Even with the switch S73 in safety position, the servo pressure supplying the
joysticks and pedals is interrupted when tilting up the safety lever .
3.3.7 Driving
Driving straight ahead
Fig. 3-62 Driving straight ahead
1 Idler 5a / 5b Pedal for left drive unit

2 Sprocket wheel 6a / 6b Pedal for right drive unit
Caution!
When driving, the upper carriage must be rotated to the chassis in such a way that
when driving forwards, the sprocket wheel 1 is in front and the idler 2 is at the rear.
Driving forwards:
 Push both pedals forward (5a and 6a).
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Reversing:
Caution!
Before reversing, ensure that the area behind you can be safely entered.
 Push both pedals down (5b and 6b).
Turning on the spot
Fig. 3-63 Turning on the spot
Turning left (A):

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

 Push the right pedal down (6b).
 Push the left pedal forwards at the same time (5a).
Turning with a crawler
Fig. 3-64 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).
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Note!
If possible, avoid turning backwards in order to preserve the running gear parts.
Controlling the speed

The driving speed is influenced by button S21. The travel motors can be operated in
two different positions:
– Normal drive (position 1):
Maximum tensile force of both drive units at moderate speed.
– Fast drive (position 2):
Reduced tensile force of both drive units at maximum speed.
 Transfer from normal drive to fast drive is activated.
While driving, the machine will automatically switch from normal drive to fast drive as
the ground conditions permit. After transferring to fast drive, LED 2 illuminates. If the
ground conditions become more difficult again, the system will automatically switch
from fast drive to normal drive. LED 1 illuminates.
 Press button S21.
 Transfer from normal drive to fast drive is deactivated.
When button S21 is switched off, the travel motors remain continually in position 1.
Braking the machine

The hydrostatic travelling mechanism of the machine also functions as a service bra-
ke.
 Disengage the pedals for the drive units.
 The pedals will return to the neutral position.
 The travelling mechanism will be stopped.
 The machine will be braked.
When the pedals for the drive units are in the neutral position, the hydrostatic drive
prevents the machine from rolling off.
In the neutral position, the parking brake will be applied automatically after a few se-
conds. The work equipment can, however, still be moved.
Actuating a travel pedal again will disable the travel brake.
Caution!
Disengaging the pedals quickly causes the machine to halt abruptly.
 Before starting the machine, always fasten the safety belt.
The travel brake can also be directly actuated by using button S354.
 Press button.
 Travel brake is engaged.
 Undercarriage is locked.
 Travel brake is disabled.
 Undercarriage is unlocked.
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Working with the machine
Note!
If the travel brake has been activated by using the button S354, the only way to di-
sabled the travel brake is to pressure S354 again. I.e. actuating the travel pedals
won’t have any effect.
3.4 Working with the machine
Working safely with 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 parti-
cular care when working near them. If necessary, inform the responsible authori-
ties.
– Maintain a safe distance from electrical aerial lines. Do not allow the equipment
to come near cables when working near electrical aerial lines. Risk of fatality! 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 equipment,
• do not leave the driver’s cab,
• warn any personnel in the vicinity not to come close to the excavator and
not to touch 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 re-
gulations beforehand.
– Always turn on the lights in conditions of poor visibility or darkness.
– Do not permit any passengers in the machine.
– Only work when seated properly and with the safety belt securely fastened (if
available).
– Report all function faults and ensure that all necessary repairs are carried out 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.
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– 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 equipment; this applies particularly when using the grab.
– Position the upper structure in the longitudinal direction when moving and hold
the load as close to the ground as possible.
EXCEPTION : excavators used for loading and unloading, see the part "Safe use
when loading and unloading (particularly when loading and unloading wood)" on
page 79.
– Adjust your driving speed to suit local conditions.
– Avoid any working movements which may tip the machine. Should the machine
start to tip or slide sideways, however, turn the upper structure to face downhill
and lower the equipment at the same time.
– As far as possible, work downhill or uphill and not side on to the slope.
– Drive safely on stony, sleepery or inclined ground
– Only drive downhill at the permitted speed or you could lose control of the machi-
ne.
– Always shift down to a lower running step before a slope. When doing this, the
diesel engine must run at maximal speed and the speed may only be reduced
using the foot pedals.
– Load an occupied truck only if all safety requirements are fulfilled, notably in order
to protect the truck operator.
– For demolition work, digging and crane operations etc., always use protective 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 equipment 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.
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.
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– Inspect the machine for damage if the attachment has been swung into a wall or
any other obstacles.
– Applications in which the attachment is to be used to strike the material being 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
applications are required.
– Do not attach too large bucket or bucket with side cutters or that are during ope-
rations with rocky material. This would prolong the work cycles and may lead to
damage to the bucket as well as further machine components.
– With the 2x45° offset articulation, the offset position may only be employed if the
working tool or the attachment does not touch the material.
– Operation of the offset articulation to drill into the material is not permitted.
– Do not lift the machine during operation. Should this happen, lower the machine
slowly back to the ground.
– Do not let the machine fall heavily on the ground and do not hold it back with the
hydraulics. This would damage the machine.
– During operation with the attachment it is forbidden to raise the machine with the
dozing blade (e.g. carving at the ceiling when tunnelling).
– Do not dig under the undercarriage. Take all necessary measures to prevent
ground collapse under the machine.
– The practice of following working methods is forbidden:
• Batter pulling, also known as Scaling or Ripping,
• Double benching, also known as Split benching or Double flitching.
The practice of these methods will result in increased stresses to steel structu-
res and components of Liebherr Mining Machines. It may significantly reduce
the expected life of structures and/or components.
Liebherr does not condone and does not approve the operation of Liebherr Mi-
ning Machines in this manner.
Safe use with a hydraulic hammer

– The hydraulic hammer must be selected with particular care. When using a hy-
draulic hammer not permitted by LIEBHERR, steel structures or the other machi-
ne components can become damaged.
– Before beginning breaking tasks, position the machine on firm and level ground.
– Use a hydraulic hammer designed exclusively for breaking stone, concrete and
other breakable materials.
– Only operate the hydraulic hammer in the longitudinal direction of the machine
and with the windshield closed or with a front protective grid.
– Ensure during hammer operation that no cylinder is entirely extended or retracted
and that the stick is not in the vertical position.

– In order to avoid damages to the machine, try not to break stone or concrete while
performing retraction and extension motions of the hydraulic hammer.
– Do not apply the hydraulic hammer uninterrupted for more than 15 secs. at a time
to the same place. Change the breaking point. Too long uninterrupted operation
of the hydraulic hammer leads to an unnecessary overheating of the hydraulic oil.
– Do not use the drop force of the hydraulic hammer to break stone or other mate-
rials. Do not move obstacles with the hydraulic hammer. Misuse of this nature
would damage both the hammer and the machine.
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– Do not use the hydraulic hammer to lift objects
Safe use when loading and unloading (particularly when loa-

ding and unloading wood)
– According to use, it can be necessary when working with a grab to move with the
equipment raised and the load lifted up; this applies, for example, when loading
and unloading wood.
– Here, the centre of gravity of the machine will be displaced upwards in the vertical
direction. The driving characteristics of the machine will thus be influenced per-
sistently, e.g. through reduction of the dynamic stability.
• Adjust vehicle handling to suit the altered machine characteristics and environ-
mental conditions.
noeuvres.
rection.
• Only rotate the upper structure when the undercarriage is stationary.
• Only rotate the upper structure after you have picked up the load.
• Only move the machine when you have picked up and lifted the load and rota-
ted the upper structure to the driving position.
• There is a danger of possible swinging movement and dropping of the load
when the equipment is raised.
• A protective grid (FOPS) in accordance with ISO 10262 must be attached to the
cab.
• A protective roof (FOPS) in accordance with ISO 10262 must be attached if the-
re 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 pro-
duct, such as moisture, must be noted.
– Working procedures when using machines with grabs require the machine ope-
rator 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 upper structure is
over the centre of the undercarriage, which reduces the risk of tilting.
– The machine can still sway and tilt despite being aligned!
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When moving the machine:

• Rotate the upper structure parallel to the undercarriage (transport position).
• Draw the equipment as close as possible to the machine.
• Only at this point may the support feet be retracted and the machine moved.
• Moving with loads is not permitted.
• Check the terrain to be covered to ensure that the ground is solid and even. Po-
tholes 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
(slewing) the upper structure out of the transport position.
• It is imperative that you check the contact surface of the support (load carrying
capacity of the substrate). A support subsiding would have disastrous conse-
quences!
• Carry out all movements with increased care.
• To slew the load, move the equipment as close as possible to the machine
(Caution! swinging grab)and hold the load close to the undercarriage and
above the substrate.
• Avoid braking or accelerating the equipment or upper structure abruptly.
• Do not lift any loads which are heavier than those given in the load chart.
Protection from vibration

– Vibrational loads on mobile building machinery are mainly the result of the type
and method of use. The following parameters in particular are decisive influences:
• Terrain conditions: Uneven areas and potholes;
• Operational techniques: Speed, steering, brakes, controlling the machine’s
control elements when driving and working.
– To a large extent, the machine operator determines the vibrational loads since he
selects the speed, gearbox ratio, working method and route himself.
This means that there is a wide range of different vibrational loads for the same
machine type.
Whole-body vibrational load for the machine operator can be reduced if the following
recommendations are observed:
– Select suitable machines, equipment parts and auxiliary devices for each part of
the job.
– Use a machine that has a suitable seat (i.e. for earth-moving machinery such as
hydraulic excavators, this should be a seat which corresponds with EN ISO

7096).
tructions.
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– Check the maintenance status of the machine, particularly with respect to: tyre
pressure, brakes, steering, mechanical connections etc.
– Do not steer, brake, accelerate, shift gears, move or load the machine’s equip-
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 The uppercarriage swing movements

The swing movements of the uppercarriage are controlled by the left joystick.
Fig. 3-65 Rotating the uppercarriage
Caution!
The joystick functions described below refer to the normal control, fitting out the
machine at delivery and according to ISO-standards.
On machines equiped in addition with a special control system, and if this special
control system is activated by the operator, the joystick functions correspond to the
information on the label which is sticked on the side window of the cab and is spe-
cific to the installed special control system.
 Push the left joystick to the left c:

 The uppercarriage rotates to the left.
 Push the joystick to the right d:
 The uppercarriage rotates to the right.
Braking the uppercarriage

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

 Let the left joystick move back to neutral position.
 The hydraulically swing braking of the uppercarriage takes place. In normal
working conditions, the braking efficiency is sufficient to bring the uppercarria-
ge to a standstill rapidly.
 Move the left joystick in the opposite direction.
 The maximum hydraulic braking action of the uppercarriage is achieved.
The mechanical swing brake
The mechanical brake is a negatively acting multidisc brake which is integrated in the
swing gear. It allows to stop the uppercarriage in any desired position (for parking,
when working on a slope, ...)
 Press button "Swing brake" button S17.
 Swing brake is applied.
 Swing brake is released.
Semi-automatic swing brake control (optional equipment)
 Press button S17 to release the swing brake.
 The swing gear brake is in mode semi-automatic and can now be controlled
as follows by the rocker switch S57:
 Tilt down the rocker switch S57 on the joystick handle.

 The brake is applied when the uppercarriage is at standstill, respectively it ap-
plies as soon as the uppercarriage speed gets lower than a limit value.
 Tilt up the rocker switch S57.
 The brake remains released permanently.
Note!
The red LED beside the button S17 is lighting in any case when the brake is applied.
If this light does not go out when the rocker switch S57 is tilted up, the button S17
must first be pushed to pre-select the semi-automatic mode.
Caution!
The brake only applies when the uppercarriage is near standstill and if no swing mo-
tion is actuated via the joystick!
In order to stop the uppercarriage when working on a slope, tilt the switch S57 down
and reduce the uppercarriage speed by braking with joystick.
Move the joystick back to «0» position only after the brake has applied.
Emergency stop of the uppercarriage swing motion

The swing brake can be applied independently of the uppercarriage RPM by swit-
ching the "Swing brake" button S17 to position "applied".
Caution
Perform this braking via "Swing brake" button S17 only exceptionaly, i. e. in emer-
gency cases, since it causes fast abrasion of the brake discs.
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To check the mechanical swing gear brake:

 When the uppercarriage is stationary.
 Press button S17 to apply the mechanical swing brake.
 Push the left joystick to the right and then to the left as far as the stop.
 If the swing brake function is OK, the uppercarriage does not start swinging.
3.4.2 Working position
Fig. 3-66 Working position – machine
 Work with the machine is generally to be carried out over the idler.
Note
 Drive backwards when you are working lengthwise with the backhoe bucket.
3.4.3 Joystick functions when setting up the machine
Caution!
The machine is dispatched as standard with normal control.
On request, the machine can be equipped with a control system that deviates from
the norm (eg. with LIEBHERR control). The additional operating instructions for this
control system apply in this case.
The joystick functions described here refer exclusively to normal control.
Operating the stick cylinder

The stick cylinder is operated using the left joystick 4.
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Fig. 3-67 Operating the stick cylinder
 Push the joystick back a.

 Stick will be drawn in.
 Push the joystick forwards b.
 Stick will be extended.
Operating the boom cylinder

The boom cylinder is operated using the right joystick 3.
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Fig. 3-68 Operating the boom cylinder
 Push the joystick back g.

 Equipment will be raised.
 Push the joystick forwards h.
 Equipment will be lowered.
Operating the bucket

The bucket cylinder is operated using the right joystick 3.
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Fig. 3-69 Operating the bucket cylinder
 Push the joystick to the left e.

 Bucket will be tilted inwards.
 Push the joystick to the right f.
 Bucket will be tilted outwards.
Operating the bottom dump shovel bucket

Fig. 3-70 Operating the bottom dump shovel bucket
The bottom dump shovel bucket is moved via two pedals, 7a and 7b.
 Push pedal 7a.
copyright by
3 - 86 R9400 / 11000047
MJFCIFSS
 Shovel bucket will be closed.

 Push pedal 7b.
 Shovel bucket will be opened.
Float position of boom cylinder for bucket operation (optio-

nal equipment)
Fig. 3-71 Float position
To turn on the float position for the lift cylinders,

 Move the right joystick 3 forward,
 Push the button S5 or S6 on top of the handle at the same time.
Now the bucket can be used for grabing work while moving the joystick 4 forward to
extend the crowd cylinders.
The attachment can then move freely up or down depending on grade and the bucket
will automatically follow the ground contour.
Combined movements
Moving a joystick diagonally results in the work functions concerned being combined.
This allows different equipment movements to be activated at the same time.
The operator can do the following movements without any additional manipulations.
When the swing movement is actuated, all working functions / movements are 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 equipment can be lowered when the diesel engine is not run-
ning.
copyright by
R9400 / 11000047 3 - 87
MJFCIFSS
General working methods
Fig. 3-72 Lowering the equipment when engine is not running
 Turn the ignition key to contact position 1.

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

To increase the service life of the machine and avoid unnecessary damage and the
resulting repairs, please note the following points:
– Do not stop the rotary motion of the upper carriage when slewing into a ditch by
stopping the equipment on the walls of the ditch.
– Using the machine for applications where the equipment is knocked against the
material to be removed, in the longitudinal direction too, is not permitted. Repea-
tedly 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.
copyright by
3 - 88 R9400 / 11000047
MJFCIFSS
3.5.2 Preparatory activities
Danger!
Risk of fatal injury and damage to the machine when working.
 Observe the safety information “Notes for safe working” at the start of these ope-
rating instructions.
Fig. 3-73 Working position – machine
 Position the machine so that the load material can be taken up above the idler.
Danger!
Insufficient support and machine damage.
Fig. 3-74 Hazard area
Danger!
Risk of fatal injury due to rotating the machine.

 Ensure that nobody stands within the hazard area r of the machine.
copyright by
R9400 / 11000047 3 - 89
MJFCIFSS
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 fa-
ce, including allowing for any rocks or material that may fall down.
Fig. 3-75 Recommended digging
The recommended digging range is about a 90° arc in front of the machine (A).
Note!
Avoid digging at right angles to the tracks.
3.5.4 Working with the backhoe bucket

Danger!
Risk of fatal injury and damage to the machine when moving the backhoe bucket.
 Ensure that the backhoe bucket is not slewed too close to the cab.
 The backhoe bucket could damage the cab and injure the machine’s opera-
tor.
 Ensure that nobody is standing within the hazard area of the backhoe bucket.
copyright by
3 - 90 R9400 / 11000047
MJFCIFSS
Digging
Fig. 3-76 Optimal angle for digging
Fig. 3-77 30° forward to the vertical.
 Align the shovel arm in such a way that its underside is at an angle of approx. 30°
forward to the vertical.
 Align the backhoe bucket in such a way that its underside can enter the ground
at an angle with the axle of the shovel arm between 10° and 20°.
copyright by
R9400 / 11000047 3 - 91
MJFCIFSS
Fig. 3-78 Taking up grab material
 To lift out the grab material, slowly and evenly slew in the shovel arm.
Fig. 3-79 45° backward to the vertical
 As soon as the shovel arm is at an angle of approx. 45° backward to the vertical,
raise the boom slowly and evenly in addition to slewing in the shovel arm and the
backhoe bucket. Stopping suddenly will result in impact loads and vibrations.
 When the backhoe bucket is full or the shovel arm can no longer be slewed in,
raise the boom and backhoe bucket until the filled surface is parallel to the
ground.
Note!
For a efficient digging, the depth of the excavated face shouldn’t exceed the length
of the shovel arm.
copyright by
3 - 92 R9400 / 11000047
MJFCIFSS
Loading the transport vehicle
Danger!
Risk of fatal injury due to falling grab material.
 Do not load the transport vehicle so high that the grab material could drop out
over the walls of the vehicle.
 Ensure that nobody is standing in the danger.
 Load an occupied truck only if all safety requirements are fulfilled, notably in or-
der to protect the truck operator.
 Do not slew the equipment over the driver’s cab.
Fig. 3-80 Emptying grab material
 If possible, the machine should stand higher than the transport vehicle to avoid
having to lift the grab material unnecessarily.
 Stop the transport vehicle in a position that allows it to be loaded from the rear or
the side.
 Slew the machine's equipment above the loading area of the transport vehicle.
 Distribute the grab material evenly over the loading area of the transport vehicle
by slewing the backhoe bucket and shovel arm out, slewing the upper carriage
and possibly also moving the boom.
 If the backhoe bucket is not sufficiently emptied or there is still grab material in the
backhoe bucket, slew the backhoe bucket in and out several times to loosen the
grab material.
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.
copyright by
R9400 / 11000047 3 - 93
MJFCIFSS
Fig. 3-81 Digging
 Most digging should be started with the bucket almost fully crowded back (50mm
off stops or end of cylinders).
 When cleaning up or digging at floor level, angle the teeth aggressively to break
out any toe that may be encountered.
 Keeping the heel of the bucket off the ground 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.
copyright by
3 - 94 R9400 / 11000047
MJFCIFSS
Transport
Unload the bucket
Fig. 3-82 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.
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 abrassive material will influence the lifetime of
the components and attract additional cost for the undercarriage components.
In general travel action has to be kept to the lowest level that is possible. Minimize
travelling with turning through a narrow turning circle and long distance travel.
To minimize the travel ratio, professional mine planning with longfront winning 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 procedu-

res 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 po-
sition, depress travel pedals all the way forward with the toes. Direction of travel is in
the direction of idlers.
copyright by
R9400 / 11000047 3 - 95
MJFCIFSS
Transport
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-
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. 3-83 Hazard area r
Walking the machine distances means any movement of the machine of more than
100 m or for a time period longer than 3 minutes, whatever comes first.
In addition to above mentioned guidelines, when moving the machine during loading
operations, the following procedures apply :
– It is required to have somebody standby with a heat gun, to monitor the tempera-
ture of the drive components, including the track and carrier rollers.
Danger!
The person which is checking the temperature of the different rollers must always
be out of the hazard area r of the machine during its movement.
For the checking of the temperature, the excavator should stop moving. And only
when the excavator is stopped, the person could go in the hazard area r to check
the temperature of the different rollers.
The machine could only start moving again when the driver has seen the operator
out of the hazard area r.
– If temperature of any moving part is growing up about 20°C above ambiant tem-
copyright by
3 - 96 R9400 / 11000047
MJFCIFSS
Transport
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 tra-
velling 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 rol-
lers. However, always ensure that clear forward vision is maintained.
Travelling the machine down grades or upgrades

In addition to above mentioned guidelines, when moving the machine during loading
operations or when walking the machine distances, the following procedures apply :
– When travelling down grades greater than ten percent, it would be better to walk
the machine down with the track 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 recommen-
ded 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 corres-
ponding 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,
copyright by
R9400 / 11000047 3 - 97
MJFCIFSS
Transport
– with the best possible equal load distribution,

– only being sure that the lifted element has been already dismounted,
– only after having drained tanks (hydraulic, fuel…),
– if no specific value is indicated on the corresponding transport drawing, always
respecting the angles given on the figure bellow:
•  < 60°
•  < 30°
Fig. 3-84 Lifting angles
Lashing precautions
Fig. 3-85 Lashing angles

A Diagonally lashing
B Cross-diagonally lashing
1 Load 4 Transversal axis
2 Lashing chain 5 Longitudinal axis
3 Vertical axis 6 Loading plane
Lash element:
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3 - 98 R9400 / 11000047
MJFCIFSS
Transport
– 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 corres-
ponding transport drawing,
– if no specific value is indicated on the corresponding transport drawing, always
respecting the angles given on the figure above:
• 0°    50°
• 25°  x  50°
– always ensuring a sufficient coefficient of friction (0,2 or higher) between load and
supporting surface so as to avoid element to slip (e.g. using wooden parts, non-
slip mats...).
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 gravity center are also given.
The aim of these drawings is to ensure safe operation during transport, handling and
storage.
Note!
The lashing and lifting points are indicated on the concerned elements of the exca-
vator by specifics labels (see § "Signs on the machine"). To be easily recognized,
lifting points are painted in yellow (in red if excavator is yellow) as well.
Danger!
The lifting points given on a transport drawing for an element are designed to lift this
element only and nothing else.
 Never lift an assembly of several elements by the lifting points of only one of the-
se elements.
copyright by
R9400 / 11000047 3 - 99
MJFCIFSS
Transport
copyright by
3 - 100 R9400 / 11000047
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 quic-
kly. 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.
copyright by
R9400 / 11000047 4-1
MJFCIFSS
Malfunctions Operating manual
Error code charts
4.1 Error code charts
Danger!
When switching over to emergency operation, the speed can no longer be changed
using the arrow keys on the monitoring screen. The servo control, parking brake
and swing gear brake can no longer be activated.
 Please also note the section “Emergency operations” in the chapter “Control and
operation” in this regard.
4.1.1 Sensors
Error code Effect Cause Measure / remedy

E 004 Coolant level B3 not being Accidental ground Check coolant level, consult
E 005 monitored. Accidental + LIEBHERR customer service.
E 006 Broken wire

E 010 Hydraulic oil level B14 not Accidental ground Check hydraulic oil level,
E 011 being monitored. Accidental + consult LIEBHERR customer
service.
E 012 Broken wire
E 013 Hydraulic oil temperature B67 Accidental ground Check hydraulic oil for
E 014 not being monitored. Accidental + contamination, consult
LIEBHERR customer service.
E 015 Broken wire
E 454 Swing speed B53 not being Accidental + Consult LIEBHERR customer
E 455 monitored Broken wire service.
E 455 Accidental ground

E 456 Fuel level transmitter B1 not Accidental ground Consult LIEBHERR customer
E 458 being monitored Broken wire service.
E 465 Pump 1 leak oil temperature Broken wire Consult LIEBHERR customer
E 466 B64_1 not being monitored Accidental + service.
E 477 Swing pump 1 leak oil temp. Broken wire Consult LIEBHERR customer
E 478 B64_7/1 not being monitored Accidental + service.
E 480 Swing pump 2 leak oil temp. Broken wire Consult LIEBHERR customer
E 481 B64_7/2 not being monitored Accidental + service.
E 542 Gradient sensor passing over Consult LIEBHERR customer

from threshold or parting of a service.
cable
E 599 Default test sensor attenua- Consult LIEBHERR customer
tion service.
copyright by
4-2 R9400 / 11000047
MJFCIFSS
Operating manual Malfunctions
Error code charts
4.1.2 Regulating circuit

E 022 Diesel engine speed B12 not Accidental ground Consult LIEBHERR customer
E 023 being monitoring, Diesel Accidental plus service.
engine speed cannot be
E 024 adjusted using keyboard, Broken wire
reduced hydraulic power
E 027 Solenoid valve for power Cable defect Consult LIEBHERR customer
control Y4 LR1 not being service.
monitored
E 030 Output ventilator oil Y10.2 not Cable defect Consult LIEBHERR customer
being monitored service.
E 033 Output ventilator water Y10.1 Cable defect Consult LIEBHERR customer
not being monitored service.
E 036 Output Y3.1 EL1 not being Cable defect Consult LIEBHERR customer
monitored service.
monitored service.
monitored service.
4.1.3 Keyboard

E 302 Coding plug missed in No coding plug Consult LIEBHERR customer
keyboard service.
E 303 No CAN 1 connection Error detected also if BST is Consult LIEBHERR customer
between control unit S2 and not operative : no power service.
circuit board BST supply, ...)
E 305 No CAN 2 connection Error detected also if ESP01 Consult LIEBHERR customer
between control unit S2 and is not operative service.
circuit board ESP01
E 312 No CAN 1 connection No CAN bus connection Consult LIEBHERR customer
between control unit S2 and service.
E1036 (connection box pump
transmitters)
A1020 (FSG plate)
copyright by
R9400 / 11000047 4-3
MJFCIFSS
Error code charts
4.1.4 Display

display or no function of the
control unit
4.1.5 Coding error

E 319 Coding BST not compatible Coding error Consult LIEBHERR customer
with coding control unit S2 service.
E 321 Unknown excavator type Coding error Consult LIEBHERR customer
from BBT service.
E 322 Unknown hardware coding Coding error Consult LIEBHERR customer
from BST service.
4.1.6 Connection box pump transmitters

E 311 No CAN 1 connection on Consult LIEBHERR customer
E1036 (connection box pump service.
transmitters)
E 320 No CAN 1 connection Consult LIEBHERR customer
between E1036 (connection service.
box pump transmitters) and
translater J1939
4.1.7 Joysticks

E 411 Problem on A1020 - X96/3 / Zero point not allready Consult LIEBHERR customer
Swing control started service.
E 413 Broken wire, Current >21mA
or <3mA
Stick control started service.
or <3mA
Tilt control started service.
or <3mA
copyright by
4-4 R9400 / 11000047
MJFCIFSS
Error code charts

Boom control started service.
or <3mA
Travel left control started service.
or <3mA
Travel right control started service.
or <3mA
Trap open control started service.
or <3mA
Trap close control started service.
or <3mA
4.1.8 Error due to warning symbols in SY field

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

E 459 Injector solenoid driver circuit Voltage below normal or
open circuit
E 460 Symbol appears Exhaust gas temp. deviation See symbol description
E 461 Exhaust gas sensor Voltage below normal or
open circuit
E 462 Exhaust gas temp. deviation Voltage above normal or
shorted to high source
E 463 Intake manifold temperature / Abnormal rate of change
Symbol appears
E 495 Diesel engine is started while Do not start the Diesel engine
coolant temperature too low. as long as the corresponding
symbol is on.
Install optional preheating

system if necessary.
E 501 Symbol appears Oil pressure low See symbol description
E 502 Symbol appears Coolant level low See symbol description
E 503 Symbol appears Coolant overheating See symbol description
(moderate or high)
E 504 Symbol appears Hydraulic oil level low See symbol description
E 505 Symbol appears Hydraulic oil overheating See symbol description
copyright by
R9400 / 11000047 4-5
MJFCIFSS
Error code charts

E 506 Symbol appears Splitterbox oil temperature See symbol description
too high
E 540 Symbol appears Coolant pressure low See symbol description
E 543 Symbol appears Lifetime sealing oil level low See symbol description
E 544 Symbol appears External swing teeth greasing See symbol description
E 545 Symbol appears Grease level low See symbol description
E 562 Symbol appears Oil level splitterbox low See symbol description
E 564 Symbol appears Oil level splittebox high See symbol description
E 566 Symbol appears Pump 1 clogged See symbol description
E 572 Symbol appears Swing pump 1 clogged See symbol description
E 573 Symbol appears Swing pump 2 clogged See symbol description
E 578 Symbol appears Overheat pump 1 See symbol description
E 584 Symbol appears Overheat swing pump 1 See symbol description
E 585 Symbol appears Overheat swing pump 2 See symbol description
E 590 Symbol appears Hydraulic tank pressure low See symbol description
E 591 Symbol appears Splitterbox oil pressure low See symbol description
E 592 Symbol appears Centinel oil level See symbol description
E 593 Symbol appears Fuel temperature See symbol description
E 594 Symbol appears Fuel pressure See symbol description
E 595 Symbol appears Blowby pressure See symbol description
E 596 Symbol appears Engine oil level See symbol description
E 597 Symbol appears Manifold temperature See symbol description
E 598 Symbol appears Oil change required See symbol description
D 115 Engine magnetic speed / Position lost both of two
Symbol appears signals
D 214 Symbol appears Engine oil overheating See symbol description
D 234 Engine crankshaft speed / Most severe level
position to high /
Symbol appears
D 342 Electronic calibration code Out of calibration
incompatibility /
Symbol appears
D 418 Symbol appears Water in fuel See symbol description
D 421 Symbol appears Engine oil temperature high See symbol description
D 441 Symbol appears Battery voltage low See symbol description
D 442 Symbol appears Battery voltage high See symbol description
D 449 Symbol appears Rail overpressure See symbol description
copyright by
4-6 R9400 / 11000047
MJFCIFSS
Error code charts

D 599 Auxiliary commanded dual Special instructions
output shutdown /
Symbol appears
D 689 Engine crankshaft speed/ Data erratic, intermittent or in-
position / correct
Symbol appears
1257 At least one intake manifold Abnormal rate of change
temperature /
Symbol appears
1362 Symbol appears Engine oil filter diff. pressure See symbol description
1517 At least one module has a Condition exists
most severe fault /
Symbol appears
moderately severe fault /
Symbol appears
least severe fault /
Symbol appears
1852 Symbol appears Water in fuel high level See symbol description
2963 Symbol appears Coolant overheating (low) See symbol description
4.1.9 Heating/air conditioning system
Note!
The following error codes concerning the heating and air conditioning system are
displayed directly on the front panel of its control unit.
Error code Affected elements Description / possible causes Possible effects / measures
F0 Room temperature sensor Short circuit or disconnection of Control function no longer
cable, connector or control unit. operational.
Defective sensor.
F1 Exhaust air temperature Short circuit or disconnection of Control function no longer
sensor cable, connector or control unit. operational.
Defective sensor.
F2 Exhaust air temperature Short circuit or disconnection of Control function no longer
sensor (head area) cable, connector or control unit. operational.
Defective sensor.
F3 Outside temperature Short circuit or disconnection of Control function no longer

sensor cable, connector or control unit. operational.
Defective sensor.
F4 High-/Low pressure switch Failure on condenser fan, Control function no longer
evaporator blower, expansion operational.
valve, compressor or refrigerant
circuit.
copyright by
R9400 / 11000047 4-7
MJFCIFSS
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 outsi-
engine oil used de 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 immedia-
tely
copyright by
4-8 R9400 / 11000047
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 / sounddevelopment Exhaust system leaking Check exhaust system / repair
on exhaust side
4.2.2 Hydraulic system

Unusual noise / sounddevelopment 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 immedia- check intake lines for leaks
tely
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 lea- Leading wheel tracking on track rol- Adjust the leading wheel tracking
ding wheel ler 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
authorized specialist personnel)
Track roller or support roller sticking Running gear extremely dirty Clean running gear
copyright by
R9400 / 11000047 4-9
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 dama- Mount plug connector correctly or
panel drop out ged, 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 functio-
ning. 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 equi- Bearing points worn out Replace bearing parts
pment
Bucket does not move Valve block on tilting cylinder incor- Switch over valve block
rectly switched
copyright by
4 - 10 R9400 / 11000047
MJFCIFSS
Fuses and relays
4.3 Fuses and relays
Danger!
Incorrect or bypassed fuses do not offer the machine's operator or the electrical
system the required degree of protection.
 Only use original fuses.
 Never bypass electrical fuses.
 If required, order replacement fuses from LIEBHERR.
4.3.1 Power electrical box E1003

The power electrical box E1003 is located under the cabin in the cab elevation.
Fig. 4-2 Power electrical box E1003
K11 Relay current charging K20_2 Relay attachment floodlight

K16_1 Startrelay E1003 K20_3 Relay fuel tank floodlight
K16_2 Startrelay E1003 K20_4 Relay hydraulic tank floodlight
K19_1 Relay Kl15 K20_5 Relay counterweight floodlight
copyright by
R9400 / 11000047 4 - 11
MJFCIFSS
Fuses and relays
K19_2 Relay Kl15 K20_6 Relay counterweight floodlight

K19_3 Relay Kl15 K20_7 Relay reserve
K19_4 Relay Kl15 K110 Relay for M10
K20_1 Relay attachment floodlight K112 Relay for M11
Fig. 4-3 Fuses in power electrical box E1003
F12_1 Fuse / attachment floodlight F131 Reserve

F12_2 Fuse / attachment floodlight F137 Fuse / Quantum
F12_3 Fuse / fuel tank floodlight F138 Fuse / service circuit supply
F12_4 Fuse / hydraulic tank floodlight F139 Fuse / M10 supply
F12_5 Fuse / counterweight floodlight F140 Fuse / board
F12_6 Fuse / counterweight floodlight F141 Fuse / E14
F20_1 Fuse / supply cabin Kl15 F142 Fuse / lighting
F20_2 Fuse / supply E1005 Kl15 F143 Fuse / lighting
F20_3 Fuse / charging current F144 Fuse / ladder / trap door
F20_4 Fuse / Kl30 floodlight F145 Reserve
copyright by
4 - 12 R9400 / 11000047
MJFCIFSS
Fuses and relays
F20_5 Fuse / Kl30 counterwght flood. F147 Fuse / M11 supply

F20_6 Fuse / engine F152 Fuse / Quantum
F37 Fuse / ether F164 Fuse / E1003
F119 Fuse / S1 / Kl30 F166 Reserve
F120 Fuse / air conditionning F167 Fuse / elevation pressure fan
F121 Fuse / air conditionning F169 Fuse / charging
F122 Fuse / option. windshield wiper F170 Reserve
F123 Fuse / supply A1020
4.3.2 Cabin electrical box E1005

The cabin electrical box E1005 is located in the cabin, behind the operator’s seat.
Fig. 4-4 Cabin electrical box E1005
F29 Fuse / reserve cameras K22_1 Relay / reserve

F30 Fuse / attenu. plate supply res. K22_2 Relay / reserve
F31 Fuse / A1020 boom / shovel tilt K23 Relay second air conditionned
F32 Fuse / A1020 stick / swing K98 Relay / travel alarm
F33 Fuse / A1020 travel / trap door K99 Relay / supply A1020
copyright by
R9400 / 11000047 4 - 13
MJFCIFSS
Fuses and relays
F34 Fuse / A1020 FSG K139 Relay / fire alarm

F35 Fuse / A1020 controller FSG K183 Relay / reserve
F124 Fuse / S7, A1001 K193 Relay / reserve
F125 Fuse / A1019, U16 KT10 Relay timer emergency stop
F126 Fuse / A1001 KT17 Relay timer / reserve
F127 Fuse / greasing KT51 Relay timer / reserve
F128 Fuse / board
F129 Fuse / cabin
F130 Fuse / A1001
F148 Fuse / A1019
F161 Fuse / A1036
4.3.3 Heating / air-conditioning electrical box E1006

Heating / air-conditioning electrical box E1006 is located in the ceiling of the cab.
Fig. 4-5 Heating / air-conditioning electrical box E1006
F131 Fuse / evaporator engine 1 K23A Relay / second air conditioner

F132 Fuse / evaporator engine 2 K121 Relay / switching A/C
F133 Fuse / evaporator engine 3 K273 Relay / heater
F134 Fuse / heater motor KT52 Relay timer / air conditioner

F135 Fuse / motor dryer 2
F136 Fuse / motor dryer 2
F190 Fuse / air conditioning
copyright by
4 - 14 R9400 / 11000047
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
available in order to carry out maintenance work.
– The inspection and maintenance schedule given at the end of these operating
instructions defines precisely who is required / permitted to carry out what work.
Jobs listed as daily / weekly work may be carried out by the machine's driver or
maintenance personnel when they have received appropriate instruction.
The remaining work may only be carried out by specialist personnel with appro-
priate training.
– Replacement parts must correspond to the technical requirements determined by
the manufacturer. Original replacement parts are always guaranteed to meet the-
se 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 maintenan-
ce 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 uppercarria-
ge’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.
copyright by
R9400 / 11000047 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
areas. Before operating these units, check ventilation.
– In addition, always follow applicable local regulations.
Cleaning
– Clean oil, fuel or care products off the machine before starting maintenance or 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 machi-
ne for the first two months after initial set-up of the machine (or after repainting).
– Do not use combustible liquids to clean the machine.
– Before cleaning the machine with water or steam jets (high pressure cleaner) or
other cleaning materials:
• lubricate all bearing points, bolt connections and the rim bearing to prevent 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
lower than 20 inches
• the water temperature should not exceed 60°c (140°F)
• limit the water pressure to 80 bar maximum (11500 PSI)
• if you employ cleaning fluid, only use neutral cleaning agents such as customa-
ry car shampoos diluted to 2 or 3 percent maximum
– After cleaning:
• remove all covers completely.
• check all fuel, engine oil and hydraulic lines for leakage, loosened connections,
chafing and damage.
• rectify any defects found immediately.
• lubricate all bearing points, bolt connections and the rim bearing to displace any
water or cleaning products that may have entered.
Field of view
– Mirrors and cameras, which were possibly removed for the transport, must be ine-
vitably 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, du-
ring 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.
copyright by
5-2 R9400 / 11000047
MJFCIFSS
Operating manual Maintenance
• on the right to check the right side of the machine.

• above the counterweight to check the rear side of the machine.
– On some machines, some mirrors may be replaced with cameras.
– At each extension, construction or change on the machine, the sight conditions
must be maintained. These conditions must otherwise be checked according to
ISO 5006.
– Mirrors must be cleaned at least at daily intervals.
– Damaged mirrors and cameras must be immediately replaced.
– The site has to be organised so that the dangers due to a restricted field of view
are minimized, particularly for machines with an operating weight which is 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 maintenan-
ce plan:
• every 250 operating hours by the machine owner’s maintenance personnel.
• every 500 operating hours by authorised specialist personnel.
– It is advisable to carry out these tests: supported, on firm, horizontal substrate,
with the equipment in longitudinal and cross direction for variable loads. Current
accident prevention regulations must be adhered to.
– Especially check the supporting components, in particular :
• framed construction undercarriage with axle and gearbox storage, support
outriger, lower slewing ring support with tower and slewing ring.
• framed construction uppercarriage with bearing for boom and hoist cylinder, 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 chan-
ge 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 pe-
netration test should be carried out as a crack test on areas which do not have
good visibility, such as the ring bearing support, in order to increase testing safety.
– Any damage found must be rectified immediately. Welding work on load-bearing
parts of the earth-moving machinery, loading devices and transport devices may
only be carried out by trained specialist personnel and only in accordance with the
accepted rules of welding engineering. In case of doubt, contact the LIEBHERR
customer support service to discuss suitable remedies.
Welding, drilling, firing and grinding work

– Any welding on structural parts (as undercarriage, uppercarriage, equipment
parts,…) may only be done the manufacturer, or authorized official dealer. If this
rule is neglected, the warranty is voided.
copyright by
R9400 / 11000047 5-3
MJFCIFSS
– 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 the swing ring, joints, gears,
bushings, rubber parts and 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 them so that they do not
present a risk. Only use suitable and correctly functioning lifting devices and load
take-up devices with adequate load capacity.
Do not stand or work under swinging loads.
– Do not use lifting devices which are damaged or do not have sufficient load
carrying capacity.
Wear work gloves when working with wire cables.
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
purpose.
When working at height, wear a harness to prevent falling.
Ensure that all grips, steps, rails, platforms and ladders are free of dirt, snow and
ice.
– Pneumatic cylinders do not have to be used as handles. Open doors and covers
carefully, so that pneumatic cylinders do not hit their stops, because this could
cause mechanical damages.
– Make sure the equipment on which you will operate is securely supported before
working (e.g. replacing teeth). Prevent metal touching metal when doing this.
– For safety reasons, never open and remove a track chain unless having previous-
ly totally released the pretension of the chain tensioning unit.
securely supported with appropriate supports.
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5-4 R9400 / 11000047
MJFCIFSS
– 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 equi-
pment.
– 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 swit-
ching off the engine, with the start key in contact position and with the safety lever
down into its lowest position, you must operate all pilot control devices (joystick
and pedals) in all directions in order to reduce the actuating and dynamic pressu-
res in the work circuits. You must then reduce the internal tank pressure as des-
cribed 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 vol-
tage, 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.
copyright by
R9400 / 11000047 5-5
MJFCIFSS
– Before working on a hydraulic accumulator, you must reduce the pressure in the
hydraulic system (hydraulic system including hydraulic tank), as described in the-
se 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 vi-
sible damage and any possible damage must be immediately checked for leaka-
ge.
– 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 pertai-
ning 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.
copyright by
5-6 R9400 / 11000047
MJFCIFSS
Maintenance access doors
– The following is to be noted when replacing lines and hoses:

• Always ensure that the lines and hoses are installed free of torsion. For 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 proper-
ly fastened. Doing this will prevent vibration and damage during operation.
• Install the lines and hoses in such a way that they cannot chafe on other lines,
hoses or parts.
• A minimum distance from other parts of approx. half the exterior diameter of the
hose is recommended. The distance should not, however, be less than 10 to
15 mm.
• When replacing the lines or hoses on moving parts (e.g. from the boom to the
stay), check before initial start-up that there are no chafing areas in the entire
area of movement.
5.2 Maintenance access doors
The machine has access doors for maintenance. The locks integrated in the handles
must be unlocked before starting to drive.
Caution!
Access doors can close accidentally and trap the operator or maintenance person-
nel.
 When you have opened the access doors, latch them using the retainer.
copyright by
R9400 / 11000047 5-7
MJFCIFSS
Maintenance access doors
Fig. 5-1 Access doors
1 Counterweight access 5 Fuel tank and cab elevation access

2 Left catwalk access 6 Right catwalk access
3 PowerPack access 7 Counterweight access
4 Centralized lubrication system 8 Pumps and splitterbox access
access
copyright by
5-8 R9400 / 11000047
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 accep-
table manner using the removable oil filter cartridges.
Danger!
When checking and changing lubrication and operating materials, ensure that the
following precautions are adhered to:
 Unless otherwise indicated, carry out all work on the machine on level, solid
ground and with the engine switched off.
 Whenever you reach into the engine compartment, always secure the cover and
side doors against accidentally falling back or closing.
 Only refuel the machine when the engine is switched off, do not smoke and
avoid naked flame.
 Turn the main battery switch to position 0 (off) and remove the ignition key.
copyright by
R9400 / 11000047 5-9
MJFCIFSS
5.3.2 Lubricating chart
Fig. 5-2 Lubricating chart
copyright by
5 - 10 R9400 / 11000047
MJFCIFSS
Symbol Display Quantity*

Diesel engine
Reserve system
Engine coolant
Hydraulic system
Swing gear
Travel gear
Lifetime sealing interspace
Splitterbox
Fuel
Grease / Swing ring teeth
Grease
Coupling
Windshield washer
Check oil level
Oil change
First oil change
Oil analysis
Tab. 5-1 Lubricating chart key
*The given quantities are only guidelines. Check fluid level after each change or refilling.
5.3.3 Service trap

To simplify the oil change and the refilling procedure, the drain of the following major
components on the uppercarriage are centrally connected to a service trap:

• The lube oil for the Diesel engine
• The optional reserve system or Centinel
• The splitterbox
• The two swing gears
• The fuel tank
• The hydraulic oil tank
• The tank for windshield washer fluid
• The grease tank for general lubrication
copyright by
R9400 / 11000047 5 - 11
MJFCIFSS
• The grease tank for swing ring teeth lubrication
Component Adapter Flow max.

WIGGINS
Swing gear OSP2 50 l/min
Splitterbox C-1807 50 l/min
Engine oil OSP2 50 l/min
Oil reserve OSP2 50 l/min
Hydraulic oil 6000B12 100-200 l/min
Fuel ZZ9A 1 500 l/min
Windshield washer EC280B8 25 l/min
Principal grease OSP2 15-30 l/min
Teeth grease 6000B12 15-30 l/min
Tab. 5-2 Service trap couplings
Fig. 5-3 Service trap

copyright by
5 - 12 R9400 / 11000047
MJFCIFSS
5.3.4 Lubricant chart
Designation Medium Symbol Classification Viscosity Quantity*
Diesel engine Engine oil 210 l.
See the Operation and Maintenan-

Reserve system ce Manual for CUMMINS engine. 300 l.
Hydraulic tank See section "Lubricating and ope- 2200 l. in hy-

rating material specifications". draulic tank
4200 l. in
whole system
Swing gear Transmission See section "Lubricating and ope- 2 x 39 l.

oil rating material specifications".
Travel gear Transmission See section "Lubricating and ope- 2 x 80 l.

oil rating material specifications".
Lifetime sealing interspace Engine oil Use same oil as 2 x 8 l.

used for hydraulic
tank.
Travel brake Use same oil as 4 x 0,4 l.

used for hydraulic
tank.
Splitterbox Transmission API-GL-5 SAE 90 65 l. in split-

oil MIL-L 2105 B, C or SAE 80W-90 terbox
D 90 l. in lub.
pump
Elastic coupling Lube oil for Mercedes Benz SAE15W-40 1,35 l.

elastic coupling 228.1
Swing ring roller bearing races Lubricating Multipurpose grease Consistency 2 200 l.
and general lubrication points grease KP2k or EP2 (extre- NL GI N°2 Gra-
me pressure N°2 de
grade)
Swing ring teeth Lubricating See section "Lu- Special grease 80 l.

grease bricating and ope-

rating material
specifications".
Track roller ITT ITT L203 18 x 3,8 l.
Berco 90% Agip Rotra LSX 18 x 2,7 kg.

10% Agip Rocol ASO R
copyright by
R9400 / 11000047 5 - 13
MJFCIFSS
Designation Medium Symbol Classification Viscosity Quantity*
Carrier roller ITT ITT L203 4 x 1.0 l.
Berco 90% Agip Rotra LSX 4 x 2,04 kg

LEC PANOLIN EP Gear Synth ISO 220 4 x 2,35 l.
Idler Wheel ITT ITT L227 2 x 4,83 l.
Berco 90% Agip Rotra LSX 2 x 3,04 kg

LEC BP Energear HYPO SAE 80W-90 2 x 4l
Hinges, joints, locks Engine oil - - - -
Rubber seal on doors and trim Silicon spray or - - - -

panels talc
Tab. 5-3 Lubricant chart
5.3.5 Operating material chart
Designation Medium Symbol Quantity*
Fuel tank See the Operation and Maintenance Manual for CUM- 6908 l.
MINS engine.
Engine coolant See the Operation and Maintenance Manual for CUM- 320 l.
MINS engine.
Windshield washer Commercially available windshield washer fluid or denatu- - 75 l.

system red alcohol
Refrigerating agent for R 134 a - 7 kg

air conditioner
Refrigeror oil in air con- PLANETELF PAG SP 20 - 0,207 l.

ditioner compressor
Tab. 5-4 Operating material chart
5.3.6 Service trap

For safety reasons and ease of maintenance, oil for the connected components
should only be drained and refilled via the quick-change couplings in the service trap.
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However, these components are also equipped with oil drain valves, see description
for oil change procedure of these components.
To lower and raise the service trap
Fig. 5-4 Control box E1022_2 and disable lock button S122 on control board
When the service trap is lowered, the service plate is accessible from the ground le-
vel.
The service trap can be moved up and down via the four push buttons on the control
box E1022_2 mounted on the access ladder.
The service trap can also be actuated with the engine shutted down.
It should only be moved out if the uppercarriage and the undercarriage are aligned.
To lower the service trap from its uppermost position

 First push the switch S161 to unlock the trap.
 Then push the switch S162 to move the trap downward.
To retract the trap

 First push the switch S159 until the red indicator light H69 goes out.
 Then push the switch S160 to lock the trap until the lock pin has reached its stop
position.
The lighting of the red indicator light H70 indicates that the locking pin of the trap is
not in end (locked) position.
The lighting of the red indicator light H69 indicates that the trap is not in upper end
position.
The locking of the trap via switch S160 is possible only when light H69 is out.
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Caution!
For safety reasons, the excavator can only be operated if the service trap is locked
in its uppermost position. Otherwise the red indicator light H70 goes on.
This means that the swing and travel movements remain locked.
However, this safety measure can be bypassed for as long as the button S122 on the
right front instrument panel is depressed.
5.3.7 Location of oil sample points

To make the oil sampling easier, some components of the excavator have been fitted
either with an oil sample extraction valve (Diesel engine, splitterbox, hydraulic cir-
cuit), or with a special drain valve allowing good accessibility and sampling condi-
tions (both travel gears).
Fig. 5-5 Oil sample point
5 Cap 6 Flow adjustment valve
To make an oil sample:

 Remove cap 5.
 Attach a sampling hose, e.g., a high-pressure hose for pressure gauge.
 Turn the valve 6 to adjust and close off the oil flow.
Note!
The location of these sample points is indicated in the description for oil change for
the concerned components further in this chapter.
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Lubricating and operating material specifications
5.4 Lubricating and operating material specifica-

tions
5.4.1 Lubrication oil for the diesel engine

Standard or with the Centinel system.
See the Operation and Maintenance Manual for CUMMINS engine.
5.4.2 Fuel
5.4.3 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 LIE-
BHERR.
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.
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LIEBHERR oils for hydraulic system
Requirements
Fig. 5-6 LIEBHERR oils for hydraulic system
A Ambient air temperature

B Operating range
C Extra-cold start range if excavator fitted with operating Liebherr arctic kit (with
warm-up instruction)
Fans 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. 5-7 Engine oils for hydraulic system
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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
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. 5-8 Hydraulic oil for hydraulic system

B Operating range
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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
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 fol-
lowing 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.
Biodegradables hydraulic oils

The use of biodegradables 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-33-A-93:
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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.
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 additionnal questions about oil selec-
tion.
Oil mixing
In principle, oil mixing between two different oil types must be avoided. Mixing two
different oil types leads to an unknown lubricant with resultant unknown physical pro-
perties (viscosity, pourpoint, flash point, ageing behaviour, lubricity, reaction with ad-
ditives...).
 However, if mixing is absolutely necessary, respect the following maximum

mixing proportions:
– Mixing LIEBHERR oils with hydraulic oils, or LIEBHERR oils with mineral oils, or
hydraulic oils with mineral oils, or two different mineral oils together, or two diffe-
rent hydraulic oils together:
max. 10%
– Mixing HEES oils with hydraulic oils or mineral oils or LIEBHERR oils:
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max. 2%
Hydraulic oil monitoring
Note!
Environmentally acceptable hydraulic fluids should generally be checked at
regular intervals by oil analysis.
Oil analysis is recommended for mineral oils.
 Machines in normal use: at least every 500 operating hours.
Hydraulic oil change intervals
Oil changes in pre-set intervals
Note!
Oil change in pre-set intervals are only permitted for mineral oils. When using envi-
ronmentally friendly hydraulic fluids, oil sample analysis reports must be used to de-
termine the time of the oil change, see "Optimised oil change intervals determined
through oil sample analysis reports".
Fig. 5-9 Changing oil
Optimised oil change intervals determined through oil sample analysis

reports
Use this procedure to take oil samples in pre-set intervals. The intervals may be ex-
tended between two oil changes as long as the properties of the oil are still satisfac-
tory. The time when the oil must be changed is determined by the lab report.
LIEBHERR recommends to submit the oil samples to "WEAR-CHECK" for oil analy-
sis. A kit for 6 complete analysis at WEAR-CHECK is available : Id. No. 7018368 (the
kit contains the sample containers, documentation, shipping container and oil sam-
ple hose). A hand pump is required to take the oil sample, and should be ordered
seperately (Id. No. 8145666).
Fig. 5-10 Taking an oil sample
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5.4.4 Swing and travel gear oils

Use gear oil meeting following viscosity classes and specifications (depending on the
ambient temperature):
Fig. 5-11 Gear oils for use as swing and travel gear oils
* LBC-1: Gear oil according to DIN 51517, part 3, CLP-HC(1)

(1)
HC / Synthetic carbon hybrid (poly-alpha-olefin PAO)
TEST / REQUIREMENT STANDARD / REFE- REQUIRED LEVEL /

RENCE 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
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")
** LBC-2: Gear oil according to API classification GL5

RENCE 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
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*** LBC-3: Gear oil according to API classification GL5

RENCE 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
5.4.5 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. 5-12 Gear oils for use as splitterbox oil
5.4.6 Lube oil for elastic coupling

Use engine or gear oil with viscosity classification SAE 15W40 and meeting specifi-
cation MB 228.1.
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5.4.7 Lubricating grease and other lubricants
Lubricant Description / manufacturer

Lubricating grease for the The grease must correspond with the specifica-
swing ring / general oiling tion KP2k, consistency 2 of NLGI grade in accor-
points dance with DIN 51818 and DIN 51825 or EP 2 in
accordance with NF-T-60 132.
The grease must consist of a lithium complex and
have a four ball tester value of at least 2300 N in
accordance with DIN 51350 and ASTM D 2596.
Between 0°C and -15°C Use a grease with consistency classification 1 NL

(32°F and 5°F) GI or EP1 grease.
Between -15°C and -40°C Only employ synthetic greases. We recommand

(5°F and -40°F) the grease Mobilith SHC 460 or Mobilith SHC
PM.
LIEBHERR part N° : 8502769 for a 50 kg (110

lbs) container, or 8503731 for a 180 kg (400 lbs)
container.
Grease for swing ring teeth This grease must comply with following recom-
mendations :
 be of consistency classification 2 in NL-GI vis-
cosity per DIN 51818,
 have a four ball tester value of a least 5500N
per DIN 51350 or ASTM D 2596,
 show a water resistance of 1-90 per DIN
51807.
LIEBHERR recommends the use of :
Grease BP Energol OGL 461 F, Liebherr order
n° : 8503629 for a 50 kg (110 lbs.) barrel
Contact spray for slip rings Cramolin
Lubricant for pistons, piston Gleitmo 800
nuts and piston bearing ins-
tallations on the hydraulic cy-
linders
Special anti-corrosive mate- Castrol-Tarp
rial for installation areas of
sealingelements on hydraulic
cylinders
Anti-corrosion grease for Liebherr special grease CTK
open piston rods (cylinders
that do not move often or

transportation)
Tab. 5-5 Lubricating grease and other lubricants
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5.4.8 Coolant
5.4.9 Lubricants specifications for -40°C
Engine oil
See Cummins Operation and Maintenance Manual.
First filling : BP Vanellus Ultima 5W30 Ident-Nr. : 11001385 (20 l), Ident-Nr. :
11001386 (208 l) from -40°C to +30° (if the excavator is equipped with a preheating
the temperature range can start at -50°C instead of -40°C).
Hydraulic oil
See the part hydraulic oils
Gear oil
SAE 75W90 API GL5 : Purpoint < -54°C
Like BP gear oil SHXM 75W90 :
– Ident-Nr. 8503299, drum 20 l
– Ident-Nr. 10033025, drum 208 l
From -50°C to +40°C
Like AVIA Gear oil Synthogear FE 75W90 EP from -50°C to +40°C
Grease : general lubepoint

– Low temperature grease : Liebherr universal grease Artic
–Ident-Nr. 10296828 cartridge of 400 grams
–Ident-Nr. 10296827 1 pack of 24 cartridges of 400 grams
–Ident-Nr. 10296825 container 10 kg
–Ident-Nr. 10296822 drum 180 kg
– Grease BP Energrease SY PM drum 165 kg from -30°C to +30°C,
Ident-Nr.8503731
– Grease BP Energrease SY PM drum 45 kg from -30°C to +30°C,
Ident-Nr.10279983
– Grease Liebherr Spezialfett 1026 LS drum 180 kg from -30°C to +60°C,

Ident-Nr.10113698
– 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 universal grease Artic
–Ident-Nr. 10296828 cartridge of 400 grams
–Ident-Nr. 10296827 1 pack of 24 cartridges of 400 grams
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Diesel engine

–Ident-Nr. 10296822 drum 180 kg
from -50°C to +20°C
Grease Petro-Canada Vulcan Synthetic Arctic from -55°C to -20°C.
5.5 Diesel engine
Refer to the CUMMINS operation and maintenance manual for detailed description
of maintenance work to be performed.
In addition, accurately observe the following items and perform all maintenance work
according to the intervals given in the control and maintenance chart.
5.5.1 Diesel engine oil level check
Fig. 5-13 Dipstick for engine oil level indication and oil filler neck
1 Dipstick 2 Oil filler neck
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Diesel engine
Danger!
Risk of burning.
The engine oil is hot when it is at operating temperate.
Avoid contact with hot oil and components containing oil, since it could cause seve-
re burns.
 The machine must be standing level, parked in firm and level ground.
 Wait for a few minutes for the oil to drain to the oil pan.
 Check the oil level in the engine with the dipstick 1.
5.5.2 Diesel engine oil change
Fig. 5-14 Coupling on service trap for diesel engine oil change
5 Diesel engine oil change coupling
Note!
Only carry out the oil change when the engine is warm.
To drain the oil:

 Bring the engine to operating temperature.
 Turn off the engine.
 Drain the oil via the quick change coupling 5 of the service trap.
 As a help way, the oil can also be drained via the oil drain plug at the bottom of
the oil pan of the diesel engine.
 To do so, remove oil drain plug, attach a drain hose and drain the oil into a suitable
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Diesel engine
container.
 Remove the hose, check, clean and reinstall the oil drain plug.
To change the oil filter elements:
Danger!
Risk of burning.
 When removing the filter, be careful to avoid contact with hot oil, it could cause
severe burns. Use gloves to avoid burns and personal injury due to 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 minutes
after stopping the engine before disassembling the filter.
Fig. 5-15 Oil filters
 Unscrew and remove the filter elements 3.

 Clean the sealing surfaces on the filter mounts.
 Lightly lubricate the rubber seal on the new filters with oil.
 Install and tighten the filters with both hands.
 For detailled installation, see also CUMMINS operation and maintenance manual.
 Check after every oil change or after adding oil that oil reaches correct level on
the dipstick 1.
To change the oil filter element on the optional oil centrifuge:
Danger!
Risk of burning.
 When removing the filter, be careful to avoid contact with hot oil, it could cause
severe burns. Use gloves to avoid burns and personal injury due to 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 minutes
after stopping the engine before disassembling the filter.
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Diesel engine
Fig. 5-16 Optional oil centrifuge
 Remove the cap from the centrifuge 3.

 Remove the sludge collecting paper insert located in the centrifuge 3 and the
sludge accumulated on it.
 Clean the sealing surfaces of the centrifuge 3.
 Install the new sludge collecting paper insert and replace the o-ring with a new
lubricated one on the rotor of the centrifuge 3 (see also CUMMINS Operation and
Maintenance Manual).
 Reinstall the cap of the centrifuge 3.
5.5.3 Engine oil sump refilling

 Add oil via the quick change coupling 5 of the service trap until the oil reaches the
maximum level mark on the disptick 1.
 A small amount of oil can also be refilled via the filler neck 2.
 For oil quantities, oil specifications and oil change intervals, see lubrication and
maintenance charts.
Note!
To extend the oil change interval, it is advised to use the chart method of CUM-
MINS.
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Diesel engine
5.5.4 Engine oil sampling
Fig. 5-17 Engine oil sampling ports
10 Unfiltered oil sampling port 20 Filtered oil sampling ports
To sample engine oil:

 Use port 10 to sample unfiltered oil.
 Use one of the ports 20 to sample filtered oil.
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Diesel engine
5.5.5 Mounting screws
Fig. 5-18 Mounting screws
 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.
Any improper fastening would greatly reduce the expected life of the rubber mounts.
11 Hex. head screw M20 560 Nm 17 Hex. head screw M16 280 Nm
16 Hex. head screw M16 280 Nm
Caution!
Loctite (Ident 8503598) must be applied on mounting screws 3, 4, 11, 16 and 17
when installing the screws in order to avoid possible damages on the parts.
The screws 3, 4, 11, 16 and 17 shall only be tightened after the engine and the split-
terbox as a complete unit has been positioned on the PowerPack frame, so that a
pretentioning of the rubber mounting can be avoided.
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Diesel engine
5.5.6 Elastic bedding
Fig. 5-19 Elastic bedding
 The four rubber cushions 15 at the front face of engine must be checked and re-
placed at regular intervals.
5.5.7 Alternator belt

Fig. 5-20 Belt
 Regulary check belt for correct condition, tension, alignment...
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Splitterbox

 For maintenance description, see CUMMINS operation and maintenance ma-
nual.
5.6 Splitterbox
5.6.1 Mounting screws
 Check the mounting screws on the splitterbox brackets regularly for tightness, re-
torque if necessary.
Any improper fastening would greatly reduce the expected life of the rubber mounts.
3 Lower Hex. hd. screw M20 560 Nm 4 Upper Hex. hd. screw M20 425 Nm
Caution!
Loctite (Ident 8503598) must be applied on mounting screws 3, 4, 11, 16 and 17
when installing the screws in order to avoid possible damages on the parts.
The screws 3, 4, 11, 16 and 17 shall only be tightened after the engine and the split-
terbox as a complete unit has been positioned on the PowerPack frame, so that a
pretentioning of the rubber mounting can be avoided.
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Splitterbox
12 Hex. head screw M12 117 Nm
 Check the tightness of mounting screws 12 from the splitterbox to the diesel en-
gine SAE housing regularly.
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Splitterbox
5.6.2 Elastic bedding
Fig. 5-23 Elastic bedding
 The two rubber buffers 2 at the splitterbox side must be checked and replaced at
regular intervals.
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Splitterbox
5.6.3 Air filter
Fig. 5-24 Breather on splitterbox
The air filter in the splitterbox breather 1 must be checked, cleaned and changed re-
gularly.
To clean the air filter:

 Open breather 1 by pushing it and turning it ¼ turn.
 Remove filter from breather housing.
 Check filter condition and clean it with fuel.
 Reinstall filter in breather housing.
 Close breather 1.
 For check, clean and change intervals, see maintenance schedule.
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Coupling
5.7 Coupling
5.7.1 Geislinger coupling wear check
Fig. 5-25 Wear gauge 735 on Geislinger coupling
764 Wing bolt 735 Wear gauge
To check wear on Geislinger coupling:

 Make sure the Diesel engine is switched off.
 Fix the wear gauge 735 to the coupling with the wing bolt 764.
 After measurement, unscrew wing bolt 764 and remove wear gauge 735.
Caution!
The wear gauge 735 must never remain installed on the coupling when the Diesel
engine is started.
 For detailled information about wear measurement, refer to Geislinger instruction

handbook.
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Cooling system
5.8 Cooling system
5.8.1 Checking and cleaning the cooling system
Fig. 5-26 Coolant expansion tank
6 Cap 7 Level indicator
Optimal cooling can only be achieved when the cooler is kept clean.
 Clean the radiator with pressurised air or a stream cleaner, if necessary.
 If the safety valve of the cooling system in the radiator cap 6 of the expansion tank
is leaking, replace the cap.
 Regularly check the connector hoses between the radiator and the engine, as
well as the heater hoses for condition and leaks.
 Check the tightness of hose clamps.
5.8.2 Checking the coolant level
Danger!
At near operating temperature, the engine coolant is hot and under pressure.
Avoid contact with components containing coolant, since it could cause severe
burns.
 Check coolant level only when the radiator is cool enough to touch.
 Check the coolant level when the engine coolant is cold.

 Coolant level should reach the middle range of the indicator 7.
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Cooling system
5.8.3 Coolant antifreeze and anti-corrosion fluid
Fig. 5-27 Coolant filters
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 approx. 50 % antifreeze).
 For volume, see operating material chart
The coolant filters 1 contain a corrosion protector. They are installed on the diesel
engine, facing the radiator.
 Regularly check the corrosion protection concentration in the coolant circuit.
 If necessary, corrosion protective additives must be added to the coolant, see
Cummins Operation and Maintenance Manual.
5.8.4 Changing the coolant
Danger!
Risk of burning due to hot coolant.
 Only change the coolant when the engine is cold.
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Cooling system
Changing the coolant filters
Fig. 5-28 Coolant filters
The filters contain a paste-like corrosion protection additive, which ensures the pro-
per corrosion protection properties of the coolant.
The filters must be replaced every 250 operating hours.
 Turn the shut off valve located on the right of the coolant filters to the OFF posi-
tion,
 Unscrew and remove the filter elements,
 Lightly oil the seal rings on the new filter element,
 Screw on the new elements until the seal ring touches the filter housing, and then
turn it by hand 1/2 - 3/4 turns (do not use any tools to tighten the filters!)
 Turn the shutoff valve to the ON position.
 For detailed information, refer to the CUMMINS engine operation and maintenan-
ce manual.
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Fuel system
Draining the coolant
Fig. 5-29 Coolant drain plugs
 For coolant change interval, see CUMMINS operation and maintenance manual.
The two drain plugs 26 are located under the radiator.
 For the procedure to drain and refill the engine cooling system refer to the CUM-
MINS engine operation and maintenance manual.
Caution!
When refilling the system, make sure that the expansion tank is refilled to correct
level on the indicator 7 and until coolant level no longer drops.
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.
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Fuel system
5.9.1 Refuelling
Service trap
Fig. 5-30 Service trap
 Add fuel via the service trap.

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Fuel system
5.9.2 Draining the fuel tank
Fig. 5-31 Fuel tank drain valve
 Place a suitable container under the drain valve 2.

 Turn the drain plug 1 on the drain valve 2 two turns counterclockwise.
 Drain off the water until clean fuel starts to come out.
 Close the drain plug 1.
 For maintenance intervals, refer to control and maintenance chart.
Note!
To reduce the formation of condensate in the tank, keep the fuel level as high as
possible.
Display H1 indicates the fuel level.

 In the event of a low fuel level, refill the tank before starting to work.
5.9.3 Emptying and cleaning the fuel tank

Use the drain valve 2 to drain the fuel tank. Cleaning access to the tank is possible
vias covers located on the top of the tank or via the tank access door.
 Always use a suitable container to collect the water and the fuel.
 Check the fuel tank.
 Wash out the fuel tank.
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Fuel system
 Close covers and access door again.
5.9.4 Fuel filtering system

The fuel filtering system is composed of preliminary filters 4 and fuel filters 5.
Fig. 1 Fuel filters assembly
4 Preliminary filters 5 Fuel filters
A red mark on the bell of the preliminary filters indicates maximum allowable fuel le-
vel.
 Change all preliminary filters and fuel filters as soon as fuel level reaches this
mark.
 Preliminary filters and fuel filters must be changed at least every 250 hrs.
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Fuel system
Draining water separator on the preliminary filters
Fig. 5-32 Preliminary filters
 Drain the preliminary filters every day.
To drain water:
 Shut off the engine.
 Close the fuel supply shutoff valve.
 Open the vent cap located on the top of each preliminary filter.
 Use your hand to open the water separator drain valve located on the preliminary
filter cartridge (see also CUMMINS engine Operation and Maintenance manual).
 Turn the drain valve counterclockwise until draining occurs.
 Drain the water sump of water until clear fuel is visible.
 Turn the drain valve clockwise to close it.
 Close the vent cap.
 Open the fuel supply shutoff valve.
Caution!
Do not overtighten the valve. Overtightening can damage the threads.
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Fuel system
Draining and cleaning fuel filters cartridges
Fig. 5-33 Fuel filters
To drain water:
 Clean.
 Unscrew and remove the three filter elements.
Each filter element is a combination fuel filter comprising a full flow element and a by-
pass element.
 Clean the sealing surfaces on the filter mounts with a clean, lint-free cloth.
 Apply a light film of clean engine oil to the filter gasket.
 Fill the filter with clean fuel.
 Install and tighten the filters with both hands (see also enclosed CUMMINS engi-
ne Operation and Maintenance manual).
Caution!
Do not overtighten the valve. Overtightening can damage the threads.
Priming the fuel system

Fuel filters and preliminary filters must be primed after filter change prior to starting
the engine. The procedure for priming both filter types is covered in the same steps,
as follows.
To prime the fuel system:

 Check the drain valves are closed at the base of the filters.

 Remove the vent cap from the top of the filters.
 Fill the filters with clean fuel.
 Install the vent cap.
 Tighten the vent cap by hand only.
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Pressurized air system
 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" position
for approximately 30 seconds before repeating.
 See also CUMMINS engine Operation and Maintenance Manual.
5.10 Pressurized air system
During operation, the pressure on both pressure gauges 15 must be between 6,2 and
7,25 bar.
Fig. 5-34 Pressure regulator 2 and pressure gauges 15
5.10.1 Pressure regulator and compressor

Check if you can hear the pressure regulator 2 at regular intervals click the compres-
sor on and off.
To check, proceed as follows:
 Run the Diesel engine at low idle.
 Slowly open the tank pressure release valve located at the back of the cabin and
let out the air in the tank until the air pressure drops to approx. 6,2 bar.
 The pressure regulator 2 must now shift the compressor into the working cy-
cle.
 Continue to run the engine at low idle.
 When the pressure reaches 7,25 bar, the regulator 2 shifts the compressor to
the neutral cycle.
 If necessary, adjust the pressure regulator until both pressures are correct.
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 For maintenance intervals, refer to the control and maintenance chart and to the
CUMMINS operation and maintenance manual.
5.10.2 Air dryer
Fig. 5-35 Air dryer
1 Nuts 6 Centering piece

2 Cover 7 Spring
3 Air dryer 8 Air cleaner cartridge
4 Air pressure line outlet 9 O-ring
5 Threaded rod 10 O-ring
The air dryer in the air pressure circuit dries and filters the pressurized air.
The air filter element must be replaced at regular intervals.
Caution!
Open the air dryer only when the air pressure system is out of pressure.
 If necessary, empty the air pressure tank.
To replace the air cleaner element:

 Relieve the pressure in the air pressure system via the drain valves (as described
below).
 Disconnect the air pressure line on the outlet 4 to the air tank.
 Remove nuts 1 and cover 2.
 Unscrew the threaded rod 5.

 Remove the centering piece 6 and spring 7.
 Slowly pull out the air cleaner cartridge 8 (if necessary, turn the cartridge back and
forth).
 Lubricate the o-rings 9 and 10 with oil.
 Install the new air filter cartridge using a turning motion.
 Make sure the o-ring 9 on the upper end of the cartridge is inserted into the filter
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housing.
 Reinstall spring 7, centering piece 6, o-ring 10, cover 2.
 Tighten nuts 1.
To drain the air tank:
Fig. 5-36 Air tank 11 with drain valve 12
Condensation in the air tank 11 is automatically discharged via the drain valve 12
when the pressure in the system drops.
However, we still recommend to drain condensation manually by pushing the pin on
the bottom of the drain valve 12 regularly as specified in the control and maintenance
chart.
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Dry air filter
5.11 Dry air filter
Fig. 5-37 Air intake system
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 multi cyclone precleaner 14 and fine filter 9 with primary and sa-
fety element are designed to give maximum protection at long maintenance intervals.
Maintenance also includes replacing the filter elements.
For safety reasons, we do not recommend to clean the filter elements.
The vacuum indicator (pos. 16) stores the maximum recorded vacuum pressure on
the filter outlet, during the diesel engine operation.
When the red stripe (pos. 17) appears in the window 18, the maximum permissible
vacuum of 50 mbar has been reached.
At that time, the corresponding primary filter element must be replaced.

To reset the vacuum indicator, press the "Reset" button 19.
We recommend to change the primary filter elements 3 only, when the maxi-
mum vacuum pressure has been reached, or at intervals specified in mainte-
nance schedule.
If the elements 3 are removed and installed too often, the seals between the filter ele-
ments and the filter housing may be damaged.
The safety elements 6 should be replaced after the primary elements have been
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Dry air filter
changed three times, or at intervals specified in maintenance schedule.

Before installing a new element, carefully clean the seal and the sealing surface of
the filter housing.
The dust in the cyclone precleaner 14 is constantly drawn in by the exhaust system
and discharged.
5.11.1 To change the primary filter element
Fig. 5-38 Primary filter element

 Remove nuts 2.
 Remove the dirty primary filter elements 3.
 Clean the inside of the air filter housing 9.
 Wipe off the sealing surface in the filter housing with a damp rag.
 Do not blow out the housing with pressurised air.
 Insert the new primary filter elements.
 Make sure they are seated correctly.
 Tighten nuts 2.
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Dry air filter
5.11.2 Changing the safety element
Fig. 5-39 Safety element
The safety elements 6 are installed with a special wing nut with built in maintenance
indicator (pos. 5).
 Check the wing nut for tightness.
 However, if a visual inspection shows that the green dot 5a on the wing nut has
turned red, the safety elements should be replaced immediately.
Note!
We recommend that the safety elements are replaced by a qualified maintenance
or LIEBHERR service technician.
To remove the safety elements, proceed as follows :

 Remove the primary elements 3 as outlined before.
 Remove the special wing nut and take out the safety element 6.
 Carefully clean the inside of the air filter housing 9 with a damp rag.
 Clean the sealing surfaces in the housing and check for damage.
 Carefully insert the new safety elements and secure with the special wing nuts.
 install the primary filter element 3, as outlined before.
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Dry air filter
5.11.3 To clean the air channels for the precleaner
Fig. 5-40 Air channels for the precleaner
Check the condition of the air channels in the precleaner 14 at the intervals specified
in the maintenance schedule.
 Open the filter cover 1 and check the channels.
 If the channels are plugged with dust, use compressed air to blow the channels
out from the inside of the filter towards the outside.
Caution!
Do not use steam.
The safety elements 6 must remain in place.
Do not direct the air flow towards the filter elements.
5.11.4 Check the air intake system, hoses, elbows, clamps
Fig. 5-41 Rubber hoses
The rubber hoses and elbows between filter housing end engine (pos. 7) must be
checked for damage, wear, tightness and leaks whenever the filter elements are re-
placed.
 If necessary, retighten the screws on the clamps 8.
The connection to the air intake side of the air compressor must also be checked for
leaks.
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Hydraulic system
 If necessary, include the visual inspection of the air intake system in the daily
maintenance.
5.12 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.
The pipe and hose network should be checked at regular intervals for leaks.
Note!
Strict cleanliness is of particular importance for the hydraulic system.
For this reason, the intervals given
– for changing the return-line filter,
– for changing hydraulic tank air filter,
– for cleaning the oil cooler,
– for changing the oil
must be adhered to.
5.12.1 Preparatory activities
Fig. 5-42 Machine position for checking the oil level or for adding oil
When checking the oil level or adding oil :

– Park the machine on level ground.
– Rest the attachment on the ground, with stick and tilt cylinders fully extended, and
bucket closed.
– Turn the engine off.
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Hydraulic system
5.12.2 Checking the oil level in the hydraulic tank
Fig. 5-43 Level inspection window for hydraulic oil
When the machine is in the check position, the level must not lie below the central
marking on the inspection window.
 If this is not the case, add oil via the service trap coupling or a return filter until the
level reaches the center mark.
The upper marking MAXI shows the maximum oil level if all cylinders are fully retrac-
ted.
The lower marking MINI shows the minimum oil level if all cylinders are fully exten-
ded.
If the oil level drops below the lower marking MINI, a warning symbol appears on
screen when the lowest quantity is reached.
5.12.3 Depressurising the hydraulic system
Danger!
A fine stream of liquid can penetrate the skin when under high pressure and cause
serious injury.
 Do not inspect leaks with bare hands.
Note the following points:

 The machine must be in the position described above.

 Ignition key must be on contact position
 Move the pilot control devices (joystick and pedals) in all directions (with the igni-
tion key in the contact position).
 Open the tank pressure release valve located behind the driver’s cab.
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Hydraulic system
Danger!
The hydraulic oil is hot when at operating temperature.
 Do not allow the hot oil or oil-bearing parts to touch the skin.
5.12.4 Emptying and refilling the hydraulic tank
Fig. 5-44 Hydraulic tank pressure release valve
Caution!
Before draining the oil or before adding oil via the service trap or a filter cover,
always open the tank pressure release valve located at the back of the cabin.
After each hydraulic oil change, vent the hydraulic pumps.
Fig. 5-45 Hydraulic oil change coupling on service trap
 Open hydraulic tank pressure release valve.

 Use the quick change coupling 8 of the service trap to drain and refill hydraulic oil
until oil level reaches the center mark of the inspection window.
 Close hydraulic tank pressure release valve.
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Hydraulic system
Fig. 5-46 Hydraulic tank shut-off valve
 As a help way, the hydraulic system can be drained using a drain hose via the
drain coupling and the shut-off valve 1 at the bottom of the tank.
Fig. 5-47 Return filter on hydraulic tank
As a help way, or for small quantities oil can also be added via the cover of a return
filter:
 Open hydraulic tank pressure release valve.
 Remove the cover 3 from the return filter (see below § "Leak oil and return-line
filters").
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Hydraulic system
 Add oil via the return filter until the level is exactly at the center mark of the ins-
pection window.
 Reinstall the cover 3.
 Close hydraulic tank pressure release valve.
5.12.5 Hydraulic oil sampling
Fig. 5-48 Hydraulic oil sampling valve
The hydraulic oil sampling valve is mounted next to the rear bearing of the splitterbox
housing.
5.12.6 Hydraulic oil coolers

Clean hydraulic oil coolers are necessary to achieve 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.
5.12.7 Leak oil and return-line filters

The leak oil filter and the return-line filters are located on the top of the hydraulic tank.
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Hydraulic system
Fig. 5-49 Leak oil filters and return-line filters parts
1 Return-line filters 11 Leak oil filter
 Clean the magnetic rods of the filters according to intervals given in the control
and maintenance chart.
 Change the filter insert according to intervals given in the control and maintenan-
ce chart.
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Hydraulic system
Fig. 5-50 Filter assembly
11 Cover 15 Filter element

12 Magnetic rod 18 O-ring
13 Fixing parts
To clean the magnetic plug and replace the filter element:

 Loosen the fixing parts 13 and lift out cover 11 and magnetic rod 12.
 Carefully clean off any dirt sticking to the magnetic rod 12.
 Remove the used filter element 15 from the bracket.
 Insert a new filter element 15 on the bracket vertically into the tank and press
down lightly.
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Hydraulic system
Caution!
 Ensure that the filter cartridge is standing vertical in the tank and that the lower
section of the element touches the bottom of the canister.
 Make sure the o-ring 18 is in good condition and seated correctly.

 Reinstall the cover 11.
 Tighten the fixing parts 13.
5.12.8 Oil filters in PowerPack
Fig. 5-51 Control oil filter on control unit and replenishing filters on splitterbox
4 Filter element 6 Filter head

5 Filter housing 7 O-ring
Three hydraulic filters ensure filtration of the auxiliary circuits:

– 1 control oil filter, mounted on the control oil unit located over the hydraulic pumps
assembly,
– 2 replenishing oil filters, mounted on the splitterbox for the swing circuit.
 Change this filters at regular intervals as indicated in the control and maintenance
chart.
Note!
It is not permitted to clean the filter element.
 Change the filter element each time you open the filter housing.
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Hydraulic system
To replace a filter element:

 Relieve hydraulic tank pressure.
 Remove the filter housing 5.
 Remove the filter element 4.
 Clean filter head 6 and housing 5.
 Install the new filter element 4.
 Make sure the sealings such as o-ring 7 are correctly installed.
 Lightly lubricate the threads of the housing 5.
 Reinstall the filter housing 5, tightening it by hand.
 Pressurize the hydraulic tank.
5.12.9 High pressure filters on valve bank
Fig. 5-52 High pressure filters on valve bank
1 Filter housing 4 O-ring

2 Filter element 5 O-ring
3 Filter head
Four high pressure filters are mounted on the inlet ports of the control valves.
The filter elements should be checked or replaced at the intervals specified in the
control and maintenance chart.
Caution!
The concerned filter elements must be changed after each replacement or repair of
a working pump.
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Hydraulic system
To check or change the filter element:
Caution!
Risk of oil spilling when removing the filter housing. Oil spilling could be reduced by
using a vacuum pump.
 Relieve hydraulic tank pressure.

 Remove the filter housing 1.
 Remove the filter element 2, check it and clean it with non flammable cleaning
fluid, or replace it if necessary with a new element.
Note!
The filter element 2 can be cleaned up to three times. Then it must be replaced by
a new one.
 Clean the filter housing 1 and the filter head 3 and reinstall, making sure the o-
rings 4 and 5 are seated properly.
 Turn the filter housing 1 in the filter head 3 up to the stop.
 Loosen the filter housing 1 by 1/6 turn.
Note!
Any time the filter element is cleaned or replaced, check for leaks.
 To check for leaks, start the engine, operate the machine for a short period, and
check for leaks between the filter housing 1 and the filter head 3.
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Hydraulic system
5.12.10 Control circuit
Fig. 5-53 Accumulator on valve bank
Danger!
Before working on the control circuit, the control pressure must be depressurized
as follows:
 Lay the work equipment on the ground.
 Operate both joysticks (with ignition key in contact position).
The control oil circuit does not require any special maintenance.
 Inspect the pipe network and connections on all units (pressure accumulator,
pressure limiting valve, pressure filter etc.) regularly for leaks.
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Hydraulic system
5.12.11 Hydraulic pumps bleeding
Working pumps bleeding
Fig. 5-54 Leak oil connection on working pump
After every repair on the pumps and/or after every hydraulic oil change, the hydraulic
pumps must be bled.
 Slightly loosen the hose on top of the leak oil connection on the pump housing (do
not remove) and allow air to escape.
 As soon as hydraulic oil without air bubble emerges, tighten the leak oil hose
again.
Before starting the pump for the first time, after repairing or replacing the pump, the
pump housing must be filled with hydraulic oil via the same connection.
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Hydraulic system
Swing pumps and cooling pumps bleeding
Fig. 5-55 Bleeding plugs on swing pumps and leak oil connection on cooling
pumps
After every repair on the pumps and/or after every hydraulic oil change, the hydraulic
pumps must be bled.
 To bleed the swing pumps, slightly unscrew the the bleeding plugs on the swing
pumps and allow air to escape.
 To bleed the cooling pumps, slightly loosen the hose on top of the leak oil con-
nection on the pump housing (do not remove) and allow air to escape.
 As soon as hydraulic oil flows out densely, close the connection again.
5.12.12 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.).
Bleeding procedure
 Make the engine run at low idle.

 If possible, move the attachment in such a way that the side to be bled (not-sup-
plied side) of the cylinder is in the upper position.
 Slowly extend the cylinder to the stop and then slowly retract it again to the stop.
Ensure that all movements are slow and even. Repeat this process at least for 5
minutes.
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Hydraulic system
Danger!
If the cylinder is not properly bled, gas bubbles might form in the system (mixture of
air and hydrocarbon). At high operating pressures in the cylinder, these gases mi-
ght explode (Diesel effect).
5.12.13 Hydraulic pumps intake hoses removal
Fig. 5-56 Hydraulic shut-off valve and oil suction pipe
1² Hydraulic tank shut-off valve. 16 Socket head screw M16. 35+17 Nm

15 Compensator. 24 Hex. head screw M20. 60+30 Nm
23 Compensator. 28 Hex. head screw M20. 55+27 Nm
40 Compensator. 30 Oil drain plug M30.
If an expansion joint on an hydraulic pump or on the main collector must be exchan-

ged:
 Close the shut-off valve 1 on the hydraulic tank.
 Release the tank pressure.
 Remove the cover on the leak oil filter, so to prevent the oil return via this filter and
hydraulic pumps.
 Mounting bolts 16, 24 and 28 for the compensators must be torqued at prescribed
value and coated with Loctite 243 (Id. 8503598).

 After repair, reinstall the leak oil filter cover.
 Return the shut-off valve 1 in open position.
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Hydraulic system
5.12.14 Oil cooler protection filters (optional)
Fig. 5-57 Oil cooler protection filter
Protection filters 15 can be installed between the valve bank and the oil cooler in or-
der to reduce the impact on the operating conditions of the excavator in case of pos-
sible hydraulic component failure.
 Check and clean filters regularly.
 Check filters in case of hydraulic component failure.
 Change filter in case of impact or mesh rupture.
Caution!
If filters maintenance isn’t correctly carried out, filters clogging due to regular ope-
ration of the excavator could lead to following risks:
– cooling capacity drop,
– negative impact on oil quality.
To check or change a filter:

 Shuf-off valve between hydraulic tank and pumps must be closed.
 Use a vacuum pump connected to the hydraulic tank in order to minimize oil loss.
Note!
During maintenance operation, if one or several filter(s) is/are defective and if no
replacement filter is available, the excavator can still be operated with one or seve-
ral filter(s) missing. This until delivery of a new filter.
 Make sure to always have sufficient operational filter in order to reduce mainte-
nance time.
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Hydraulic system
5.12.15 Servicing the hydraulic cylinder
Checking the condition of the piston rod mount
Fig. 5-58 Piston rod mount
Note
When a leak appears on the piston rod mount of a hydraulic cylinder (boom), the
sealing kit must be replaced by a LIEBHERR dealer.
Protecting the piston rods
Fig. 5-59 Machine with piston rods drawn in
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
drawn into the cylinders.
 Cover any loose piston rods with a thick layer of non-corrosive anti-corrosion fluid
to all exposed sections of the piston rods.
Grease quality: see “Lubricating and operating materials”
 For sea transportation (salt water), or in winter (road salt), check the condition of
the piston rods once more after loading the machine, since the anti-corrosive
grease may have been removed by the wiper ring.
 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
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Hydraulic system
hydraulic oil (eg. cylinder on slewing arm when working over ground).
 Check the condition of hydraulic cylinders which are not moved a great deal re-
gularly.
5.12.16 Replacing hydraulic hoses
General information
Fig. 5-60 High pressure hose with SAE fitting
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.
Installed high pressure hoses with SAE connections have a nominal diameter of 16,
20, 25, 32 or 40 (5/8", 3/4", 1", 1"1/4, or 1"1/2).
 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 screw 4 Torque value in Nm - Quality 10.9

Half flanges 5a Flat flange 5b Conical flange 5c

M8 31 / /
M10 62 45 65
M12 108 70 110
M14 172 120 180
M16 264 170 250
Tab. 5-6 Tightening torques for SAE fittings - Quality 10.9
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Hydraulic system
Half flanges 5a Flat flange 5b Conical flange 5c

M20 350 250 450
Half flanges 5a
M8 22
M10 44
M12 76
M14 122
M16 187
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.
5.12.17 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).
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Oil changes on components
Fig. 5-61 Criss-cross tightening
 Pre-tighten mounting screws by hand.

 Tighten screws progressively in a criss-cross pattern:
– first to 30% of the prescribed torque value,
– then to 60% of the prescribed torque value,
– finally to 100% of the prescribed torque value.
 Check tightening torque clockwise.
5.13 Oil changes on components
5.13.1 General information

 The machine must be standing level.
 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.
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5.13.2 Swing gears – oil change
Fig. 5-62 Oil change on the swing gear
1 Oil drain plug 6 Swing gear oil change couplings

3 Filler tube 7 Expansion tank
4 Sealing cap
Note!
The oil in the swing gears must be changed via the two quick-change couplings 6
from the service trap and when the oil is at operating temperature.
 For oil specifications and oil quantity, refer to the lubrication chart.
 For oil-changing intervals, refer to the control and maintenance chart.
To drain the oil:

The lower plug 1 for oil drain of each gear is directly connected to an oil change cou-
pling 6 on the service trap: no oil drain is possible at the lower section of the gears.
 Remove the sealing cap 4 on the expansion tank 7.
 Use the quick-change coupling 6.
 Drain the oil into a suitable container.

 When drained, reinstall the sealing cap 4.
To fill the oil:

For small quantities:
 Add oil via the filler tube 3 of the expansion tank 7 (each expansion tank 7 is con-
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nected to the upper section of a swing gear via two hoses).

 When correct oil level is reached, reinstall the sealing cap 4.
For larger amount:
 Add oil via the quick-change coupling 6.
 When correct oil level is reached, reinstall the sealing cap 4.
Oil level:
The oil level must reach the middle of the lower sight gauge "L" of the expansion tank
7 when the oil is cold, and must not overpass the upper sight gauge "H" when the oil
is hot.
5.13.3 Lifetime Travel gear – oil change
Caution!
 The following travel gear elements are filled with protective oil on delivery. They
have to be drained and refilled with the same oil as used for the hydraulic tank
before first start of the excavator:
– four travel brakes (two on each travel gear),
– two Lifetime sealing interspaces (one on each travel gear).
 The following travel gear elements have to be filled with the same oil as used for
the hydraulic tank before first start of the excavator as well:
– expansion tank chamber connected to the Lifetime sealing interspaces (see §
"Oil change on Lifetime sealing interspace" below),
– hydraulic lines between interspaces oil expansion tank and the interspaces
themselves.
Danger!
When the oil is hot, the travel gear elements may be under pressure.
 Before draining the oil, carefully loosen the oil filling plugs to allow the internal
pressure to escape.
Note!
For oil specification and oil quantity, refer to the lubrication chart.
For oil changing-intervals, refer to the maintenance schedule.
If possible, drain the oil when the oil is at operating temperature.
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Oil change on travel gear
Fig. 5-63 Oil change on travel gear
1 Oil drain plug 4 Interspace oil filling plug

2 Oil filling and level plug 5 Interspace air vent plug
3 Interspace oil drain plug 8 Oil sampling plug
To drain the oil

 Make sure you have a suitable oil drain container at your disposal.
 Remove the two filling plugs 2.
 Remove the two drain plugs 1.
 Reinstall both drain plugs 1 and both filling plugs 2.
To add oil:
 Make sure the drain plugs 1 are installed.
 Remove filling plugs 2.
 Add oil via one of the filling plugs 2 until oil reaches the level of the second one.
 Reinstall both filling plugs 2.
To sample oil:
 Use plug 2 or 8 to sample oil from the travel gear.
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Oil change on Lifetime sealing interspace
Fig. 5-64 Interspaces oil expansion tank
9 Filler tube 11 Expansion tank

10 Sealing cap
Caution!
For the Lifetime sealing interspaces and associated expansion tank, always use the
same oil as used to fill the hydraulic tank.
To drain the oil:

 Remove sealing cap 10.
 Remove drain plug 3.
 Reinstall both plug 3 and cap 10.
To flush the Lifetime sealing interspace:
Caution!
The flushing line must be equipped with a pressure relief valve (3 bar) in order to
avoid damaging the travel gear in case of clogging.
 Set the flushing device above travel gear level.
 Remove filling plug 4.
 Connect the vacuum pump to connection 4 and operate the vacuum pump.
 Remove drain plug 3.
 Install hose on connection 3 and connect it to the return line of the flushing device.
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 Remove the vacuum pump from connection 4 and connect the flushing line of the
flushing device to connection 4.
 If necessary repeat the procedure and make sure all the interspace oil has been
flushed (see lubricant chart for quantity).
 Remove the flushing device.
 Reinstall both plugs 3 and 4.
To add oil:
Caution!
For the interspaces oil expansion tank, always use the same oil as used to fill the
hydraulic tank.
Never add oil under pressure (over 3 bar).
 Make sure drain plug 3 is installed on the travel gear.

 Remove sealing cap 10.
 Remove interspace air vent plug 5.
 Add oil via filler tube 9.
 Control oil level via sight gauge on expansion tank 11.
 When correct level is reached, reinstall sealing cap 10 and air vent plug 5.
Oil change on travel brake
Caution!
For the travel brakes, always use the same oil as used to fill the hydraulic tank.
Old design travel brake
Fig. 5-65 Oil change on old design travel brake
5 Travel brake drain plug 7 Travel brake oil level plug

6 Travel brake filling plug 8 Pressure port
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To drain the oil:

 Remove filling plug 6 located on the upper side of the travel brake.
 Remove drain plug 5 located on the lower side of the traval brake.
To add oil:
 Make sure plugs 5 and 7 are installed.
 Add oil via filling plug 6 until no more bubbles emerge.
 Correct level using level plug 7 (add oil or let excess oil flow out as necessary).
 Reinstall level plug 7.
 Apply a pressure of 19 bar through pressure port 8 to release brake.
 Remove drain plug 5 and let 0,3 l oil flow out.
 Reinstall drain plug 5 and filling plug 6.
New design travel brake
Fig. 5-66 Oil change on new design travel brake
5 Travel brake drain plug 7 Travel brake oil level plug

6 Travel brake filling plug 8 Pressure port
To drain the oil:

 Remove filling plug 6 located on the upper side of the travel brake.
 Remove drain plug 5 located on the lower side of the traval brake.
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To add oil:
 Make sure plugs 5 and 7 are installed.
 Apply a pressure of 19 bar through pressure port 8 to release brake.
 Add oil via filling plug 6 until no more bubbles emerge.
 Correct level using level plug 7 (add oil or let excess oil flow out as necessary).
 Reinstall filling plug 6 and level plug 7.
5.13.4 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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5.13.5 Oil level check on idler (ITT idler only)
Fig. 5-67 Oil level on ITT idler
1 Maximum level 7 Oil filling hole

2 Minimum level 8 Oil filling hole
To check the oil level:

 Turn the idler until oil flows out of oil filling hole 8.
 Check oil level according to the position of the oil fillling hole as described on the
fig. above: oil level must never drop below minimum level.
 If necessary, add oil to top up the idler or drain and refill the idler with oil until cor-
rect oil level is reached.
 Reinstall filling plug 8.
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Note!
The idler side is fitted with two oil filling plugs 7 and 8.
 Turn the idler so as to get filling plug 7 in lower vertical position ("6 o’clock").
 Filling plug 8 will be automatically positioned to maximum oil level check po-
sition.
5.13.6 Splitterbox – oil change
Fig. 5-68 Oil change on the splitterbox
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1 Drain valve 4 Splitterbox oil change coupling

2 Dipstick 5 Oil sampling valve
3 Oil inlet cap
Splitterbox oil level check

 Turn the engine off and wait 15 minutes for the oil to collect into the oil pan.
 Read oil level using the dipstick 2.
Note!
The oil in the splitterbox must be changed via the quick-change coupling 4 on the
service trap and when the oil is at operating temperature.
Refill the splitterbox up to the mark on dipstick 2. Do not overfill.
 For oil specification and oil quantity, refer to the lubrication chart.
 For oil-changing intervals, refer to the control and maintenance chart.
To drain the oil:

 Use the quick-change coupling 4 on the service trap.
As a help way, the oil can also be changed via the drain valve 1 located at the bot-
tom of the splitterbox:
 Remove the cap from the drain valve 1.
 Screw on a drain hose.
 Remove the drain hose.
 Reinstall the cap on the drain valve 1.
To add oil:
 Remove the oil inlet cap 3.
 Add oil via the threaded bore hole of the removed cap 3 up to the mark on dipstick
2.
 When correct oil level is reached, reinstall the oil inlet cap 3.
 After each oil change, allow the engine to run for a few minutes, turn the engine
off. Then wait a few minutes and recheck the oil level with dipstick 2.
Splitterbox oil sampling

The splitterbox oil sampling valve 5 is mounted to the output of the splitterbox oil
pump.
5.13.7 Coupling – oil change

The elastic coupling between diesel engine and splitterbox is filled with oil
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To change the oil in the coupling
Fig. 5-69 Changing the oil in the coupling
1 Filling hose 9 Coupling inner star

2 Return hose 907Coupling connector
5 Coupling flange 909Coupling connector
Note!
The coupling may remain installed during an oil change.
Execute an oil change in a warm service condition of the coupling and with a pre-
heated new coupling oil (oil temperature min 40°C).
Note!
For oil specification and oil quantity, refer to the lubrication chart.
For oil change intervals, refer to the Maintenance Schedule.
Use the tool Id. 9943251 to change the coupling oil

 Turn the diesel engine until the connectors 907 and 909 are accessible. The die-
sel engine can be turned via the pin on the SAE housing (see CUMMINS Opera-
tion and Maintenance Manual)
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Rotary connection (from SN 28066)
 Fill the oil container of the tool (on pump side) with 6 liters of flushing oil
 Connect the filling hose 1 of the filling pump to the connector 907 of the inner star
9.
 Connect the return line 2 of the tool to the connector 909 of the flange 5.
 Switch on the pump and press an amount of flushing oil into the coupling (approx.
6 liter: approx. 1,6 liter to fill the coupling and the holdover to rince the coupling)
Caution!
Do not suck in any air
 Switch off the oil pump and pull the filling hose 1 of the inner star 9, plug connector
907.
 Leave the return hose connected until no more oil emerges, i.e. until the filling
pressure has sunk to the ambiant pressure again.
 Pull off the return hose 2 and plug connector 909.
5.14 Rotary connection (from SN 28066)
On excavator from SN 28066, the rotary connection must be greased regularly.

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Track components
Fig. 5-70 Grease nipple on rotary connection
1 Grease nipple M10 x 1,5
To grease the rotary connection:

 Use the grease nipple 1.
5.15 Track components
The track components are maintenance-free until the track needs to be reconditio-
ned or has to be replaced.

The design of the carrier rollers, track rollers and idle wheels increases the track
components lifetime and metal sealing make them insensitive to dirt.
Sprocket wheels are maintenance free.
Idler wheels, track rollers and carrier rollers oil must be changed at regulator inter-
vals.
 For idler wheels and rollers maintenance intervals, see control and maintenance
chart.
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Track components
5.15.1 Track components mountings check

 Regularly check the tightening of the track components mounting screws.
 For tightening values, refer to the following tables.
Fig. 5-71 Undercarriage components
1 Central part 25 Travel motors protection

2 Side frame 30 Ladder
5 Idler wheel 45 Track guide
10 Rotary connection 50 Track roller
13 Travel gear 55 Carrier roller
18 Track tensioning unit 100 Track chain
20 Sprocket wheel 111 Cover
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Track components
Fig. 5-72 Undercarriage mounting screws
3 Hex. head screw M36x200 3300 Nm 37 Washer

4 Space sleeve 51 Hex. head screw M36x260 3300 Nm
20 Stud M42 971,5 kN 52 Washer
21 Stud M42 971,5 kN 56 Hex. head screw M30x190 1900 Nm
22 Washer 57 Washer
23 Protection nut M42 550±100 Nm 58 Hex. head screw M33x260 2600 Nm
27 Hex. head screw M20x40 560 Nm 59 Washer
28 Washer 60 Hex. head screw M24x110 960 Nm
29 Washer 61 Washer
30 Bushing 62 Bushing
31 Washer 80 Cover
32 Hex. head screw M42x240 4975 Nm 81 Cover

34 Pin 84 Hex. head screw M20x40 560 Nm
35 Split pin 85 Washer
36 Hex. head screw M36x240 3300 Nm
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Track components
Fig. 5-73 Tractor-type (left) and dual pin (right) track pads
Tractor-type chain
6 Locking screw M42 1000 Nm Pre-tightening torque
160° Tightening angle
6500 Nm Check torque
Dual pin chain

7 Locking screw 1"-14UNSx85 1650±80 Nm Tightening torque
5.15.2 Monitoring the track tension
Fig. 5-74 Monitoring the track tension

 Relieve the tracks by driving the machine forwards and backwards.

 Place the measuring rod 1 in the area between the idler and the carrier roller.
 Measure distance A between the measuring rod lower edge.
 Retension track if necessary.
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Track components
5.15.3 Track tensioning system
Fig. 5-75 Track insufficiently (A) and correctly (B) tensioned
Fig. 5-76 Track tensioning valves
To tension the track

 Make sure valve(s) VTL (left chain) and/or VTR (right chain) in the swing ring area
is/are closed.
 Start the engine of the excavator.
 The chain(s) will automatically be tightened.
To release the track
Danger!
Risk of injury due to sudden pressure relief of the crawler chain.
 Before attempting to release the chain tension, release and remove every forei-
gn body which may be stuck in the chain while driving forwards and backwards
or doing as described in the section "Cleaning the track components" thereafter.
 Actuate valve VTL or VTR to release the track tension pressure on the side you
are working on.
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Electrical system
5.15.4 Cleaning the track components
Caution!
Do not start the machine up if large stones, pieces of wood or of metal, wires or ca-
bles are stuck in the running gear.
Dried or frozen mud as well as stones or other foreign bodies in the travel gear parts
could result in considerable damages for the machine if this one is operating or if
you try to release the machine using engine power.
Note!
After a chain change, all chain pins must be cleaned and then greased with black
grease (Ident Nb. 8503279). After any operation on a chain component, the corres-
ponding chain pin must be cleaned and greased as well.
5.16 Electrical system
5.16.1 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 batte-
ries.
 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 Quantum system (ECM) 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.
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Electrical system
5.16.2 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.
Fig. 5-77 Battery switches
Fig. 5-78 Connectors on ECM
 Before starting any work on the electrical system switch the principal batteries
switches S9_1, S9_2 (located in the electrical box on top of the left catwalk) to
position "off". For welding work on the machine also disconnect the 21-pins and
31-pins connectors from the ECM U18 on the Diesel 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
measured value sensors such as oil pressure switches to any direct jets.
 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
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Electrical system
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 "off".
5.16.3 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 re-
gularly 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. 5-79 Battery care
1 Cable terminal 2 Acid tester
 From time to time, measure the acid concentration using an acid tester 2.
When the battery is fully charged, the unit weight is 1.28 kg/l (31.5° Bé).
 If the acid tester displays a lower value, the batteries is virtually flat and should be
charged if necessary.
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Electrical system
5.16.4 Electrical components location
Fig. 5-80 Electrical components location
A1001 ESP01 Platine S9_1 Engine battery switch

E1003 Power connection box S9_2 Quantum switch
E1005 Cabin connection box S100_1 Emergency stop cabin
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Heating/air conditioning system
E1006 Cabin connection box A/C S100_2 Emergency stop pump

E1010 Cabin connection box greasing S100_3 Emergency stop engine
E1022_1 Connection box principal ladder control S100_4 Emergency stop counterweight
E1022_2 Connection box service trap control S100_5 Emergency stop control valve
H1 Display U15 Electronic box greasing
S2 Keyboard
5.16.5 Electrical boxes and cab pressurization
Fig. 5-81 Aeration device
These aeration devices are installed as follows:

– on the left side on the cab elevation,
– on the back of the cabin.
The air filters for electrical boxes and cab pressurization must be cleaned regularly.
 To clean the air filters, press to open the dust discharge valve 5.
 Regularly change the main element as well as the safety element of the air filter
system of this device.
5.17 Heating/air conditioning system
The excavator features a heating and an air-conditioning system as standard.

The heating system functions with a heater installed under cabin floor.
The air-conditioning unit is composed of the following elements:

– a compressor mounted on the Diesel engine,
– an evaporator mounted in the cabin roof,
– a filter/dryer/receiver unit installed in the cab elevation,
– a condenser mounted on the Diesel engine cooling radiator.
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Note!
A dual air-conditioning system can be installed optionally. In this case, a second air-
conditioning unit is installed behing the cab and comprises:
– a compressor (hydraulically driven by an additional pump mounted on the split-
terbox),
– a condenser battery,
– a filter/dryer/receiver unit.
Note!
In case of repair works at condenser or receiver, the refrigerant must be emptied
and collected in a special tank. The collected refrigerant can be cleaned an re-pre-
pared by refrigerant manufacturers.
5.17.1 Heating system
Fig. 5-82 Coolant shut-off valves 1 on Diesel engine

Fig. 5-83 Heater
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3 Fresh air filter 4 Heat exchanger
If filters are dirty, the air flow in both heating and air conditioning systems is reduced.
This results in the forming of frost and system shut-off.
 Remove and clean the heat exchanger 4 and the fresh air filter 3 at intervals
specified in the control and maintenance chart.
 Do not operate the machine, even briefly, without these filters, since the heat ex-
changer 4 will otherwise quickly become blocked.
Caution!
Independently from weather conditions, the two coolant shut-off valves 1 located on
the Diesel engine must always remain open.
However, the coolant shut-off valves 1 must be closed during coolant change.
To clean and change the fresh air filter:

 Remove fresh air filter 3 located under heater.
Note!
 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.
5.17.2 Air-conditioning system

 Switch on the air-conditioning system for approx. 10 minutes every 2 or 3 weeks,
regardless of the season.
 During the warm season, perform following checks or maintenance works:
Filter check:
Fig. 5-84 Evaporator filter
 Check and clean the recirculated air filter 2 integrated in the roof of the cab.
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Filter/drier/receiver unit check:
Fig. 5-85 Filter/dryer/receiver unit
5 Receiver bottle 7 Sight glass

6 Filter/drier
 Check condition of receiver bottle 5 and filter/drier 6.

 Should corrosion, rust or mechanical damage be observed, the receiver bottle
has to be replaced by reasons of explosion. While replacing, take care of the
mounting direction. The exit is marked with an "A" and the top side is marked with
"OBEN".
 Change the filter/drier 6 in air conditioning unit at regular intervals, at least once
a year. The filter/drier 6 also have to be changed after each opening of the refri-
gerant circuit. The arrow symbols on the filter/drier have to be placed in the direc-
tion of the expansion valve.
 In addition, the refrigerant charge of the system must be checked at regular inter-
vals, by observing the sight glass 7 of the receiver/filter/drier unit while the air con-
ditioning system is operating.
Bubbles or foam in the sight glas 7 indicate an insufficient refrigerant charge.
 In this case, the system must be checked and refilled by a trained specialist.
 Check the color of the indicator in the sight glass 7. If the indicator becomes yel-
low, it means that there is too much humidity in the system. The filter/drier 6 must
be changed immediatly by a trained specialist.
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Condenser check:
Fig. 5-86 Condenser
 Check the condenser 9 mounted on the engine cooling radiator. If necessary blow
it out with pressurised air or steam, from the inner side (fan side) to the outside.
Compressor check:
Fig. 5-87 Compressor for the air conditioning system
8 Compressor 11 V-belt
 Check for possible damages on the compressor 8 installed on the Diesel engine.
 Check compressor fastening.
 Check condition, alignment and tension of V-belt 11.
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5.17.3 Dual air-conditioning system (optional)

 Also switch on the second air-conditioning system for approx. 10 minutes every 2
or 3 weeks, regardless of the season.
Fig. 5-88 Condenser unit for optional dual air conditioning-system
5 Receiver bottle 8 Compressor

6 Filter/drier 9 Condenser battery
7 Sight glass 10 Fan
 During the warm season, perform the same following checks and maintenance
works as for standard air-condioning system concerning:
– filter/drier 6 and receiver bottle 5,
– compressor 8,
– condenser battery 9.
 Also check condition of fans 10. If one fan 10 is defective, it has to be replaced.
The fans have to be free of dirt and damages.
5.17.4 Additional maintenance operations

 Check operation of evaporator blowers and condenser fans. All blowers have to
be in working order in order to avoid air short circuit.
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Check mounting bolts for tightness
 Check electric installation.

 Check all hose fittings and couplings for leakage.
 Check setting and function of defrosting thermostat at the evaporator coil.
 Check compressor pressure switch. If the pressure at the compressor on the low
pressure side is too high, the compressor pressure switch lights up an indicator
lamps. This means that the compressor is not working well.
5.18 Check mounting bolts for tightness
 The mounting bolts listed below must be regularly checked and retighten if neces-
sary.
 See control and maintenance chart for check intervals.
Note!
When installing bolts of size bigger than M40 the thread of the screw must be sli-
ghtly coated with a MoS2 based grease. Also grease the bolt head supporting sur-
face, unless hereafter otherwise specified.
Danger!
Due to their size, most of the below listed mounting bolts require, to be tensioned
to the prescribed torque, the use of a special hydraulic or electric actuated tensio-
ning 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 (espacially the bolts listed below), of
the hydraulic hoses and of the counterweight must be replaced after every removal.
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5.18.1 Counterweight mounting bolts
Fig. 5-89 Counterweight bolts
Torque Quantity
4 Bolt M42x440 4810 Nm 8
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5.18.2 Swing ring mounting bolts
Fig. 5-90 Swing ring bolts
Torque Tension Quantity

15 Stud M36 707,5 kN 80
20 Stud M36 707,5 kN 80
30 Protection nut M36 600±100 Nm 160
The use of special tensioning procedure and tool is necessary to obtain the correct
bolt tension (contact LIEBHERR customer service).
Danger!
The special tool may only be operated by qualified personnel, especially trained for
the use of this high pressure tensioning device and aware of the operating instruc-
tions as well of the recommendations for accident and damage prevention concer-
ning this tool.

Use appropriate working platforms and lifting devices to install and hold in position
the special tool while tensioning the bolts.
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5.18.3 Fuel tank mounting bolts
Fig. 5-91 Fuel tank bolts
Torque Quantity
2 Bolt M30x240 1900 Nm 4
3 Bolt M30x300 1900 Nm 3
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5.18.4 Hydraulic tank mounting bolts
Fig. 5-92 Hydraulic tank bolts
Torque Quantity
5 Bolt M30x240 1900 Nm 4
6 Bolt M30x300 1900 Nm 5
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5.18.5 PowerPack mounting bolts
Fig. 5-93 PowerPack bolts
Torque Quantity
3 Bolt M36x300 3300 Nm 6
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5.18.6 Swing gears and swing motors mounting bolts
Fig. 5-94 Swing gear and swing motor bolts
Torque Quantity
5 Bolt M30x340 1900 Nm 16
6 Bolt M24x70 960 Nm 2
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5.18.7 Hydraulic pumps mounting bolts
Fig. 5-95 Hydraulic pumps assembly
Note!
An intermediate flange is located between the working pumps and the splitterbox.
Check and respect the following tightening torque values for the mounting bolts of
the pumps (Px) and the flanges (Fx).
Torque Quantity
F2 Socket head screw M20x65 425 Nm 8
F3 Socket head screw M20x65 425 Nm 8
P2 Hexagonal head screw M20x65 560 Nm 8
PS1 Hexagonal head screw M20x55 425 Nm 4

P6.1 Socket head screw M16x70 210 Nm 4
P10.1 Hexagonal head screw M12x45 85 Nm 2
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If the optional dual air-conditioning system is installed on the excavator, an additional

pump P11 is mounted on the splitterbox.
Torque Quantity
5.18.8 Side frames mounting bolts
Fig. 5-96 Side frames bolts
Torque Tension Quantity

20 Bolt M42 971,5 kN 40
21 Bolt M42 971,5 kN 12
23 Protection nut M42 550±100 Nm 52
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5.18.9 Cabin elevation mounting bolts
Fig. 5-97 Cabin elevation bolts
Torque Quantity
2 Hexagonal head screw M30x300 1900 Nm 7
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Drive unit brakes and swing gear brakes
5.18.10 Driver’s cabin mounting bolts
Fig. 5-98 Driver’s cabin bolts
Torque Quantity
21 Socket head screw M16x45 280 Nm 12
5.19 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.
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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 counterwei-
ght, 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 QUANTUM system (ECM).
 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 slewing ring,
hinges, bearings, sockets, rubber elements 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. In particu-
lar, visual checks such as crack testing are only possible on a clean machine.
 Clean the machine before you start maintenance work (see also the chapter
“Servicing the machine safely”, subheadings “Cleaning" and "Crack testing”).
Note!
The daily maintenance work that the device operator has to carry out comprises a
function check of the brakes (swing brake and travel brake), and the electrical and
hydraulic systems.
Additionally, a visual check must be made for leaks on the engine, hydraulic system
and transmission.
WORK TO BE PERFORMED
R9400
Note
Weekly
 First and only interval

Daily
 Repeat interval
DIESEL ENGINE & SPLITTERBOX
  Check oil level

  Check coolant level
  Check speed on RPM gauge
  Check running noises
  Check exhaust gas colour
  Check engine and external pipework for leaks
  Check exhaust connections for leaks. Check oil supply / return pipework for leaks
  Empty water separator at fuel filters
  Check for air filters clogging at the restriction indicators
  Check oil pressure and coolant temperature during operation
  Check coupling for leaks

 Check oil level in splitterbox
 Check condition of the cyclone tubes of the precleaner, clean if necessary
 Check air intake hose for condition and leaks
 Check and clean radiator core and fan
 Check radiator cap for leaks, replace if necessary
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R9400
Note
Weekly

Daily
 Repeat interval
 Drain fuel tank

 Check fastening of thermic protection on exhaust manifold
  Daily : perform the complete "Daily" Maintenance Echelon, as started in CUMMINS Ope-
rating and Maintenance Manual
HYDRAULIC SYSTEM
  Check oil level in hydraulic tank

  Check hydraulic system for leaks
  Check all hoses, lines and fittings for any external visible damage
  Inspect the fastening and the good condition of pipes and hoses for damage and leakage
  Clean magnetic rods in one of the return filters (each week another one) (daily during the
first 300 hrs.)
  Clean magnetic rods in leak oil filter (daily during the first 300 hrs.)
  Check hydraulic cylinder rods for leaks and good condition
 Inspect, and if necessary clean oil coolers
ELECTRICAL SYSTEM
  Clean and check LCD screen of the display for proper function when starting
  Check indicator lights and gauges on control panel when starting
  Clean the air filter in aeration devices for cabin and electrical boxes
 Check head and floodlights, clean if necessary
 Visual inspection of wiring system damage
AIR SYSTEM
  Check cut in and cut out pressure of air pressure regulator 6,2-7,25
bar
  Check hydraulic tank pressure 0,2-0,4 bar

 Drain air tanks
SWING RING
  Check function of swing ring bearing lubrication system during operation

  Check function of swing ring teeth lubrication system during operation
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R9400
Note
Weekly

Daily
 Repeat interval
  Visually check the grease delivery (outlet of new grease around the swing ring)
SWING GEAR
  Check function and operation of swing brake

  Visually check mounting bolts of gear and oil motor
  Check for leaks on swing gears, check oil level in expansion tanks
TRAVEL GEARS
  Check for leaks, if gear is leaking, check oil level

  Check function and operation of travel brakes
TRACKS
  Clean track chain (after working)

  Visually check and tighten if necessary mounting screws of side frames
  Check tensioning cylinders, idler, carrier and track rollers for leaks
  Visually check and if necessary tighten screws of sprocket, rollers, idlers, chain guides
and track pad bolts
  Visually check track chain tension
CAB, HEATER & AIR CONDITIONER
 Operate air conditioner every week for 10 minutes

 Visually check condenser unit and evaporator filter
 Check refrigerant level, if necessary refill circuit
 Check tension of V-belt for air conditioner
 Perform weekly maintenance for the second air-conditioning system (optional feature)
UNDER / UPPERCARRIAGE & ATTACHMENT
  Check function of working attachment lubrication system during operation

  Visually check the grease delivery at each lube point
  Visually check bucket teeth for wear
  The daily maintenance work must include the check of the proper function of hydraulic,
electric, pneumatic and brakes systems before starting operation
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R9400
Note
Weekly

Daily
 Repeat interval
 Visually check and if necessary tighten mounting screws of counterweight, tanks,

PowerPack, control valve console, cab, catwalks, grease box, ladder
 Check fastening of pin covers
 Check fastening of hoses and pipe clips
 Check level in reservoir for winshield washer, refill if necessary 75 l (19,8
US Gal.)
CENTRALIZED LUBRICATION SYSTEM
  Daily : perform a complete daily maintenance as stated in LINCOLN Servicing Manual

 Weekly : perform a complete weekly maintenance as stated in LINCOLN Servicing Ma-
nual
Tab. 5-8 Daily / weekly maintenance schedule R9400
R9400
At 7500, 15000, ....hrs
Note
At 1000, 3000, ....hrs
At 2000, 4000, ....hrs

At 500, 1500, ....hrs
At 250, 750, ....hrs

 Repeat interval
At delivery
      Perform all checks and works in the daily / weekly maintenance schedule
DIESEL ENGINE & SPLITTERBOX
     Change all preliminary filters and fuel filters as soon as fuel level reaches the
red mark on the bell of the preliminary filters or at least every 250 hrs
  Change filter in splitterbox breather
  Check the tightness of all screws and bolts on splitterbox

   Check the oil quality in splitterbox, change if necessary 65 l (17,2
US Gal.)
    Replace oil in Diesel engine 210 l (55
US Gal.)
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R9400
At 7500, 15000, ....hrs

At 1000, 3000, ....hrs Note
At 2000, 4000, ....hrs
At 500, 1500, ....hrs
At 250, 750, ....hrs

 Repeat interval
At delivery
  Replace oil in elastic coupling 1,35 l

(0,36 US
Gal.)
 Check mounting screws of engine and splitterbox for tightness

  Check the engine rubber buffers (replace if necessary and at least every 10000
hours)
Replace primary element of air cleaner (if necessary or once a year)
Replace safety element of air cleaner (if necessary or once a year)
Every 250 hours or 6 months, perform a complete "250 hrs" Maintenance

Echelon, as stated in CUMMINS Operation and Maintenance Manual.
Every 1500 hours or 1 year, perform a complete "1500 hrs" Maintenance

Echelon, as stated in CUMMINS Operation and Maintenance Manual
Every 6000 hours or 2 years, perform a complete "6000 hrs" Maintenance

Echelon, as stated in CUMMINS Operation and Maintenance Manual
See CUMMINS Operation and Maintenance Manual for other maintenance

(Eliminator, Centinel, Fleetguard, valves and injectors adjustment)
Every 20000 hours, perform a complete "20000 hrs" Maintenance Echelon, as

stated in Geislinger (coupling manufacturer) Manual
HYDRAULIC SYSTEM
   Change control oil filter elements (first after 500 hrs)

   Change swing pumps replenishing oil filter elements (first after 500 hrs)
   Change filter element of leakage oil filters (first after 500 hrs)
   Change filter element of return filters (first after 500 hrs)
  
Check mounting of components (pumps, motors, clamps, ...)

     Perform a detailled check of all hoses, lines and fittings for any external visible
damage
 Every 4000 hrs (or at least once a year), all hydraulic pumps must be checked
and adjusted by trained and qualified Liebherr personnel
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R9400
At 7500, 15000, ....hrs Note

At 1000, 3000, ....hrs
At 2000, 4000, ....hrs

At 500, 1500, ....hrs
At 250, 750, ....hrs

 Repeat interval
At delivery
 Every 8000 hrs, 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 cir-
cuits,
• all HP pilot hoses of the swing pumps regulation,
– all hoses between upper deck and attachment,
– all hoses of the oil cooler fan drive circuit, including pilot hoses,
– all hoses of the water cooler fan drive circuit, including pilot hoses.
   Check and adjust primary and secondary pressure relief valves
 Replace hydraulic oil 2200 l
(581 US
Gal.)
   Check oil cooler protection filter, clean or change if necessary (optional featu-
re)
 Visually check the cooling fan blades, replace if necessary
Bleed servo system and hydraulic pumps (as necessary)

 Check filter element of high pressure filters, replace if necessary (replace the
concerned filter elements after each replacement or repair of a working pump)
CENTRALIZED LUBRICATION SYSTEM
  Every 1000 hours, perform a complete 1000 hrs Maintenance Echelon as sta-
ted in LINCOLN Servicing Manual
  Every 7500 hours, perform a complete 7500 hrs Maintenance Echelon as sta-
ted in LINCOLN Servicing Manual
ELECTRICAL SYSTEM
   Check level and specific gravity of the electrolyte in the batteries

  Check and clean battery terminals
     According to operating conditions, change the filter element of the aeration de-
vices for cabin and electrical boxes every 250 hrs or 500 hrs.
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R9400
At 7500, 15000, ....hrs

At 1000, 3000, ....hrs Note
At 2000, 4000, ....hrs
At 500, 1500, ....hrs
At 250, 750, ....hrs

 Repeat interval
At delivery
AIR SYSTEM
 Change filter cartridge of air dryers
SWING RING
  Check and if necessary tighten mounting screws

  Check pinion gear mesh
  Check axial play of swing ring
SWING GEAR
   Replace gear oil (first after 500 hrs) 2x39 l

(2x10,3
US Gal.)
 Sample and analyse gear oil (only if filled with mineral oil)
 Check mounting screws of gear and oil motor
TRAVEL GEAR
  Check mounting screws of gear, sprocket wheels and oil motors

   Replace gear oil (first after 500 hrs) 2x80 l
(2x21,1
US Gal.)
 Sample and analyse gear oil (only if filled with mineral oil)
   Replace Lifetime sealing interspace oil (first at 500 hrs) 2x8l
(2x2,1
US Gal.)
    Sample and analyse gear interspace oil
 Every 5000 hours, replace brake oil 4x0,4 l

(4x0,11
US Gal.)
TRACKS
  Check tightening torque of screws of rollers, pin locking screws and chain gui-
des
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Centralized lubrication system
R9400
At 7500, 15000, ....hrs Note

At 1000, 3000, ....hrs
At 2000, 4000, ....hrs

At 500, 1500, ....hrs
At 250, 750, ....hrs

 Repeat interval
At delivery
  Check tightening torque of side frames screws
CAB, HEATER AND AIR CONDITIONER
  Check locks and hinges on doors and windows (lubricate if necessary)

 Check heater for leaks, heat exchanger and heater filter
Change the air conditioner filter/drier (at least once a year)
Yearly check condition of the refrigerant receiver, if necessary replace it
Change main element on air cleaners (at least once a year)
Change safety element on air cleaners after 3 services of main element
Perform maintenance for the second air-conditioning system (optional feature)
Lubricate all doors seals with silicone or talc (before cold season)
UNDER / UPPERCARRIAGE & ATTACHMENTS
    Check all parts for cracks

  Check and lubricate cover hinges and locks
 Check tightening of mounting screws for counterweight, tanks, PowerPack,
control valve console, cab, catwalks, grease box, ladder
 Explain proper use and maintenance to the operator
Tab. 5-9 Maintenance schedule R9400
5.22 Centralized lubrication system

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Owners manual
Centralized Lubrication
PBM/013/D/02
SUBJECT : LIEBHERRR EXCAVATOR R9350 Tier 2 / R9400
CODE WORD :
CUSTOMER : LFR
ORDER NO. :
SUPPLIER : LINCOLN GMBH
69183 WALLDORF
Cover R9400 PBM013D02.docx / 12.06.2012 Subject to change without notice page 1 of 1

LINCOLN GmbH & Co. KG Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259
Servicing Manual
Centralized Lubrication System for LIEBHERR Hydraulic Excavator
R9350/R9400
Manual R9350/R9400
Servicing Manual
R9350 Tier 2 Type 1369 (Analog)
R9400 Type 1257 (Analog)
Subject to change 1
LINCOLN GmbH Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259 Tx 466088
Servicing Manual
R9350/R9400
Manual R9350/R9400
A. Description of the system as a whole
1 FUNCTION OF THE LUBRICATION SYSTEM ................................................................................................... 3

1.1 DESCRIPTION OF THE ENTIRE SYSTEM ............................................................................................................... 3
1.2 SEQUENCE OF A LUBRICATION CYCLE ................................................................................................................ 3
1.2.1 System 1 (Single line system)................................................................................................................. 3
1.2.2 System 2 (Progressive system) .............................................................................................................. 3
1.3 LUBRICATION DIAGRAM .......................................................................................................................................... 4
1.3.1 200L System (Version I) ......................................................................................................................... 4
1.3.2 80L System (Version I) ........................................................................................................................... 4
1.3.3 200L System (Version II+III) ................................................................................................................... 6
1.3.4 80L System (Version II+III) ..................................................................................................................... 7
2 OPERATION ......................................................................................................................................................... 8
3 INSPECTION AND MAINTENANCE .................................................................................................................... 9
4 TOPPING UP GREASE RESERVOIRS ............................................................................................................. 10
4.1 P1 AND P2: FILLING OF THE CONTAINER.......................................................................................................... 10
5 MALFUNCTIONS AND THEIR REMEDY .......................................................................................................... 11
B. Description of the components of the lubrication system
1. Description of the hydraulic pump, 200l reservoir ............................................................Manual
2. Description of the hydraulic pump 80l reservoir ...............................................................Manual
3. Manual Flowmaster hydraulic pump .................................................................................Manual
4. Description of the injectors LM5 .......................................................................................42.A-18002-C07
5. Description of the progressive plunger metering devices SSV .........................................22.EN-20001-J11
6. Description of the solenoid valves ....................................................................................9.3A-68001-B00
7. Data sheet Rod probe .......................................................................................................Liquicap FMI51
8. Data sheet: electronic pressure switch with digital display……………………..93DE_EN_-FR-58003-A08
9. Data sheet: piston detector ...............................................................................................93A-20014-A97
10. Data sheet: electronic controller .......................................................................................93EN-98002-A11
11. Data sheet: hydraulic valve ...............................................................................................84980_C8_313
12. Data sheet: Heating Pad for 200L Container ....................................................................
13. Data sheet: Heating Pad for 80L Container ......................................................................
14. Data sheet: Thermostat TSW3 .........................................................................................234-13116-8
15. Data sheet: Filter...............................................................................................................528-32616-1
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Servicing Manual
R9350/R9400
Manual R9350/R9400
1 Function of the lubrication system
1.1 Description of the entire system
The lubrication points of the hydraulic excavator are supplied by two mutually independent centralized lubrication systems:
System 1 – Equipment lubrication- Slewing rim lubrication
Single-line system
Main components: Hydraulic pump "P1" 609-77500-1 (Version I), 609-77546-1 (Version II), 609-77504-1 (Version
III) Injectors LM 5
Progressive metering devices SSV
System 2 – Gear rim lubrication
Main components: Hydraulic pump "P3" 609-29966-1 (Version I), 609-77272-1 (Version II), 609-77273-1 (Version
III)
Progressive metering devices SSV
1.2 Sequence of a lubrication cycle

1.2.1 System 1 (Single line system)
Version I
Upon expiration of the pause time the pump begins operating and supplies the lubricant to the injectors (LM 5) via the main line.
The pistons in the injectors are actuated by the lubricant under pressure and discharge a pre-dosed quantity of lubricant to the
connected lubrication points.
The pressure continues to rise in the main line until the value (220 bar) set at the pressure switch (B69) is reached. The control
unit stops the pump and, at the same time, the main line is discharged via the hydraulic valve (Y79). The relieved lubricant
reaches the pump reservoir via a bypass.
The pistons in the injectors (LM 5) return to their initial position by spring force.
The pause time begins. The system is ready to carry out a new lubrication cycle.
Version II+III
Just like version 1, however, including a 3/2-way valve (Y114) that allows circulation of lubricant during the pause time.
As soon as a pressure of 220 bar is reached, the control unit will not switch off the pump. At the same time the main line will be
relieved by switching off the solenoid valve (Y79) and the circulation line will be opened by switching off solenoid valve (Y114).
By doing so lubricant is pumped into the reservoir again. The relieved lubricant is fed to the pump reservoir via bypass. Spring
force makes the pistons in the injectors 9 (LM-5) return to their initial positions.
The pause time starts. Now the system is ready for a new lubrication cycle.
1.2.2 System 2 (Progressive system)
After the pause time has elapsed, the pump supplies the lubricant to the connected progressive metering devices.
A progressive metering device (SSV 10) is equipped with a proximity switch for control and monitoring.
A lubrication cycle is completed after the SSV 10 has supplied twice, and the pump is switched off again.
Version II+III
Just like version 1, however without switching the pump off during the pause time, and with a 3/2-way valve (Y97) that allows
circulation of lubricant during the pause time.
Subject to change 3
Servicing Manual
R9350/R9400
Manual R9350/R9400
1.3 Lubrication diagram

1.3.1 200L System (Version I)
609-77500-1
B50-1 “High level“ and “Low level“ sensor for P1 B185-1 “High level” Additional Sensor
1 Grease tank Y95 Solenoid valve / hydraulic pressure drive for P1
P1 Lubrication pump -attachment 9 Grease injector banks LM5
(Y79) Hydraulic valve / pressure release U15 Lubricating system monitor
B69 Limit switch for P1
Subject to change 4
Servicing Manual
R9350/R9400
Manual R9350/R9400
1.3.2 80L System (Version I)
P3
B50-2 “High level“ and “Low level“ sensor for P3 B185-2 High level “Additional Sensor”
P3 Lubrication pump -swing ring teeth B51 Limit switch on progressive distributor for P3
U15 Lubricating system monitor
Subject to change 5
Servicing Manual
R9350/R9400
Manual R9350/R9400
1.3.3 200L System (Version II+III)
B50-1 “High level“ and “Low level“ sensor for P1 B185-1 “High level” Additional Sensor
P1 Lubrication pump -attachment 9 Grease injector banks LM5
Y79 Solenoid valve / pressure release U15 Lubricating system monitor
Y114 Solenoid valve / Bypass B69 Limit switch for P1
Subject to change 6
Servicing Manual
R9350/R9400
Manual R9350/R9400
1.3.4 80L System (Version II+III)
B50-2 “High level“ and “Low level“ sensor for P3 B185-2 High level “Additional Sensor”
P3 Lubrication pump -swing ring teeth B51 Limit switch on progressive distributor for P3
U15 Lubricating system monitor Y97 Solenoid valve / Bypass
Subject to change 7
Servicing Manual
R9350/R9400
Manual R9350/R9400
2 Operation
CAUTION
Only allow operation by properly instructed personnel
Do not exceed permissible system pressures
Top up lubricant or change drum in good time
When the machine is started all centralized lubrication systems are automatically pressurized.
Each pump triggers one lubrication cycle, stops only for the preadjusted pause time, ... etc.
When the excavator is delivered from the factory the time period between two lubrication cycles is 6 minutes for pump P1 and 8
minutes for pump P2. This corresponds to a grease consumption of approx. 850 g/h for P1, 40 g/h for P2.
Subject to change 8
Servicing Manual
R9350/R9400
Manual R9350/R9400
3 Inspection and maintenance
* Do not perform any repairs while system is pressurized.

* To relieve pressure open a threaded connection carefully
* Caution: Lubricant may escape while pressurized
Regular inspection and maintenance are the prerequisites for proper operation of the centralized lubrication system over a
prolonged period of time. The warranty on our product can only be valid if the prescribed maintenance intervals are adhered to.
The regular inspections and maintenance procedures are described below:
1. System as a whole
Daily: Visual check of the lubrication points for escaping lubricant

Visual check of the hose connections for leaks or wearing
Weekly: Visual check of the screwed pipe connections for leakage

Determining the time for one operating cycle. If the time determined differs from the usual operating time, the
individual components (pump station, injectors, pipes) must be checked.
Functional check of the pressure switch
2. Pump station
Weekly: Check that threaded connections and hoses are firm and tight.
Visual check of pump tube gland seal
Check function of the solenoid valve
Check electrical cable connections
Clean outside of pump station
1000 hours: Clean filter element of grease filter
7500 hours: Hydraulic pump: Change gland seal
3. Injectors
Daily: Check movement of control pins: During the work cycle the pins must be retracted depending on the metering
quantity; in the resting phase all the pins must be extended.
Weekly: Visual check for leaks
4. Progressive Plunger Metering Device
Weekly: Visual check for leaks
Subject to change 9
Servicing Manual
R9350/R9400
Manual R9350/R9400
4 Topping up grease reservoirs
CAUTION Lines are pressurized. Be careful when decoupling.

Observe extreme cleanliness when topping up the grease reservoirs.
Contaminated lubricant causes malfunctions and premature wear of the grease pump and
other components of the system.
Clean surroundings before topping up
Switch off centralized lubrication system (turn off engine)
4.1 P1 and P2: Filling of the container
Filling of the container through service-plate
Remove dust protective cap at the filling coupling and the dust
protective cap at the filling nipple
Couple the filling hose at item 10 and switch on the filling pump
When the reservoir is full, the ultrasonic sensor transmits an
electric signal to the control unit. Visual control is possible through
the sight-glass on the 600 L rectangle reservoir
the filling pump is switched off
Disconnect the filling coupling and reinstall the dust protective
caps
Subject to change 10
Servicing Manual
R9350/R9400
Manual R9350/R9400
5 Malfunctions and their remedy
In the following, only malfunctions of the system as a whole are described. You will find detailed remedies for malfunctions of
the individual units in the respective User’s Information.
Malfunction: No pressure build-up in the system
Cause: Remedy:
Malfunctions of the pump See Troubleshooting: Pump
Leakage in the main line Check main lines, eliminate leaks, tighten threaded
connections, replace defective hoses
Air trapped in the main line De-aerate the line
Injectors leaky or worn See Troubleshooting: Injectors
Malfunction: No pressure relief or too slow pressure relief in the main line
Cause: Remedy:
Pressure control device faulty Replace pressure control device, check electric cable
Solenoid valve faulty Replace solenoid valve, check voltage supply
Grease too hard or not suitable for low temperatures Change lubricant
Subject to change 11
Technical Description Error Codes 664-36957-7
Display Display
G Fault Cause Type of signal Lubrication
E__ G__ on:
Exceeding of lubricating time
Pressure sensor on rising edge P1 (B69) or
(t=90sec+1min) and no emitter signal H138 lit; H109 activated; Emergency
01 problem with pump that is blocked or stuck E501 P1
(+ 1 minute: to allow pressure rise in the buzzer can be switched off operation
due to insufficient rinsing
lubrication circuit)
Pressure sensor on rising edge P2 (B71) or
(t=30sec+1min) and no emitter signal H138 lit; H109 activated; Emergency
02 problem with pump that is blocked or stuck E502 P2
(+ 1 minute: to allow pressure rise in the buzzer can be switched off operation
due to insufficient rinsing
Pressure sensor for monitoring on rising (t=10sec+1min) and no emitter signal H138 lit; H109 activated; Emergency
03 E503 P3
edge P3 (B51) (+ 1 minute: to allow pressure rise in the buzzer can be switched off operation
Pressure sensor on falling edge P1 (B69) or Lubricating pressure >40 bar in the case of H138 lit; H109 activated; Emergency
04 E504 P1
solenoid valve Y79 blocked the next cycle start buzzer can be switched off operation
Pressure sensor on falling edge P2 (B71) or Lubricating pressure >40 bar in the case of H138 lit; H109 activated; Emergency
05 E505 P2
solenoid valve Y79 blocked the next cycle start buzzer can be switched off operation
H138 lit; H109 activated;

Defective pressure sensor 4-20mA P1 Emergency
06 Wrong grounding E506 P1 buzzer can be switched off;
(B69) operation
LED pressure P1 flashing
07 Fault during supply E507 P1 buzzer can be switched off;
(B69) operation
08 Wrong connection E508 P1 buzzer can be switched off;
(B69) operation

09 Wrong grounding E509 P2 buzzer can be switched off;
(B71) operation
PBM / 22.07.2009 Subject to Change 1/7

LINCOLN GmbH ∗ POB 1263 ∗ 69183 Walldorf ∗ Germany ∗ Tel +49 (6227) 33-0 ∗ Fax +49 (6227) 33-259 ∗
Display Display
E__ G__ on:
10 Fault during supply E510 P2 buzzer can be switched off
(B71) operation

11 Wrong connection E511 P2 buzzer can be switched off
(B71) operation
H138 lit; buzzer cannot be

Defective filling level probe 4-20mA P1
12 Wrong grounding E512 P1 switched off; bar graph, LED Standard operation
(B50_1)
L, LED LL for P1/2 flashing

13 Fault during supply E513 P1 switched off; bar graph, LED Standard operation
(B50_1)

14 Wrong connection E514 P1 switched off; bar graph, LED Standard operation
(B50_1)
H138 lit, Buzzer cannot be

15 Wrong grounding E515 P3 switched off; bar graph, LED Standard operation
(B50_2)
H138 lit;Buzzer cannot be

16 Fault during supply E516 P3 switched off; bar graph, LED Standard operation
(B50_2)
H138 lit Buzzer cannot be

17 Wrong connection E517 P3 switched off; bar graph, LED Standard operation
(B50_2)

Display Display
E__ G__ on:
Defective solenoid valve, pump activation
18 Circuit solenoid valve open E518 P1 buzzer can be switched off; Switch off pump
P1 (Y95_1)
LED Pump1 on flashing
Defective solenoid valve, pressure drop P1 H138 lit; H109 activated;

19 Solenoid valve disconnected E519 P1 Standard operation
(Y79) buzzer can be switched off
Defective solenoid valve, winter operation H138 lit; H109 activated;

20 E520 P1 Standard operation
P1 (Y114) buzzer can be switched off

21 Circuit solenoid valve open E521 P2 buzzer can be switched off; Switch off pump
P2 (Y95_2)
LED pump 2 on flashing


Defective solenoid valve, change-over
23 Circuit solenoid valve open E523 P1 buzzer can be switched off Standard operation
devicer P1 (Y80)
;LED Y80 flashing

24 Solenoid valve disconnected E524 P2 buzzer can be switched off Standard operation
devicer P2 (Y82)
LED Y82 flashing

25 E525 P1 and P2 buzzer can be switched off Standard operation
devicer P1/P2 (Y83)
LED Y83 flashing

Display Display
E__ G__ on:
26 Circuit solenoid valve open E526 P3 buzzer can be switched off Switch off pump
P3 (Y93)
LED Pump3 on flashing


28 Defective solenoid valve, reserve 1 E528 Standard operation
buzzer can be switched off

29 Defective solenoid valve, reserve 2 E529 Standard operation

Defective emitter control pressure 4-20mA
30 Wrong grounding E530 P1 buzzer can be switched off; Standard operation
(B184)
LED pilot flashing

31 Fault during supply E531 P1 buzzer can be switched off Standard operation
(B184)
LED Pilot flashing

32 Wrong connection E532 P1 buzzer can be switched off Standard operation
(B184)
LED Pilot flashing

Lubrication P1/ P2
33 Grease filling level in P1/P2 drum very low Filling level LL E533 P1/P2 switched off; LED LL for
off
P1/P2 flashing

Display Display
E__ G__ on:
34 Grease filling level in P3 drum very low Filling level LL E534 P3 buzzer can be switched off Lubrication P3 off
LED LL for P3 flashing
During start (signal Kl61) if P<45 bar for H138 lit; H109 activated;
35 Defective control pressure (B184) E535 P1 Standard operation
more than 5 minutes buzzer can be switched off
During operation : if P<45 bar for 5 H138 lit; H109 activated;

36 Defective control pressure (B184) E536 P1 Standard operation
seconds buzzer can be switched off
H138, display X50_1 lit;

Pressure sensor for monitoring on falling No high-level of at least 1 second with H109 activated; buzzer can
edge (B150_1) falling edge within 2 lubricating cycles be switched off; LED i3
flashing
Pressure sensor for monitoring on falling No high-level of at least 1 second with H109 activated; buzzer can
edge (B150_2) falling edge within 2 lubricating cycles be switched off; LED i4
flashing
No high-level of at least 1 second with
Pressure sensor for monitoring on falling H109 activated; buzzer
39 falling edge within 2 lubricating cycles in E539 P1 Standard operation
edge (B150_1, B150_2) cannot be switched off; LED
the case of both of the sensors
i3, i4 flashing
40 Defective emitter reserve Wrong grounding E540 P1 Standard operation
41 Defective emitter reserve Wrong connection E541 P1 Standard operation
42 Defective emitter reserve1 Wrong grounding E542 P1 Standard operation

Display Display
E__ G__ on:
43 Defective emitter reserve1 Wrong connection E543 P1 Standard operation
44 Defective emitter reserve2 Wrong grounding E544 P1 Standard operation
45 Defective emitter reserve2 Wrong connection E545 P1 Standard operation

46 Defective flash light Disconnected E546 P1 buzzer cannot be switched Standard operation
off

Defective solenoid valve, activation pump
47 Short circuit / too high current E547 P3 Buzzer cannot be switched Deactivated
P3 (Y93)
off
Defective solenoid valve, activation pump H138 lit; H190 activated;

48 Short circuit / too high current E548 P1 Deactivated
P1 (Y95_1) Buzzer can be switched off
Defective solenoid valve, activation pump H138 lit, H109 activated;

P2 (Y95_2) Buzzer can be switched off



Display Display
E__ G__ on:
Defective solenoid valve, change-over H138 lit; H109 activated;

device P2 (Y82) buzzer can be switched off

device P1/P2 (Y83) buzzer can be switched off

device P1 (Y80) buzzer can be switched off



57 Defective flash light Short circuit / too high current E557 P1 Deactivated
58 Defective solenoid valve, motor Short circuit / too high current E558 P1 Deactivated
59 Defective solenoid valve, reserve Short circuit / too high current E559 P1 Deactivated

60 Defective output voltage 5V Short circuit / too high current E560 P1 Deactivated

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

Operating Manual 9400 Liebherr

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from serial number 26377

Vehicle ident. number:

0-2 R9400 / 11000047

able for your convenience.

Modifications, conditions, copyright

1 Product description ....................................................................................................................................... 1-1

2 Safety instructions......................................................................................................................................... 2-1

3 Control and operation ................................................................................................................................... 3-1

3.3.5 Emergency operations ........................................................................................................... 3-68

3.5.2 Preparatory activities .............................................................................................................. 3-89

4 Malfunctions ................................................................................................................................................... 4-1

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

5.4.6 Lube oil for elastic coupling .................................................................................................... 5-24

5.5.5 Mounting screws .................................................................................................................... 5-32

5.13.3 Lifetime Travel gear – oil change ........................................................................................... 5-75

5.15.4 Cleaning the track components .............................................................................................. 5-91

1.1 Assembly - overview

1.1.1 Machine and construction equipment

Fig. 1-1 Machine and construction equipment

100 Uppercarriage 320 Hydraulic cylinder

Fig. 1-2 Uppercarriage

20 Swing gear installation 77 Cab elevation

Fig. 1-3 Undercarriage

208 Idler 1000 Rotary connection

1.2 Vibration emissions

Weighted effective vibration in m/s²

Machine type Typical working cycles

The measurement uncertainty is defined in standard EN 12096:1997. LEC/en/Edition: 06 / 2012

1.3 EC Declaration of Conformity

Fig. 1-4 Sample EC Declaration of Conformity (from year of manufacture 2010)

1.4 Technical data

1.4.1 Working technical data

1.4.2 Technical description

40 R 3750 Max. reach at ground level 16.30 m/53’ 5”

Bottom Dump Buckets

Wide Product Range State-of-the-art Technology

Exceptional Customer Benefit Worldwide and Independent

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

Liebherr-Mining Equipment Colmar SAS

2.1 Meaning of the symbols in this manual

– This symbol identifies a listing.

• This symbol identifies a sub-listing.

2.2 Use in accordance with the regulations

2.3 Safety Instructions

General safety instructions

Avoidance of crushing and burns

Avoidance of fire and explosions

Bringing the machine safely into service

above, in order to displace yourself safely.

If unavailable, let it be instaled before working with the door open.

Adjusting the operator’s standing position

Protection from vibration - seat adjusting

Utilisation in confined spaces

Starting the machine safely

Stopping the machine safely

Safely getting down

Working safely with the machine

• do not leave the driver’s cab,

– Depending on the equipment combination, there is a risk of collision between the

ning Machines in this manner.

Safe use with a hydraulic hammer

Safe use when loading and unloading (particularly when loa-

40 R 3750 Max. reach at ground level 16.30 m/53’ 5”