en

Operating manual

Hydraulic excavator
R 9250

from serial number 18924

Document identification
ORIGINAL MANUAL
Order number: 10069862
Edition: 02 / 2015
Valid for: R 9250 from serial number 18924
Author: LEC - Technical documentation department

Product identification
Manufacturer: Liebherr-Mining Equipment Colmar SAS
Type: R 9250
Type no.: 437
Conformity: CE
LEC/en/Edition: 02 / 2015

Address
Liebherr-Mining Equipment Colmar SAS
49 rue Frdric 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:
. . / . . / . .

LEC/en/Edition: 02 / 2015

R 9250 / 10069862
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 LIEBHERRs general business conditions will
not be enlarged upon through the above information.

MJFCIFSS
 Table of contents
1 Product description ....................................................................................................................................... 1-1
1.1 Assembly - overview.............................................................................................................................. 1-1
1.1.1 Machine and construction equipment....................................................................................... 1-1
1.1.2 Uppercarriage........................................................................................................................... 1-2
1.1.3 Undercarriage........................................................................................................................... 1-3
1.2 Vibration emissions................................................................................................................................ 1-3
1.3 EC Declaration of Conformity ................................................................................................................ 1-5
1.4 Technical data ....................................................................................................................................... 1-6
1.4.1 Working technical data ............................................................................................................. 1-6
1.4.2 Technical description................................................................................................................ 1-6

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

2.1 Meaning of the symbols in this manual.................................................................................................. 2-1
2.2 Use in accordance with the regulations ................................................................................................. 2-2
2.3 Safety Instructions ................................................................................................................................. 2-2
2.4 Servicing the machine safely ............................................................................................................... 2-14
2.5 Signs on the machine .......................................................................................................................... 2-20
2.5.1 Introduction............................................................................................................................. 2-20
2.5.2 Arrangement of signs ............................................................................................................. 2-21
2.5.3 Explanation of signs ............................................................................................................... 2-22

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

3.1 Operating and control elements............................................................................................................. 3-1
3.1.1 Overview of the operators standing position ........................................................................... 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 .................................................................................................................. 3-12
3.1.6 Main screen ............................................................................................................................ 3-14
3.1.7 Monitoring cameras ................................................................................................................ 3-29
3.2 The access and the outfit of the cab.................................................................................................... 3-31
3.2.1 Entering or leaving the cab..................................................................................................... 3-32
3.2.2 Safety lever ............................................................................................................................ 3-37
3.2.3 Operators 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 ................................................................................................................................... 3-48
3.2.12 Heating/air conditioning system ............................................................................................. 3-50
3.3 Setting the machine into operation ...................................................................................................... 3-60
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3.3.1 Starting / stopping the machine .............................................................................................. 3-61

3.3.2 Starting aids (optional) ........................................................................................................... 3-68
3.3.3 Jump start procedure ............................................................................................................. 3-71
3.3.4 Emergency operations ........................................................................................................... 3-72
3.3.5 Driving .................................................................................................................................... 3-75
3.4 Working with the machine.................................................................................................................... 3-78
3.4.1 The uppercarriage swing movements .................................................................................... 3-83
3.4.2 Working position ..................................................................................................................... 3-86
3.4.3 Joystick functions when setting up the machine .................................................................... 3-87
3.4.4 Lowering the work equipment when the engine is not running .............................................. 3-90

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3.5 General working methods .................................................................................................................... 3-91

3.5.1 Minimum impact working methods for your machine.............................................................. 3-91
3.5.2 Preparatory activities .............................................................................................................. 3-92
3.5.3 Positioning of the machine ..................................................................................................... 3-93
3.5.4 Working with the backhoe bucket ........................................................................................... 3-93
3.5.5 Working with the Shovel bucket ............................................................................................. 3-96
3.6 Transport.............................................................................................................................................. 3-99
3.6.1 Travelling procedures for mining machine.............................................................................. 3-99
3.6.2 Excavator lifting and lashing operations ............................................................................... 3-102

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

4.1 Error code charts ................................................................................................................................... 4-2
4.1.1 Sensors .................................................................................................................................... 4-2
4.1.2 Regulating circuit ...................................................................................................................... 4-2
4.1.3 Keyboard .................................................................................................................................. 4-3
4.1.4 Display ...................................................................................................................................... 4-3
4.1.5 Coding error.............................................................................................................................. 4-3
4.1.6 Connection box pump transmitters ........................................................................................... 4-4
4.1.7 Error due to warning symbols in SY field.................................................................................. 4-4
4.1.8 Heating / air conditioning system.............................................................................................. 4-5
4.2 Faults and remedies .............................................................................................................................. 4-6
4.2.1 Diesel engine and fuel system.................................................................................................. 4-6
4.2.2 Hydraulic system ...................................................................................................................... 4-7
4.2.3 Transmission ............................................................................................................................ 4-7
4.2.4 Electrical system....................................................................................................................... 4-8
4.2.5 Heating/air-conditioning system ............................................................................................... 4-8
4.2.6 Work equipment ....................................................................................................................... 4-8
4.3 Fuses and relays.................................................................................................................................... 4-9
4.3.1 Power electrical box E1003 ...................................................................................................... 4-9
4.3.2 Cab connection box E1005 .................................................................................................... 4-11
4.3.3 Heating / air conditioning electrical box E1006....................................................................... 4-13

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

5.1 Servicing the machine safely ................................................................................................................. 5-1
5.2 Maintenance access doors .................................................................................................................... 5-7
5.2.1 Overview of access doors ........................................................................................................ 5-7
5.3 Lubricants and operating fluids ............................................................................................................ 5-14
5.3.1 General information on changing lubricants and operating fluids........................................... 5-14
5.3.2 Lubrication chart ..................................................................................................................... 5-15
5.3.3 The service trap ...................................................................................................................... 5-16
5.3.4 Lubricant chart ........................................................................................................................ 5-18
5.3.5 Operating material chart ......................................................................................................... 5-19
5.3.6 Service trap ............................................................................................................................ 5-20
5.4 Lubricating and operating material specifications ................................................................................ 5-21
5.4.1 Lubrication oil for the Diesel engine ....................................................................................... 5-21
5.4.2 Fuel......................................................................................................................................... 5-21
5.4.3 Hydraulic oil specifications for LIEBHERR Mining excavators ............................................... 5-21
5.4.4 Swing and travel gear oils ...................................................................................................... 5-27
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5.4.5 Splitterbox oil .......................................................................................................................... 5-28

5.4.6 Lubricating grease and other lubricants ................................................................................. 5-29
5.4.7 Coolant ................................................................................................................................... 5-30
5.4.8 Lubricants specifications for -40C ......................................................................................... 5-30
5.5 Diesel engine ....................................................................................................................................... 5-31
5.5.1 Check of engine oil level......................................................................................................... 5-31
5.5.2 Diesel engine oil change ........................................................................................................ 5-32
5.5.3 Mounting screws..................................................................................................................... 5-34
5.5.4 Elastic bedding ....................................................................................................................... 5-35

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 Operating manual

5.5.5 Belt for the 24 V alternator of the Diesel engine..................................................................... 5-36

5.6 Splitterbox............................................................................................................................................ 5-36
5.6.1 Splitterbox mounting screws .................................................................................................. 5-36
5.6.2 Elastic bedding ....................................................................................................................... 5-38
5.6.3 Breather filter .......................................................................................................................... 5-39
5.7 Cooling system .................................................................................................................................... 5-40
5.7.1 Checking and cleaning the cooling system ............................................................................ 5-40
5.7.2 Checking the coolant level ..................................................................................................... 5-41
5.7.3 Coolant antifreeze and anti-corrosion fluid ............................................................................. 5-42
5.7.4 Changing the coolant ............................................................................................................. 5-42
5.8 Fuel system ......................................................................................................................................... 5-44
5.8.1 Refuelling ............................................................................................................................... 5-44
5.8.2 Draining the fuel tank ............................................................................................................. 5-46
5.8.3 Emptying and cleaning the fuel tank ...................................................................................... 5-48
5.8.4 Draining and changing fuel filter cartridges ............................................................................ 5-49
5.8.5 The air pressure system ......................................................................................................... 5-50
5.9 Dry air filter .......................................................................................................................................... 5-54
5.9.1 To change the primary filter element ...................................................................................... 5-55
5.9.2 Changing the safety element.................................................................................................. 5-56
5.9.3 To clean the air channels for the precleaner .......................................................................... 5-57
5.9.4 Check the air intake system, hoses, elbows, clamps ............................................................. 5-57
5.10 Hydraulic system ................................................................................................................................. 5-58
5.10.1 Preparatory activities .............................................................................................................. 5-58
5.10.2 Checking the oil level in the hydraulic tank ............................................................................ 5-59
5.10.3 Depressurising the hydraulic system...................................................................................... 5-60
5.10.4 Emptying and refilling the hydraulic tank ................................................................................ 5-60
5.10.5 Return-line filters and air filter ................................................................................................ 5-61
5.10.6 Servo oil filter.......................................................................................................................... 5-63
5.10.7 Control circuit ......................................................................................................................... 5-64
5.10.8 Bleeding the main pumps ....................................................................................................... 5-65
5.10.9 Bleeding the swing pumps ..................................................................................................... 5-66
5.10.10 Bleeding the hydraulic cylinders ............................................................................................. 5-66
5.10.11 Unscrew the intake hoses to the pump .................................................................................. 5-67
5.10.12 High pressure filters in working circuit .................................................................................... 5-68
5.10.13 Oil cooler protection filters (optional) ...................................................................................... 5-69
5.10.14 Servicing the hydraulic cylinder .............................................................................................. 5-70
5.10.15 Replacing hydraulic hoses ..................................................................................................... 5-71
5.10.16 Progressive criss-cross tightening procedure......................................................................... 5-74
5.11 Oil changes on components ................................................................................................................ 5-75
5.11.1 General information ................................................................................................................ 5-75
5.11.2 Swing gear transmission oil change .................................................................................... 5-76
5.11.3 Oil change on travel gear and Lifetime travel gear (optional)................................................. 5-78
5.11.4 Swing gears and travel gears flushing ................................................................................... 5-80
5.11.5 Splitterbox oil change .......................................................................................................... 5-81
5.12 Track components ............................................................................................................................... 5-83
5.12.1 Checking the track components mountings ........................................................................... 5-83
5.12.2 Monitoring the track tension ................................................................................................... 5-85
5.12.3 Retensioning the track............................................................................................................ 5-85
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5.12.4 Releasing the track tension .................................................................................................... 5-86

5.12.5 Cleaning the travel gear ......................................................................................................... 5-86
5.13 Electrical system.................................................................................................................................. 5-87
5.13.1 Notes on the electrical system ............................................................................................... 5-87
5.13.2 Main battery switch................................................................................................................. 5-87
5.13.3 Battery care ............................................................................................................................ 5-88
5.13.4 Electrical components location ............................................................................................... 5-90
5.13.5 Electrical boxes and cab pressurization ................................................................................. 5-91
5.14 Heating/air-conditioning system........................................................................................................... 5-91
5.14.1 Heating system....................................................................................................................... 5-92

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5.14.2 Air-conditioning system .......................................................................................................... 5-93

5.14.3 Dual air conditioning system (optional)................................................................................... 5-96
5.15 Drive unit brakes and swing gear brakes............................................................................................. 5-97
5.16 Check mounting bolts for tightness...................................................................................................... 5-98
5.16.1 Mounting bolts of the counterweight ....................................................................................... 5-99
5.16.2 Threaded studs of the swing ring ........................................................................................... 5-99
5.16.3 Mounting bolts of fuel tank.................................................................................................... 5-100
5.16.4 Mounting bolts of hydraulic tank ........................................................................................... 5-100
5.16.5 Mounting bolts of Powerpack ............................................................................................... 5-100
5.16.6 Mounting bolts of the swing gear and motor......................................................................... 5-101
5.16.7 Mounting bolts of hydraulic pumps ....................................................................................... 5-101
5.16.8 Connection of central piece and side frames ....................................................................... 5-102
5.16.9 Drivers cab mounting bolts .................................................................................................. 5-102
5.17 General maintenance points .............................................................................................................. 5-102
5.17.1 Replacing working parts ....................................................................................................... 5-102
5.17.2 Welding work on the machine .............................................................................................. 5-103
5.18 Control and maintenance chart.......................................................................................................... 5-103
5.18.1 General information .............................................................................................................. 5-104
5.18.2 How to use the maintenance chart ....................................................................................... 5-104
5.18.3 Daily Maintenance Schedule - R9250 .................................................................................. 5-106
5.18.4 250 Hours Maintenance Schedule - R9250.......................................................................... 5-112
5.18.5 500 Hours Maintenance Schedule - R9250.......................................................................... 5-118
5.18.6 1000 Hours Maintenance Schedule - R9250........................................................................ 5-125
5.18.7 2000 Hours Maintenance Schedule - R9250........................................................................ 5-133
5.19 Centralized lubrication system ........................................................................................................... 5-142

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 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

LEC/en/Edition: 02 / 2015

Fig. 1-1 Machine and construction equipment

100 Uppercarriage 320 Hydraulic cylinder

200 Undercarriage 330 Stick
300 Hydraulic jack 340 Hydraulic cylinder
310 Boom 350 Bucket

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Product description Operating manual
Assembly - overview

1.1.2 Uppercarriage

Fig. 1-2 Upper carriage

170Steel bushing 7600Control valve instal- 9300Hydraulic tank instal-

700Swing gear transmis- lation lation
sion 8200Rotating deck 9500Counterweight instal-
800Swing ring 8300Cab elevation lation
1500Service station 8500Coachbuilding 9620Tool kit
5000Powerpack 8600Lower covering
LEC/en/Edition: 02 / 2015

7200Oil radiator installa- 8700Cab

tion 8900Catwalk

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 Operating manual Product description
Vibration emissions

1.1.3 Undercarriage

Fig. 1-3 Under carriage

208 Leading wheel 1000 Rotary connection

400 Crawlers 4500 Travelling mechanism with tum-
bler wheel

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
LEC/en/Edition: 02 / 2015

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/s according to ISO
5349-1:2001.

Whole-body vibration
If the machine is operated according to the manufacturer instructions, the weighted

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Product description Operating manual
Vibration emissions

(frequency-rated) effective vibration shown for specific machine applications in the

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

Weighted effective vibration in m/s

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: 02 / 2015

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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)

LEC/en/Edition: 02 / 2015

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Product description Operating manual
Technical data

1.4 Technical data

1.4.1 Working technical data

Backhoe Shovel
Maximum working slope (15,0 m3)* 5,0 - 8,7% 4,0 - 7,0%
Maximum travelling angle (252 t) 29,1 - 55,7% 29,1 - 55,7%
Maximum tilt angle of Diesel engine 30 30
Working ambient temperature range -12C to +55C -12C to +55C
Noise emission**
LpA (inside cab) with fans at 100% 77 dB(A) 77 dB(A)
Tab. 1-1 Working technical data

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

1.4.2 Technical description

This should be taken from the accompanying technical description.
LEC/en/Edition: 02 / 2015

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Mining Excavator R 9250
Operating Weight with Backhoe Attachment: 250.000 kg / 551,200 lb
Operating Weight with Shovel Attachment: 253.500 kg / 558,900 lb
Engine Output: 960 kW / 1,287 HP
Bucket Capacity @ 1,8 t/m3 / 3,000 lb/yd3: 15,00 m / 19.6 yd
Shovel Capacity @ 1,8 t/m3 / 3,000 lb/yd3: 15,00 m / 19.6 yd
R 9250
Operating Weight with Backhoe Attachment: 250.000 kg / 551,200 lb
Operating Weight with Shovel Attachment: 253.500 kg / 558,900 lb
Engine Output: 960 kW / 1,287 HP
Bucket Capacity @ 1,8 t/m3 / 3,000 lb/yd3: 15,00 m / 19.6 yd
Shovel Capacity @ 1,8 t/m3 / 3,000 lb/yd3: 15,00 m / 19.6 yd

2 R 9250
Productivity Customer Support
Liebherr Mining Equipment enables superior productivity Liebherr builds more than just mining equipment; Liebherr
by loading and hauling maximum tonnage in the shortest also builds customer partnerships.
amount of time.
Safety
Efciency Mining demands an ever-vigilant focus on safety, and
Liebherr combines the proven capabilities of previous Liebherr strictly adheres to industry standards. Liebherr
models with new features that improve operational equipment is designed to diminish risk even under the
efciency. most extreme mining conditions.

Reliability Environment
To maximize equipment reliability, Liebherr combines Liebherr optimizes mining equipment for fuel economy,
manufacturing expertise with monitoring and diagnostic emission compliance, and extended service intervals.
capabilities.

R 9250 3
 Engine / Motor Options
Diesel engine available versions:
Cummins QSK 38 (USA/EPA Tier 2)
Cummins QSK 45 (USA/EPA Tier 1)
Fuel consumption optimized version
on Tier 2 engine (option)
Electrical motor (option):
3 phase AC squirrel cage motor
Voltage on request
50 or 60 Hz frequency

4 R 9250
 Productivity
The R 9250 is built to outperform all competitors in the medium class mining market.
Boasting a 15,00 m / 19.6 yd bucket capacity in standard conguration, the R 9250
is the ideal machine to load a eet of 100 t dump trucks. Available in both diesel or
electric versions, the R 9250 offers the exibility to perform many specic applications.

Engineered for Intense Mining

Powerful Drive System The R 9250 is equipped with a Cummins diesel
engine which has been specically adapted to
withstand the most extreme environments and to
reach the highest uptime performance for maximum
productivity. The electric drive system provides
superior performance when the machine is used in
the most specic conditions.
Optimized Cycle Times Rather than using open hydraulic circuit, the R 9250
employs a closed-loop swing circuit to enable maxi-
mum swing torque while retaining the full oil ow for
the working circuit. The independent swing circuit in
combination with the powerful drive system leads to
fast arm motion, which contributes to faster cycle times.
Precise Machine The R 9250 design integrates the Litronic Plus electronic
Motions control system to allow for easy control even when
simultaneous movements are required. The patented
Liebherr electronic damping system provides controlled
end-cushioning for smooth attachment motions.

High Digging and Lifting Capabilities

High Digging Forces Designed for the best mechanical force distribution,
the production-tailored attachment delivers high dig-
ging and lifting forces. Integrating Liebherr-made
cylinders and a wide range of buckets with mining-
optimized GET, the R 9250s attachment ensures the
highest forces, easy bucket penetration and high ll
factor to perform even in the most demanding conditions.
Power-Oriented The R 9250s attachment is equipped with the
Energy Management pressureless boom down function to enable fast
cylinder retraction without the need for pump energy.
Intelligent energy management diverts the pump
ow during boom lowering, allowing other cylinder
motions to operate unimpeded.

Litronic Plus - Electronic Control Liebherr Ground Engaging Tools (GET)

A power management system Liebherr has developed a complete mining
developed to optimize electrical, GET solution to complement Liebherrs min-
mechanical, hydraulic power ing backhoe and face shovel bucket design.
distribution which encompasses: A synergy that enables easy material pen-
Liebherr designed and built etration while extending the life of the bucket.
power components Three tooth proles and ve tooth sizes
Continuous monitoring of the Innovative bucket lip and side wall
engine and electrical system protection
Safe, fast and precise control One single locking system that limits
Optimum equipment operation tooling to one unique extraction tool

Productivity and efciency Unique hammerless locking system

maximization Effortless and quick tooth removal

R 9250 5
 Hydraulic System Efciency
The R 9250s hydraulic system is designed
for an optimized hydraulic power manage-
ment via the:
Closed-loop swing circuit
Pressureless boom down function
Electronic hydraulic pumps management
High pressure hydraulic oil ltration system
Electro-hydraulic control system
Optimized pipe and hose layout

6 R 9250
 Efciency
The R 9250 follows the Liebherr design philosophy of maximizing the machines
performance by improving the efciency of all individual subsystems. Engineered
for optimum serviceability the machine is designed to ensure maximum uptime.
The R 9250s spacious cab creates a comfortable working environment ensuring
peak operator performance, every shift.

Optimized for Maximum Protability

Electro-Hydraulic Liebherr hydraulic technology in combination with
System Efciency the precision of electronic control contributes to the
R 9250s energy optimization. The high-pressure hy-
draulic system and the optimized pipe and hose layout
maximize usable power transmission. The hydraulic
pumps are electronically managed to provide optimal
pressure compensation and oil ow management.
The hydraulic system is independently regulated over
the engine circuit for the best operational efciency.
Cooling System The oversized independent oil- and water coolers
Efciency in combination with low energy consumption fans
and on-demand cooling controls enable to maximize
available power for digging process.
Optimized Service The R 9250s high pressure hydraulic oil ltration
Intervals systems remove contaminants from the uid to offer the
highest rate of hydraulic system efciency. To maintain
the oil quality, all return hydraulic oil ow goes through
a 15/5 m ne ltration system. To promote availability,
the grease and fuel tanks are sized to considerably
extend the time between service intervals.

Comfortable Cab for Efcient Work

Superior Operator The large and spacious cab which equips the
Comfort R 9250 offers ideal working conditions and optimal
operators comfort. Mounted on silent blocks,
the cab design reduces vibrations and limit noise
pollution to provide a quiet environment.
Working Environment The R 9250s cab offers a panoramic view over
Total Control the entire machine and loading spot. Two outside
cameras show areas that cannot be observed
directly. Long-distance halogen working lights
promote efcient loading.
Fast Maintenance System Comfort-Oriented Cab Design
The service ap is hydraulically An array of features:
actuated and accessible from Tinted laminated safety glass
the ground level allowing for fast
Armored front and attachment side windows
maintenance:
Hydraulic oil rell Heavy duty sun louvers on windows
Adjustable air suspended seat
Engine oil rell and drainage
Splitter box and swing gearbox A/C with dust lter in fresh air / recirculated
oil exchange Pressurization to prevent dust penetration
Attachment/swing ring bearing Trainer seat
grease barrel relling with lters
Windshield washer water relling
Fast fuel relling line

R 9250 7
 Liebherr Vertical Integration
Liebherr-made integrated parts are:
Electronic and control technology
Hydraulic cylinders
Large diameter bearing (swing ring)
Swing and travel drives
Ground Engaging Tools

8 R 9250
 Reliability
More than 50 years of hydraulic excavator design and manufacturing experience is
the basis for the R 9250s outstanding reliability. The machine combines innovative
technologies, design optimization and Liebherr components. Customers experi-
ence durable performance from the R 9250 throughout the machines life.

Quality: the Liebherr Trademark

Liebherr Vertical As an OEM, Liebherr has built a solid reputation for its
Integration development and production of high quality strategic
mining components. The R 9250 integrates robust and
reliable mining optimized components that are devel-
oped, manufactured and controlled by Liebherr ensuring
reliability and high performance for the entire machine.
Machine Reliability Based on years of experience and the systematic
Survey measurement of key performance indicators of the
machine behavior in the eld, the Liebherr Mining Re-
liability Engineering Group is constantly seeking new
ways to enhance reliability.
Quality Management Liebherr quality begins during machine design and
Continuous Improve- simulations. Liebherr meets the highest standards
ment for special selections of steels and casting materials.
Based on the expertise of certied internal auditors and
a highly qualied workforce, all manufacturing process
steps are devised to provide the most comprehensive
control, monitoring and traceability. Liebherr-Mining
Equipment Colmar SAS is ISO 9001 certied.

Long-lasting Job Performances

Maximized Compo- The R 9250 is equipped with an automatic central lu-
nents Lifetime brication system for the entire attachment and swing
ring. All greasing points are suitably protected against
external damages. This extends component life and
ensures constant performance over the excavators
operational life.
Rugged Undercarriage The R 9250 is mounted on a heavy duty 3-piece fatigue
Structure resistant undercarriage steel structure. This design pro-
vides better weight distribution of the superstructure
and reduces ground bearing pressure. Designed and
built for both shovel and backhoe congurations, the
R 9250 provides the necessary stability and reliability.

Strengthened Attachment Design Arctic Kit (Option)

Backhoe or face shovel attachments Designed for maximum reliability in regions
are built to face all standard and with temperatures of down to -50C / -58F:
specic applications: Integrated into machine structure
Use of advanced welding techniques For maximum efciency
Reinforced with strategically located Increases machine and component lifetime
castings in high stress areas
Optimum operator comfort even in harsh
Heat treatment to reduce residual temperature conditions
stresses and increase fatigue life
Designed for maximum structure life
Use of cutting-edge engineering
tools such as Finite Element
Analysis and Fatigue Life Analysis

R 9250 9
 Liebherr Service Tools
Liebherr delivers a wide range of service
tools for excavator-specic maintenance
ensuring optimal working conditions no
matter the size of the component.
An OEM-certied solution
Maximized machine uptime
Cost-efcient maintenance
Easy machine serviceability
Uncompromising operational safety

10 R 9250
 Customer Support
As a global mining solutions provider, Liebherr is more than a mining equipment
manufacturer. Ensuring a permanent dialogue with each machine owner, Liebherr
provides tailored assistance to customer specic projects and site requirements.

Proactive Service Supplying

Liebherr Mining Network With a truly global network composed of Liebherr afli-
ates and exclusive representatives, Liebherrs worldwide
presence enables the highest level of service support ir-
respective of equipment location. Using advanced fore-
casting techniques and in-depth knowledge of regional
populations, Liebherr service centers ensure that
customers always have timely access to spare parts.
Customized Service Liebherr tailored support solutions integrate com-
Support ponents exchange and management agreements,
service and maintenance on site or maintenance
management agreements. Liebherrs highly-trained
service personnel ensures preventive and scheduled
maintenance tasks and provides emergency service.
Service Engineering Machines and components reliability data are collected
Support and monitored through the Liebherr maintenance
management system. Liebherrs sales and service
organization and product engineering groups provide
fast and proactive support over the lifetime of the
machine and promote mutual benet for all involved.

Customer Value Management

Liebherr Mining The Liebherr Mining Exchange Components program
Exchange Components enables customers to minimize the total machines
Owning and Operating Cost while maintaining peak
productivity and reliability. Through 15 Liebherr-
certied component rebuild facilities worldwide,
customers can take advantage of this program
regardless of the equipment location or eet size.
Complete Training The Liebherr Mining Training System provides
Programs operator and maintenance staff blended training
sessions that encourage productive, cost-effective
and safe mining operation. The Liebherr Mining
Training System employs online learning programs,
factory and on-site sessions and simulator training.

Liebherr Mining From-Cradle-To-Grave Support

Exchange Components
Customer specic requirement study
Exchange and repair programs for Collaborative solution development
components are conducted by
Liebherr-certied rebuild facilities On-site machine assembly
using the latest OEM rebuild speci- On-site machine settings
cations and the complete range of Training program on / off site
genuine Liebherr parts to ensure:
Machine performance monitoring
Value: signicantly reduce total
cost of ownership Spare parts supply

Quality: guaranteed as-new Parts remanufacturing facilities

performance and reliability
Availability: global network of
components rebuild facilities

R 9250 11
 Machine Access
Designed for safe access on the
machine upperstructure via:
Stairway and catwalks with handrails
and perforated steps
Walkways with slip-resistant surfaces
Emergency egress with handrails in
front of the excavator

12 R 9250
 Safety
The Liebherr R 9250 provides uncompromising safety for operators and
maintenance crews. Equipped with the service ap accessible from the ground
level and integrating wide open accesses, the R 9250 allows quick and safe
maintenance. The R 9250s cab provides numerous features for operator safety.

Service-Friendly Machine Design

Safe Service Access The R 9250s top structure is accessible via a powered
45 stairway as standard on the Tier 2 version. The
robust service ap provides easy ground level access
to the main service points.
Easy Inspection All components have been located in areas that allow
and Components for effortless inspection and replacement. The R 9250
Replacement is equipped with robust hinged louvers for easy
cleaning and maintenance. Numerous service lights
are located in the main service areas to sustain
suitable maintenance conditions, day or night.
Secure Maintenance The R 9250 eliminates hazards ensuring a safe
environment for the service staff during maintenance.
Emergency stops are strategically located at ground
level, in the cab, in hydraulic and engine compart-
ments. The battery switches are manually operated
to safely isolate the battery power. The attachment
can safely be lowered to the ground even if the
engine is off.

Safety First Working Conditions

Safety-First Cab Design In addition to its ergonomic design, the R 9250s cab
provides maximum protection for the operator. The
structure is composed of strong, low stress tubing
and safety glass. The Falling Object Protection
System (FOPS) and the armored front and attach-
ment side windows enable to create a safe working
environment for the operator.
Engine Compartment The engine compartment integrates a protection wall
Provision of Security that separates the engine from the hydraulic pumps.
This reduces the risk of hydraulic oil entering the
engine compartment. The turbochargers and exhaust
systems are heat shielded, and all the hydraulic
hoses are made from a highly resistant material.

Machine Improved Visibility Rear and Side Vision System

The machine is easily visible even The machine ergonomically integrates a rear and
by night or in extremely dusty work- side vision system composed of:
ing environments thanks to: One camera on counterweight
Eight long-range working halogen One camera on right-hand side of uppercarriage
lights located on attachment,
One LCD color screen to display cameras view
uppercarriage and counterweight
Xenon or LED lights in option
Travel alarm system with light and
buzzer

R 9250 13
 Electric Drive Version
The electric drive system is an efcient
alternative to diesel engine allowing:
Less vibration resulting in higher
component lifetime
Lower maintenance costs
Less noise pollution
High motor efciency
Maximum efciency in cold climate
conditions when combined with the
Arctic Kit

14 R 9250
 Environment
Liebherr considers the preservation of the environment as a major challenge
for the present and future. Sustainability underpins Liebherrs machines; from
raw materials selection to manufacturing process employed. Liebherr provides
solutions that allow customers to balance high performance with environmental
consciousness.

Minimized Impact on Life

Optimized Fuel Constant power regulation of the hydraulic system
Consumption and engine output optimizes equipment fuel efcien-
cy, depending on the application. Fan coolers speed
is adjusted on-demand in order to optimize energy
consumption. The automatic idling system reduces
the engine speed when the machine is at rest.
Controlled Emission The R 9250 is powered by a high horsepower diesel
Rejections engine which complies with the USA/EPA Tier 1 or
Tier 2 emissions limits. The electric drive version is
an efcient alternative for applications that do not
require frequent machine relocation. The power
system makes the R 9250 cost effective without
compromising productivity whilst reducing the
machines impact on the environment.

Sustainable Design and Manufacturing Process

Extended Components Liebherr is constantly working on ways to extend
and Fluids Lifetime component life. Through the Exchange Components
program, superior lubrication systems, and the
reinforcement of parts under stress, Liebherr can
reduce frequency of part replacement. The result
minimizes environmental impact and lowers the
overall cost of ownership.
Product Life-Cycle Subject to the stringent European Program for
Management the regulation of the use of chemical substances
in the manufacturing process REACH*, Liebherr
undertakes a global evaluation to minimize the
impacts of hazardous materials.

*REACH is the European Community Regulation on chemicals and their safe use (EC1907/2006)
It deals with the Registration, Evaluation, Authorization and Restriction of Chemical Substances.

Sound Attenuation Kit (Option) Sustainable Manufacturing Process

Developed with the latest noise With an ever-present green focus, Liebherr
measurement technologies, this contributes to the sustainable development:
approach is based on both removal Systematic risk analysis for new materials
of noise at the source and passive qualication
sound attenuation:
Promoted recovery waste management
Noise-optimized fan regulation
Controlled non-recyclable waste elimination
Valve bank covering
Eco-friendly material selection
Sound attenuation on louvers, (95% of material used on machine is recyclable)
doors and walls

R 9250 15
 Technical Data
Engine Hydraulic System
1 Cummins diesel engine Hydraulic pumps
Rating per for attachment and
SAE J 1995 ________________ 960 kW/1,287 HP at 1,800 rpm travel drive _________________ 3 variable flow axial piston pumps
Model ________________________ Cummins QSK45 Max. flow ___________________ 2 x 771 l/min. + 1 x 579 l/min./
(USA/EPA Tier 1) 2 x 204 gpm + 1 x 153 gpm
Type __________________________ 12 cylinder turbocharged V-engine Max. hydr. pressure ____ 320 bar/4,640 psi
after-cooler Hydraulic pump
two separate water cooling circuits for swing drive ____________ 2 reversible swash plate pumps,
direct injection system closed-loop circuit
Displacement _____________ 45 l/2,745 in3 Max. flow ___________________ 2 x 352 l/min. / 2 x 93 gpm
Bore/Stroke________________ 159/190 mm / 6.26/7.48 in Max. hydr. pressure ____ 350 bar/5,076 psi
or Pump management __________ electronically controlled pressure and flow
1 Cummins diesel engine management with oil flow optimisation
Rating per Hydraulic tank capacity _____ 2.281 l/602 gal
SAE J 1995 ________________ 940 kW/1,261 HP at 1,800 rpm Hydraulic system
Model ________________________ Cummins QSK38 capacity __________________________ 4.050 l/1,070 gal
(USA/EPA Tier 2 or fuel consumption Hydraulic oil filter ______________ 1 high pressure safety filter after each high
optimized setting) pressure pump + fine filtration of entire
Type __________________________ 12 cylinder turbocharged V-engine return flow (15/5 m)
after-cooler Hydraulic oil cooler ___________ cooler with temperature controlled fans
two separate water cooling circuits driven via hydraulic piston motor
direct injection system
Displacement _____________ 37,8 l/2,307 in3
Bore/Stroke________________ 159/159 mm / 6.26/6.26 in
Engine cooling system ______ fans driven via hydraulic piston motor Electro-Hydraulic Controls
Air cleaner _______________________ dry-type air cleaner with pre-cleaner,
withautomatic dust ejector, primary Servo circuit independent, electric over hydraulic
____________________
andsafety elements proportional controls of each function
Fuel tank _________________________ 5.440 l/1,434 gal Emergency control ______ via accumulator for all attachment
Electrical system functions with stopped engine
Voltage ______________________ 24 V Power distribution ____________ via monoblock control valves with inte-
Batteries ____________________ 6 x 170 Ah/12 V grated primary relief valves and flanged
Alternator ___________________ 24 V/260 Amp onsecondary valves for travel
Engine idling ____________________ automatic engine idling Flow summation _________ to attachment and travel drive
Electronic engine Control functions
control system _________________ engine speed sensing over the entire Attachment and
engine RPM range. Provides integration swing ________________________ proportional via joystick levers
ofengine with other machine systems Travel ________________________ proportional via foot pedals or hand levers
Bottom dump bucket __ proportional via foot pedals

Electric Motor (optional)

Swing Drive
1 electric motor
Power output ___________________ 1.050 kW/1,408 HP Hydraulic motor ________________ 2 Liebherr axial piston motors
Type _______________________________ 3 phase AC squirrel cage motor Swing gear ______________________ 2 Liebherr planetary reduction gears
Voltage ____________________________ 6,000 V, other voltage on request Swing ring _______________________ Liebherr, sealed triple roller swing ring,
Frequency _______________________ 50 Hz (or 60 Hz) internal teeth
Revolutions ______________________ 1,500 rpm or 1,800 rpm Swing speed ____________________ 0 4.4 rpm
Motor cooling __________________ integrated air-to-air heat exchanger Swing-holding brake _________ hydraulically actuated, maintenance-free,
Starting method _______________ inrush current limited to 2,2 full load current multi-disc brakes integrated in each swing
gear

Electric System
Uppercarriage
Electric isolation _______________ easy accessible battery isolations
Working lights __________________ high brightness halogen lights: Design torque resistant designed upper frame in
____________________________
2 on working attachment box type construction for superior strength
1 on RHS of uppercarriage and durability
3 on LHS of uppercarriage Attachment mounting _______ parallel longitudinal main girders in box-
2 on counterweight section construction
Xenon or LED lights in option Machine access _______________ (Tier 1) hydraulically driven access ladder
Emergency stop switches __ at ground level, in hydraulic compartment, on the cab side of the uppercarriage,
in engine compartment and in operator cab (Tier2) 45 access system with handrails
Electrical wiring ________________ heavy duty execution in IP 65 standard for on the cab side of the uppercarriage, full
operating conditions of 50 C to 100 C/ controlled descent in case of emergency
58 F to 212 F stop
additional emergency ladder fitted near the
cab

16 R 9250
 Technical Data
Operators Cab Service Flap
Design ____________________________ resiliently mounted, sound insulated, Design _____________________________ hydraulically actuated service flap, easily
large windows for all around visibility, accessible from ground level to allow:
integrated falling object protection FOPS fuel fast refill
Operators seat ________________ suspended, body-contoured with shock engine oil quick change
absorber, adjustable to operators weight swing ring teeth grease barrel refilling via
Cabin windows ________________ 20,5 mm/0.8 in tinted armored glass for grease filter
front window and 18 mm/0.7 in for right attachment/swing ring bearing grease
hand side windows, all other windows in barrel refilling via grease filter
tinted safety glass, hydraulic oil refill
high pressure windshield-washer system hydraulic oil draining
75 l/20 gal watertank, splitterbox oil refill
sun louvers on all windows in heavy duty windshield wash water refilling
design Other coupler type on request
Heating system/
Air conditioning ________________ heavy duty, fully automatic, high output air
conditioner and heater unit
Cabin pressurization _________ ventilation with filter Central Lubrication System
Controls __________________________ joystick levers integrated into armrest of
seat Type _______________________________ Lincoln Centromatic lubrication system,
Monitoring _______________________ via LCD-Display, data memory forthe entire attachment/swing ring
Rear vision system____________ camera installation on counterweight and bearing and teeth
right-hand side of the uppercarriage dis- Grease pumps _________________ Lincoln Powermaster pump plus separate
played over an additional LCD-display P203 pump for swing ring teeth
Automatic engine Capacity __________________________ 200 l/53 gal bulk container for attachment/
shut off ____________________________ engine self-controlled shut off swing ring bearing, separated 15 l/4.0 gal
Destroking of main bulk container for swing ring teeth
pumps ____________________________ in case of low hydraulic oil level Refill _______________________________ via the service flap for both containers,
Safety functions _______________ additional gauges with constant display for: fillline with grease filters
engine speed, hourmeter, voltmeter, safety
mode for engine speed control and pump
regulation
Noise level (ISO 6396) _______ Diesel: LpA (inside cab) = Tier 1: 77 dB(A) Attachment
with oil/water fans at 100 % and AC fan
at65 % Design ____________________________ box-type structure with large steel castings
Electric: LpA (inside cab) = 70 dB(A) in all high-stress areas
with oil/water fans at 100 % and AC fan Stick _______________________________ wear protection underneath lower beam
at65 % plate
Pivots ______________________________ sealed and floating pins
Hydraulic cylinder _____________ Liebherr design, sealed bearings,
electronically controlled end-cushioning
Undercarriage Hydraulic connections ______ pipes and hoses equipped with SAE
split-flange connections
Design 3-piece undercarriage,
____________________________ Pivots bucket-to-stick
box type structures for center piece and Pivots bucket-to-link _________ O-ring sealed and completely enclosed
side frames, Kinematics _______________________ Liebherr parallel face shovel attachment
stress relieved geometry, electronic controlled end-
Hydraulic motor ________________ 2 axial piston motors per side frame cushioning
Travel gear _______________________ Liebherr planetery reduction gear
Travel speed ____________________ 0 2,1 2,7 km/h / 0 1.30 1.68 mph
Parking brake ___________________ spring engaged, hydraulically pressure
released wet multi-disc brakes for each
travel motor, maintenance-free
Track components ____________ D 12, maintenance-free, forged double
grouser pad
Track rollers/
Carrier rollers ___________________ 9/2 per side frame
Automatic track tensioner __ hydraulic and grease tensioner
Transport ________________________ undercarriage side frames are removable

R 9250 17
 Dimensions
(
, (
- + (

>

6,3 / *
/

2 7
8
3 5
< :
A )
=
?

mm/ft in mm/ft in
A 5.500/18 L 6.400/2011
A1 6.100/20 N 850/ 2 9
A2 6.800/22 3 P 2.200/ 7 2
B 6.183/20 3 Q 870/ 210
C 7.250/23 9 S 4.900/16
D 6.100/20 U 8.255/27
E 6.140/20 1 V 11.600/38
F 2.993/ 9 9 W 7.800/25 7
H 4.905/16 1 X 17.800/58 4
H1 6.000/19 8 Z 10.240/33 7
K 2.205/ 7 2 OEL Operators Eye Level 6.350/20 9

(
, (
- + (

> *
6,3 /
/

2 7
8

3 5
< :
A )
=
?

mm/ft in mm/ft in
A 5.500/18 L 6.400/2011
A1 6.100/20 N 850/ 2 9
A2 6.800/22 3 P 2.200/ 7 2
B 6.183/20 3 Q 870/ 210
C 7.250/23 9 S 4.900/16
D 6.100/20 U 8.255/27
E 6.140/20 1 V 17.400/57
F 2.993/ 9 9 W 6.700/2111
H 4.905/16 1 X 19.600/64 3
H1 6.000/19 8 Z 10.240/33 7
K 2.205/ 7 2 OEL Operators Eye Level 6.350/20 9

18 R 9250
 Backhoe Attachment
with Gooseneck Boom 9,00 m/296
ft m
60
Digging Envelope
18
Stick length 4,00 m/13 1
16
50
Max. reach at ground level 15,50 m/5010
14 Max. teeth height 15,20 m/4910
40
Max. dump height 10,30 m/33 9
12
Max. digging depth 8,70 m/28 6
10
30 Max. digging force (ISO 6015) 800 kN/179,847 lbf
Max. breakout force (ISO 6015) 870 kN/195,584 lbf
8

20 6

4 Operating Weight
10
2
and Ground Pressure
The operating weight includes the basic machine with backhoe
0 0
attachment and a 15,00 m3/19.6 yd3 bucket.
-2 Pad width mm/ft in 850/29
-10 Weight kg/lb 250.000/551,200
-4 Ground pressure * kg/cm2 / psi 2,09/29.63

-20 -6 * according to ISO 16754

-8
-30
-10
16 14 12 10 8 6 4 2 0 m

60 50 40 30 20 10 0 ft

Buckets
For materials classe
according to VOB, Section C, DIN 18300 <5 <5 56 56 56 78
Typical operation
according to VOB, Section C, DIN 18300 GP GP HD HD HD XHD
Capacity ISO 7451 m3 16,00 17,00 13,00 15,00 17,00 13,50
yd3 20.9 22.2 17.0 19.6 22.2 17.7
Suitable for material up to a specific weight of t/m3 1,8 1,7 2,1 1,8 1,6 1,8
lb/yd3 3,035 2,867 3,541 3,035 2,698 2,867
Cutting width mm 3.300 3.500 3.000 3.120 3.500 3.160
ft in 109 115 910 102 115 104
Weight kg 14.300 14.800 14.300 15.500 16.400 19.200
lb 31,526 32,628 31,526 34,172 36,156 42,329
GP: General purpose bucket with Liebherr Z120 teeth
HD: Heavy-duty bucket with Liebherr Z120 teeth
XHD: Heavy-duty rock bucket with Liebherr Z140 teeth

R 9250 19
 Shovel Attachment
with Shovel Boom 6,37 m/209
M[ T

Digging Envelope

Stick length 4,20 m/139

 Max. reach at ground level 13,00 m/427
 Max. dump height 11,00 m/36
Max. crowd length 4,00 m/131
  Bucket opening width T 2,15 m/ 7
T
 Crowd force at ground level (ISO 6015) 1.060 kN/238,297 lbf
 Max. crowd force (ISO 6015) 1.260 kN/283,259 lbf
 Max. breakout force (ISO 6015) 1.030 kN/231,553 lbf

 

 Operating Weight

and Ground Pressure

The operating weight includes the basic machine with shovel
  attachment and a 15,00 m3/19.6 yd3 bucket.
Pad width mm/ft in 850/29

Weight kg/lb 253.500/558,900

Ground pressure * kg/cm2 / psi 2,12/30.05

        T * according to ISO 16754

      M[

Bottom Dump Buckets

For materials classe
according to VOB, Section C, DIN 18300 <5 56 56 78 78
Typical operation
according to VOB, Section C, DIN 18300 GP HD HD XHD XHD
Capacity ISO 7546 m3 17,00 13,00 15,00 11,00 13,00
yd3 22.2 17.0 19.6 14.4 17.0
Suitable for material up to a specific weight of t/m3 1,6 2,1 1,8 2,3 1,8
lb/yd3 2,698 3,541 3,035 3,879 3,035
Cutting width mm 3.700 3.700 3.700 3.700 3.700
ft in 121 121 121 121 121
Weight kg 27.000 27.000 27.000 28.000 29.000
lb 59,525 59,525 59,525 61,729 63,934
Wear kit level I II II III III
GP: General purpose bucket with Liebherr Z120 teeth
HD: Heavy-duty bucket with Liebherr Z120 teeth
XHD: Heavy-duty rock bucket with Liebherr Z140 teeth
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.

20 R 9250
 Optional Equipment
Undercarriage Operators Cab
Different track pads width Front protective grid
Double sealed gearbox 4-point seat belt
Additional track guide Double A/C system
Additional windscreen wipers for all windows

Uppercarriage
LED lights (with flood/access lights) Attachment
Xenon lights (with flood/access lights) Cylinder rod protection (bucket)
Fast fueling system with Multiflo & Wiggins/Banlaw coupling
(otherbrand name couplings possible)
Water separator
Valve position monitoring on hydraulic tank
Customized paint compl. machine Specific Solutions
Arctic kit 30 C
Arctic kit 40 C
Sound attenuation kit (until + 40 C)

Hydraulics
Bio-degradable hydraulic oils
Oil cooler protection filter
Safety
Automatic fire fighting system (FFS)

Engine
Fuel consumption optimized version
Automatic engine shutdown (5 min.)
Cummins Cense Kit
Cummins Eliminator Kit

R 9250 21
The Liebherr Group of Companies

Wide Product Range State-of-the-art Technology

All illustrations and data may differ from standard equipment. Subject to change without notice. All indicated loads are based in accordance with ISO 9248.
The Liebherr Group is one of the largest construction To provide consistent, top quality products, Liebherr
equipment manufacturers in the world. Liebherrs attaches great importance to each product area, its
high-value products and services enjoy a high reputation components and core technologies. Important modules
in many other fields. The wide range includes domestic and components are developed and manufactured
appliances, aerospace and transportation systems, in-house, for instance the entire drive and control
machine tools and maritime cranes. technologyfor 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 1949. Since that time, the enterprise has steadily grown
excellence and acknowledged quality, Liebherr products to a group of more than 130 companies with over
offer a maximum of customer benefits in practical 38,000employees located on all continents. The corporate
application. headquarters of the Group is Liebherr-International AG
inBulle, Switzerland. The Liebherr family is the sole owner
of the company.

www.liebherr.com

Printed in Germany RG-BK-RP LFR/SP 11003236-1.5-04.13_enGB-US

Liebherr-Mining Equipment Colmar SAS

49 rue Frdric Hartmann, FR-68025 Colmar Cedex
+33 369 49 20 00, Fax +33 369 49 23 18
www.liebherr.com, E-Mail: [email protected]
www.facebook.com/LiebherrConstruction
 2 Safety instructions

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

2.1 Meaning of the symbols in this manual

Work processes and actions that could cause danger are accompanied by safety in-
formations in these operating instructions. These safety informations describe vari-
ous dangers which are emphasized by the terms Danger, Caution and Note.
These terms are identified by symbols in the operating instructions and have the fol-
lowing meaning:

Danger!
Warning relating to a danger that carries with it a high risk of death or serious injury
if the appropriate preventative measures are not taken.

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

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

This symbol identifies a listing.

LEC/en/Edition: 02 / 2015

This symbol identifies a sub-listing.

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

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Safety instructions Operating manual
Use in accordance with the regulations

If the machine operator or maintenance personnel have carried out the activities
described in an action, the result of this action will be described here.
Following these notes does not relieve you of responsibility for following ad-
ditional rules and guidelines!
Additional points that should be noted are:
the safety regulations which apply on site,
statutory road traffic regulations,
the guidelines provided by professional associations.

2.2 Use in accordance with the regulations

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

2.3 Safety Instructions

General safety instructions

Please familiarize yourself with the operating instructions before starting up the
LEC/en/Edition: 02 / 2015

machine.
Ensure that you have obtained, read and understood any additional instructions
relating to special accessories for the machine.
Only specifically authorized persons may operate, maintain or repair the machine.
The legal minimum age is to be adhered to.
Only employ trained or appropriately instructed personnel. Clearly establish
which personnel are responsible for operating, setting up, maintaining and repair-
ing the machine. Give personnel the power to refuse to carry out unsafe instruc-
tions. This also applies in relation to traffic regulations.

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Only permit apprentices and personnel who are in training or who have only gen-
eral training to operate on the machine under the constant supervision of an ex-
perienced member of staff.
As far as possible, monitor personnel to ensure that they are adhering to safe
working practices, are aware of risks and are observing the operating instructions.
Always wear safe work clothes when you are working on or with the machine.
Avoid wearing rings, wrist watches, ties, scarves, open jackets, baggy clothing
etc... There is a risk of injury from, for example, getting caught up or being drawn
in.
Wear individual protective equipment (protective goggles, safety helmets, safety
shoes and gloves, reflective vests and ear protection etc...).
Ensure that you obtain information on any special safety regulations for the job
site from the site foreman.
Always tilt up the safety lever before leaving the operators seat.
When getting in and out, do not hold on to the steering column, control panel or
joystick. Doing this could cause unintentional movement, which could result in an
accident.
Never jump from the machine; use the steps, ladders, gangplanks and supporting
straps provided for this purpose.
Face the machine when getting in or out and always use three-point support, i.e.
two hands and one foot or two feet and one hand must always be in contact with
the access system at the same time.
Familiarize yourself with the location of the emergency exit.
In the absence of any other instructions, proceed as follows for all maintenance
and repair work:
park the machine on firm, level ground
align the uppercarriage with the undercarriage so that the sprockets locate at
the back-end
anchor the bucket in the ground.
place all operating levers into neutral and tilt the safety lever up.
switch off the engine and remove the start key.
Before touching any parts of the hydraulic circuits, you must also operate all pilot
control devices (joystick and pedals) in all directions with the start key in contact
position and with the security lever lowered, in order to reduce the actuating and
dynamic pressures in the work circuits. You must then reduce the internal tank
pressure as described in these operating instructions.
Secure all loose parts on the machine.
Never operate a machine before carrying out a careful inspection tour and check-
ing whether any warning signs are missing or illegible.
Respect all danger and safety instructions.
For special applications the machine must be 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
LEC/en/Edition: 02 / 2015

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, which has generally
not been validated by LIEBHERR for installation or extension, has not to be in-
stalled or added onto the excavator without previous written agreement of LIEB-
HERR. Wherefore the necessary technical documentations has to be at
LIEBHERRs disposal.

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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
cooled to a point where it is possible to touch it. Then turn the cap carefully to let
off the overpressure.
Wear protective goggles and gloves when working on the battery. Avoid sparks
and naked flames.
Never permit the bucket to be guided by hand by auxiliary personnel.
When reaching into the engine compartment, always secure the side doors
against unintentional closing by positioning the supports if provided for this pur-
pose.
Never lay under the machine if it is raised with work 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
charging the batteries.
Always start the engine in accordance with the operating instructions.
Check the electrical system regularly.
Have all faults, such as loose connections, blown fuses and lamps and clogged
or abraded cables rectified by authorized personnel.
Do not transport any combustible liquids anywhere on the machine other than in
the tanks provided for this purpose.
Check all lines, hoses and screwed joints regularly for leakage and damage.
Rectify leakages immediately and replace damaged components.
Oil spraying out of leaking areas can easily cause a fire.
Ensure that all holds and shields are correctly installed to guard against vibration,
abrasion and heat accumulation.
LEC/en/Edition: 02 / 2015

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 drivers cab.
All doors, covers and boxes locks have to be unlocked before operation in order
to facilitate firefighting in case of fire. Only electrical boxes from and over 50V

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must remain locked during operation.

Bringing the machine safely into service

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

Safely getting up
Proceed with the the same precautions to climb up or down onto the machine, as
to install yourself at the operators 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 partic-
ular, you should ensure that they are free of dirt, oil, ice and snow.
NOTE: To ensure that the doors open properly in all weather conditions, the door
seals must be dusted with talc or silicon at least every two months or more often
if required. The door hinges and locks should be greased regularly.
Face the machine when getting in or out and always use three-point support, i.e.
two hands and one foot or two feet and one hand must always be in contact with
the access system at the same time.
If you are able to reach the door handle with your free hand, open the doors 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 in-
stuctions 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.
LEC/en/Edition: 02 / 2015

For cab with a side door:

Now continue to climb up, still using the three-point support and sit down in the
operators 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:

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Safety Instructions

Now continue to climb up, still using the three-point support and close the door
as soon as you enter the cab.
Sit down in the operators seat and fasten the safety belt (if available) before tilt-
ing down the safety lever, and start the machine.

Adjusting the operators standing position

Before starting the machine, adjust the seat, mirrors, armrests and operators
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 seats damping action and adjustment mechanisms regularly and en-
sure that these seat characteristics remain as per the seat manufacturers in-
structions.

Utilisation in confined spaces

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

Starting the machine safely

Before starting, check all control lamps and instruments for correct function, place
all operators 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 drivers 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

LEC/en/Edition: 02 / 2015

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 avail-
able.

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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 unpermitted use and vandalism.

Safely getting down

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

Working safely with the machine

Before you start working, acquaint yourself with the special features of the job site
and any special precautions and warning signals. Examples of particular work en-
vironments would be on-site or traffic obstructions, the load-carrying capacity of
the ground and any requirements to make the job site safe from public use.
Always maintain a safe distance from overhangs, edges, slopes and unsafe
ground.
Be particularly careful in conditions of reduced visibility and changeable ground
conditions.
Familiarize yourself with the location of power lines on the job site and take par-
ticular care when working near them. If necessary, inform the responsible author-
ities.
Maintain a safe distance from electrical aerial lines. Do not allow the 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 drivers cab,
warn any personnel in the vicinity not to come close to the excavator and
not to touch it,
LEC/en/Edition: 02 / 2015

instruct or initiate that someone turns off the voltage.

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

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Safety Instructions

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

Do not permit any passengers in the machine.
Only work when seated properly and with the safety belt securely fastened (if
available).
Report all function faults and ensure that all necessary repairs are carried out im-
mediately.
Assure yourself that no one is endangered when you start the machine moving.
Before you start working, test the brake system in accordance with the regulations
given in the operating instructions.
Never leave the drivers 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 ma-
chine.
Always shift down to a lower running step before a slope. When doing this, the
diesel engine must run at maximal speed and the speed may only be reduced us-
ing the foot pedals.
Load an occupied truck only if all safety requirements are fulfilled, notably in order
to protect the truck operator.
For demolition work, digging and crane operations etc., always use protective de-
vices specifically designed for the purpose.
For terrain which is difficult to gain an overview of and whenever necessary, ask
for the assistance of a spotter. Only permit one person to give you signals.
Authorize only experienced people to attach load and to give indications to the
machine operator. This people must be in the operators 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.
Depending on the equipment combination, there is a risk of collision between the
LEC/en/Edition: 02 / 2015

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.
Depending on the equipment combination, there is a risk of collision between the
work tool and the equipment parts. The greatest degree of care must be taken to
avoid damage.
Depending on the equipment combination, there is a risk of collision between the
lift ring of the attachment and the cab or the cab protection. Before operating, en-
sure that there is no risk of collision, especially on excavator with cab elevation.

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If necessary remove the lift ring.

In case of a thunderstorm :
lower the attachment to the ground and if possible anchor the digging tool into
the soil.
leave the cab and move away from the machine before the storm breaks out.
Otherwise, you must stop the excavator, turn off the radio and keep inside the
closed cab until the end of the storm.
Auxiliary control units can have various functions. Always check their functions
when starting up the machine.
Stop the swinging motion of the uppercarriage when lowering the attachment into
a ditch without striking the attachment on the ditch walls.
Inspect the machine for damage if the attachment has been swung into a wall or
any other obstacles.
Applications in which the attachment is to be used to strike the material being ex-
tracted are not permitted, even when working in a longitudinal direction.
Repeated strikes against an object leads to damage to the steel structures and
machine components.
Please refer to your LIEBHERR dealer if special teeth for heavy-duty or special
applications are required.
Do not attach too large bucket or bucket with side cutters or that are during oper-
ations with rocky material. This would prolong the work cycles and may lead to
damage to the bucket as well as further machine components.
With the 2x45 offset articulation, the offset position may only be employed if the
working tool or the attachment does not touch the material.
Operation of the offset articulation to drill into the material is not permitted.
Do not lift the machine during operation. Should this happen, lower the machine
slowly back to the ground.
Do not let the machine fall heavily on the ground and do not hold it back with the
hydraulics. This would damage the machine.
During operation with the attachment it is forbidden to raise the machine with the
dozing blade (e.g. carving at the ceiling when tunnelling).
Do not dig under the undercarriage. Take all necessary measures to prevent
ground collapse under the machine.
The 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 struc-
tures 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 Min-
ing Machines in this manner.
LEC/en/Edition: 02 / 2015

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 ma-
chine 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

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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

loading and unloading wood)
According to use, it can be necessary when working with a grab to move with the
equipment raised and the load lifted up; this applies, for example, when loading
and unloading wood.
Here, the centre of gravity of the machine will be displaced upwards in the vertical
direction. The driving characteristics of the machine will thus be influenced 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 rotat-
ed the upper structure to the driving position.
There is a danger of possible swinging movement and dropping of the load
when the equipment is raised.
A protective grid (FOPS) in accordance with ISO 10262 must be attached to the
cab.
A protective roof (FOPS) in accordance with ISO 10262 must be attached if
there is a risk of objects falling from above.
Only the maximum permissible load may be taken up using the grab.
NOTE: The weight of absorbent materials, such as logs, is dependent on length,
diameter and specific weight. The influencing variables present in a natural prod-
uct, such as moisture, must be noted.
Working procedures when using machines with grabs require the machine oper-
ator to receive special instruction and training.
LEC/en/Edition: 02 / 2015

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.

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Due to the heightened centre of gravity, the machine must be aligned horizontally
before use. In horizontal alignment, the centre of gravity of the upper structure is
over the centre of the undercarriage, which reduces the risk of tilting.
The machine can still sway and tilt despite being aligned!
The following instructions are therefore to be observed at all times:
When moving the machine:
Rotate the upper structure parallel to the undercarriage (transport position).
Draw the equipment as close as possible to the machine.
Only at this point may the support feet be retracted and the machine moved.
Moving with loads is not permitted.
Check the terrain to be covered to ensure that the ground is solid and even. Pot-
holes and uneven surfaces jeopardize the stability of the machine.
Adjust vehicle handling to suit the altered machine characteristics (high centre
of gravity) and environmental conditions.
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.
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 (slew-
ing) 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 machines
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.
LEC/en/Edition: 02 / 2015

Whole-body vibrational load for the machine operator can be reduced if the following
recommendations are observed:
Select suitable machines, equipment parts and auxiliary devices for each part of
the job.
Use a machine that has a suitable seat (i.e. for earth-moving machinery such as
hydraulic excavators, this should be a seat which corresponds with EN ISO
7096).
Keep the seat in good condition and adjust it as follows:
The seat and its damping action should be adjusted depending on the weight

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and height of the operator.

Check the seats damping action and adjustment mechanisms regularly and en-
sure that these seat characteristics remain as per the seat manufacturers in-
structions.
Check the maintenance status of the machine, particularly with respect to: tyre
pressure, brakes, steering, mechanical connections etc.
Do not steer, brake, accelerate, shift gears, move or load the machines 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 manufacturers guarantee.
Ensure that there is no one in the vicinity of the towing devices when towing.
Stretch safely and hold the towing devices. Avoid kinks on cables or ropes.
When towing, maintain the correct transport position, permitted speed and route,
and avoid lurching.
After towing, return the machine to correct operational status.
When restarting the machine, be sure only to proceed in accordance with the op-
erating instructions.

Attaching and removing equipment parts safely

Equipment or attachments made by other manufacturers or those which do not
LEC/en/Edition: 02 / 2015

have general approval from LIEBHERR for installation or attachment may not be
installed or attached to the machine without LIEBHERRs prior written consent.
LIEBHERR must be provided with the appropriate technical documentation nec-
essary 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

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 Operating manual Safety instructions
Safety Instructions

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 equipments 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 machines 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.
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.
LEC/en/Edition: 02 / 2015

Prepare the placing block to ensure against rolling back when the machine is driv-
ing up onto the flatbed.
Tilt the equipment up and drive up the loading ramp. While doing this, always hold
the equipment securely over the loading area, drive very carefully up the ramp
and onto the transportation vehicle.
Rotate the upper structure carefully to the rear and lower the equipment. Due to
restrictions during transport on hoe equipment, tilt the arm in and dismantle the
bucket during transportation.

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Servicing the machine safely

After loading the machine onto the flatbed trailer, the upper structure must be se-
cured facing the undercarriage using the stop bolts (only A devices).
Secure the undercarriage and the remaining individual parts using chains and
blocks to prevent slipping.
Before you leave the machine, reduce pressure on all pressure lines, remove the
ignition key and tilt up the safety lever.
Lock all cab and panel doors.
Before transportation, find out all details about the route to be travelled, particu-
larly as they relate to width, height and weight restrictions.
Pay particular attention when driving under electrical lines and bridges and
through tunnels.
When unloading the machine, take the same amount of care as was taken when
it was loaded. Remove all chains and blocks. Start the engine as per the operating
instructions. Drive carefully off the trailers loading area and down the ramp. Hold
the working equipment as securely as possible over the ground while doing this.
Have a spotter guide you.

2.4 Servicing the machine safely

General safety instructions

Maintenance and repair work may only be carried out by specially trained person-
nel.
Observe statutory timetables or intervals given in the operating instructions for re-
peat tests / inspections. It is imperative that a suitably equipped workshop is avail-
able in order to carry out maintenance work.
The inspection and maintenance schedule given at the end of these operating in-
structions defines precisely who is required / permitted to carry out what work.
Jobs listed as daily / weekly work may be carried out by the machine's driver or
maintenance personnel when they have received appropriate instruction.
The remaining work may only be carried out by specialist personnel with appro-
priate training.
Replacement parts must correspond to the technical requirements determined by
the manufacturer. Original replacement parts are always guaranteed to meet
these criteria.
Always wear safe work clothes when carrying out maintenance work. Avoid the
wearing of rings, wrist watches, ties, scarves, open jackets, baggy clothing etc...
There is a risk of injury from, for example, getting caught up or being drawn in.
Protective goggles, safety helmets, safety shoes and gloves, reflective vests and
ear protection etc. are required for specific jobs.
Do not remain in direct proximity of the diesel engine while the diesel engine is
running.
Persons with pacemakers should not approach within 20 cm of the running diesel
LEC/en/Edition: 02 / 2015

engine.
Do not touch voltage-carrying parts on the electrical connection of the individual
solenoid injection pumps (Unit Pumps UP) while the diesel engine is running.
Do not permit unauthorised persons to approach the machine during mainte-
nance work.
Cordon off a wide maintenance area if required.
Inform operational personnel before starting to carry out any special work and re-
pair work. Designate persons in charge of supervision.

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In the absence of any other information in the operating instructions, carry out all
maintenance work on the machine on level, firm ground with the working equip-
ment set aside and the engine switched off.
For some machines, the only one position which enables a secured access to
every maintenance locations on the uppercarriage, is when the uppercarriage is
aligned with the undercarriage so that the sprockets locate at the back-end.
The ladder situated on the undercarriage only corresponds with the uppercar-
riages access when the excavator is in this configuration.
Pull out the ignition key and shut off the main battery switch.
Always tighten any loose screw connections during maintenance and repair work.
The mounting bolts of the main components, of the hydraulic hoses and of the
counterweight must be replaced after every removal.
If safety devices have to be dismantled during set-up, maintenance and repair
work, they must be immediately reinstalled and checked at the end of the work.
When carrying out repair work, particularly when working under the machine,
hang a Do not start warning sign in a clearly visible position on the control panel.
Pull out the start key and shut off the main battery switch.
Operate combustion motors and fuel operated heaters only in well ventilated ar-
eas. Before operating these units, check ventilation.
In addition, always follow applicable local regulations.

Cleaning
Clean oil, fuel or care products off the machine before starting maintenance or re-
pair work and pay particular attention to connections and screw fittings.
Do not use aggressive cleaning products and use lint-free cleaning cloths.
Do not use aggressive cleaning products or steam jet devices to clean the ma-
chine for the first two months after initial set-up of the machine (or after repaint-
ing).
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-
ments temperature sensor do not come into contact with hot cleaning products
during cleaning work.
The fire extinguisher could start.
If you use a high pressure cleaner with steam or hot water to clean the machine,
observe following recommendations :
the distance between the nozzle and the surface to be cleaned must be no low-
LEC/en/Edition: 02 / 2015

er than 20 inches
the water temperature should not exceed 60c (140F)
limit the water pressure to 80 bar maximum (1160 PSI)
if you employ cleaning fluid, only use neutral cleaning agents such as custom-
ary car shampoos diluted to 2 or 3 percent maximum
After cleaning:
remove all covers completely.
check all fuel, engine oil and hydraulic lines for leakage, loosened connections,
chafing and damage.

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rectify any defects found immediately.

lubricate all bearing points, bolt connections and the rim bearing to displace any
water or cleaning products that may have entered.

Corrosion protection
The corrosion protection of the machine must be inspected and renewed at reg-
ular intervals. For further information, refer to the Maintenance manual for corro-
sion protection.

Field of view
Mirrors and cameras, which were possibly removed for the transport, must be in-
evitably reinstalled and correctly adjusted before the initial set-up of the machine.
Regularly check that the interior and exterior mirrors as well as the cameras are
correctly adjusted.
Control the surroundings, and particularly the nearness area of the machine, dur-
ing operation or when travelling.
Mirrors are installed on the machine:
on the left to check the left side of the machine.
on the front to check the front side of the machine.
on the right to check the right side of the machine.
above the counterweight to check the rear side of the machine.
On some machines, some mirrors may be replaced with cameras.
At each extension, construction or change on the machine, the sight conditions
must be maintained. These conditions must otherwise be checked according to
ISO 5006.
Mirrors 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 mainte-
nance plan:
every 250 operating hours by the machine owners maintenance personnel.
every 500 operating hours by authorised specialist personnel.
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It is advisable to carry out these tests: supported, on firm, horizontal substrate,

with the equipment in longitudinal and cross direction for variable loads. Current
accident prevention regulations must be adhered to.
Especially check the supporting components, in particular :
framed construction undercarriage with axle and gearbox storage, support out-
riger, lower slewing ring support with tower and slewing ring.
framed construction uppercarriage with bearing for boom and hoist cylinder, up-
per slewing ring support, cab suspension, mounting for slewing gear and coun-
ter weight.

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 Operating manual Safety instructions
Servicing the machine safely

framed construction components of attachments, e.g. boom, stick, quick

change adapter, digging tool and grapple.
hydraulic cylinders, axles, steering, pins and pin connections, ascents, ladders
and mounting elements.
The crack test should be carried out visually. If a crack is suspected, the dye pen-
etration test should be carried out as a crack test on areas which do not have
good visibility, such as the ring bearing support, in order to increase testing safety.
Any damage found must be rectified immediately. Welding work on load-bearing
parts of the earth-moving machinery, loading devices and transport devices may
only be carried out by trained specialist personnel and only in accordance with the
accepted rules of welding engineering. In case of doubt, contact the LIEBHERR
customer support service to discuss suitable remedies.

Welding, drilling, firing and grinding work

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

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

Repair work
Do not attempt to lift heavy parts. Use devices which are suitable for this purpose
LEC/en/Edition: 02 / 2015

and which have sufficient load capacity. When replacing single parts and larger
subassemblies, carefully secure them on lifting devices so that they do not pre-
sent a risk. Only use suitable and correctly functioning lifting devices and load
take-up devices with adequate load capacity.
Do not stand or work under swinging loads.
Do not use lifting devices which are damaged or do not have sufficient load car-
rying capacity.
Wear work gloves when working with wire cables.
Authorize only experienced people to attach load and to give indications to the

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

Electrical system
Check the electrical system regularly.
Have all faults, such as loose connections, blown fuses and lamps and clogged
or abraded cables rectified by personnel.
Only use original fuses with approved current strength.
For machines with electrical neutral and high tension leads:
switch the machine off immediately in the event of malfunctions in the power
supply.
LEC/en/Edition: 02 / 2015

Work on the machines electrical equipment may only be carried out by skilled
electrical personnel or by trained personnel under the supervision of an electri-
cian in accordance with electrical regulations.
When working on live parts, ensure that a second person is available to operate
the emergency-off or the main switch and overvoltage release. Cordon off the
working area with a red and white safety chain and a warning sign. Only use in-
sulated tools.
When working on neutral and high tension subassemblies, after releasing the
voltage, briefly disconnect the supply cable at earth and electronic devices such

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 Operating manual Safety instructions
Servicing the machine safely

as capacitors using an earthing rod.

First test the released parts to make sure that they are off circuit, earth them and
then disconnect them briefly. Insulate adjacent live parts.
Disconnect the battery before working on the electrical system or carrying out any
electric arc welding on the machine.
First disconnect the negative, then the positive pole. When reconnecting, proceed
in the reverse order.

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

Hydraulic lines and hoses

It is forbidden to carry out repair work on hydraulic lines and hoses!
All lines, hoses and bolt connections must be checked regularly for externally vis-
ible damage and any possible damage must be immediately checked for leakage.
Never check for leaks with your bare hands, use a sheet of paper or something
else.
Any damaged parts must be removed immediately! Spurting oil can lead to injury
and burns.
Even with correct storage and permitted load, lines and hoses are subject to the
natural aging process. This restricts their duration of use.
Incorrect storage, mechanical damage and unauthorized load are the most
common causes of failure.
In relation to duration of use, current norms, regulations and guidelines pertain-
LEC/en/Edition: 02 / 2015

ing to lines and hoses at place of use must be adhered to.

Use at the limit range of permissible load can shorten duration of use (e.g. high
temperatures, frequent movement cycles, extremely high pulse frequencies,
multiple shift usage).
Lines and hoses should be replaced if the following are found during inspection:
Damage to the outer sheath as far as the liner (e.g. chafing, cuts and cracks);
Brittleness of the outer sheath (fracture formation in hose material);
Deformations which do not correspond to the natural form of the line or hose,
whether in a unpressurized or pressurized state or on bends e.g. sheath sepa-

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Signs on the machine

ration, blistering;
Unsealed areas;
Non-adherence to requirements during installation;
Damage or deformations to the hose fittings which reduce the tightness of the
fittings or the hose / fitting connection;
Hoses working themselves out of the fittings;
Corrosion of the fittings which reduces function and tightness;
When replacing lines and hoses, use only original replacement parts.
Install and mount lines and hoses correctly. Do not mix up the connections.
The following is to be noted when replacing lines and hoses:
Always ensure that the lines and hoses are installed free of torsion. For high-
pressure hoses, the screws from the half-clamps or full flange must always be
attached to both hose ends and should only be tightened afterwards.
When tightening the flange on high-pressure lines and hoses with bent fittings,
the side with the bent fitting must always be tightened first and then the side with
the straight fitting tightened afterwards.
Any mounting clamps which are located in the centre of the hose may only be
attached and tightened subsequently.
Check daily to ensure that all clamps, covers and protective devices are prop-
erly fastened. Doing this will prevent vibration and damage during operation.
Install the lines and hoses in such a way that they cannot chafe on other lines,
hoses or parts.
A minimum distance from other parts of approx. half the exterior diameter of the
hose is recommended. The distance should not, however, be less than 10 to
15 mm.
When replacing the lines or hoses on moving parts (e.g. from the boom to the
stay), check before initial start-up that there are no chafing areas in the entire
area of movement.

2.5 Signs on the machine

2.5.1 Introduction
The machine displays several types of signs:
Safety plates provide warnings relating to dangers of accidents which could re-
sult in serious injury or death.
Information plates indicate specific points relating to the operation, maintenance
and characteristics of the machine.
Nameplates are attached to components for which the machine number must be
provided when ordering spare parts.

Danger!
Non-observance of safety plates can result in serious injury or death.
LEC/en/Edition: 02 / 2015

Check warning plates regularly to ensure that they are complete and clearly leg-
ible.
Replace missing or illegible safety plates immediately.

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2.5.2 Arrangement of signs

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Fig. 2-1 Arrangement of signs on the machine

5 Typeplate LFR 26 Label security shut off valve

7 Typeplate LFR 27 Warning label
10 Label external start 28 Label security lever
20 Label switchboard 31 Banning label
21 Label filling volume 41 Label safety ladder

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22 Label control symbol 46 Label emergency stop

23 Label control symbol 51 Label manual unlock of the ladder
24 Lubrification drawing 99 Label "CE"
25 Label key

2.5.3 Explanation of signs

Plate 5: 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 7: Typeplate LFR (Liebherr France)
This typeplate displays the following information:
Product identification number
Type
Construction year
Nominal engine power
Max. speed
Operating mass
Plate 10: Label external start
The information in the operating instructions must be carefully noted when
starting externally.

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Plate 20: Label switchboard

The label switchboard indicates and locates the indicators lights and gauges, and the
control switches.

Plate 21: Label filling volume

The label filling volume indicates the drain and the refilling of the major components
on the service trap, and indicates the fluids quantities (the given quantities are only
guidelines. Check fluid level after each change or refilling).

Plate 22: Label control symbol (with shovel bucket)

Describes the functions of the operating devices which are not labelled for a excava-
tor with a shovel bucket.

Plate 23: Label control symbol (with backhoe bucket)

Describes the functions of the operating devices which are not labelled for a excava-
tor with a backhoe bucket.
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Signs on the machine

Plate 24: Lubrification drawing

Displays the relevant capacities and the change intervals, grease quality, fill and lu-
brication positions.

Plate 25: Label key

The label key displays the keys of the control unit and of the monitoring display.

Plate 26: Label shut off valve

The information in the operating instructions must be carefully noted before first use.

Plate 27: Warning label

IThe information in the operating instructions must be carefully noted.
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Plate 28: Label security lever

Pull the security lever up fully before leaving the operators seat.

Plate 31: Banning label

The engine hood may only be opened when the engine is switched off.

Plate 41: Label safety ladder

This label indicates the safety ladder.

Plate 46: Label emergency stop

This label indicates the emergency stop.

Plate 51: Label manual unlock of the ladder

This label explains how to unlock manually the ladder.

Plate 99: Label "CE"

LEC/en/Edition: 02 / 2015

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 3 Control and operation

3.1 Operating and control elements

3.1.1 Overview of the operators standing position

LEC/en/Edition: 02 / 2015

Fig. 3-1 Operators standing position

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Control and operation Operating manual
Operating and control elements

8 Heater vent S2 Switching unit U15 Central lubrication control

12 Fuse box S57 Swing brake U21 Left joystick
E14 Cigarette lighter S5 Switch / horn U22 Right joystick
H1 Monitoring display S6 Switch / float position U23 Pedal for right travel gear
attachment
S1 "Contact" key S7 Safety lever / servo control U24 Pedal for left travel gear

Fig. 3-2 Operators standing position, seen from the operators point of view

E14 Cigarette lighter S5 Switch / horn

H1 Monitoring screen S6 Switch / float position attachment
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S1 Ignition switch U21Left joystick

S2 Keyboard U22Right joystick

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 Operating manual Control and operation
Operating and control elements

3.1.2 Arrangement of joystick

Fig. 3-3 Joystick, right (3) and left (4)

Standard control
The left joystick (4) controls the stick and slewing movements.
Direction of movement a and b: Stick is drawn in or out.
Direction of movement c and d: Uppercarriage is rotated to the left or to the right.
The right joystick (3) controls the boom or bucket and grab movements.
Direction of movement e and f: Bucket will be tilted up or down, grab will close or
open.
Direction of movement g and h: Boom will be raised or lowered.

Note!
From delivery, the machine is equipped with the standard control system corre-
sponding to the norm ISO. Nevertheless, the machine can be equipped with a com-
mutation circuit allowing the use of a special control system (for example
LIEBHERR control system).
LEC/en/Edition: 02 / 2015

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Operating and control elements

3.1.3 Keyboard

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Fig. 3-4 Excavator keyboard

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 Operating manual Control and operation
Operating and control elements

S10 - Floodlight / Equipment headlight

Press the switch.
Driving light is activated.
LED 1 in the switch illuminates.
Press switch again.
Driving light is deactivated.
LED 1 in the switch goes out.
Equipment headlight is activated.
LED 2 in the switch illuminates.
Press switch again.
Driving light and equipment headlight are switched on.
LEDs 1 and 2 in the switch illuminate.
Press switch again.
Driving light and equipment headlight are switched off.
LEDs 1 and 2 in the switch go out.
S11 Windshield washer installation
Press and hold button.
Washing water will be sprayed onto the windscreen through the outlet nozzles.
The windscreen washer runs continuously.
Release the button.
Washing water will be stopped.
Windshield washer will run continuously for approx. another 3 seconds.
S12 Heater
Press switch.
Heater fan will be switched to stage 1.
LED L in the switch illuminates.
Press switch again.
Heater fan will be switched to stage 2.
LED H in the switch illuminates.
LED L in the switch goes out.
Press switch again.
Heater fan will be turned off.
LED H in the switch goes out.
S14 Windscreen washer
Press switch.
Intermittent setting is activated.
LED I in the switch illuminates.
Press switch again.
Continuous operation is activated.
LED C in the switch illuminates.
LEC/en/Edition: 02 / 2015

LED I in the switch goes out.

Press switch again.
Windscreen washer is switched off.
LED C in the switch goes out.

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Control and operation Operating manual
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S17 Swing gear brake

Press switch.
Slewing gear brake is engaged.
Upper carriage is locked.
LED in the switch illuminates.
Press switch again.
Slewing gear brake is released.
LED in the switch goes out.
S18 Overload warning device (optional extra)
Press switch.
Overload warning device is activated.
LED in the switch illuminates.
Press switch again.
Overload warning device is deactivated.
LED in the switch goes out.
No overload warning device is built in.
Press switch.
The symbol for "No overload warning device is present" appears on the mon-
itoring screen.

LED in the switch illuminates.

Press switch again.
The symbol for "No overload warning device is present" goes out.
LED in the button goes out.
S19 No function

S20 Automatic idling

Press switch.
Automatic idling is activated.
LED in the switch illuminates.
Press switch again.
Automatic idling is deactivated.
LED in the switch goes out.
S21 - High speed gear
Press the switch.
Transfer from normal drive to fast drive is activated.
LED 1 in the switch illuminates.
LEC/en/Edition: 02 / 2015

While driving, the machine will automatically transfer from normal drive to fast drive.
LED 2 illuminates after transfer to fast drive.
Press switch again.
Transfer from normal drive to fast drive is deactivated.
LED 1 in the switch goes out.

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 Operating manual Control and operation
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S22 Additional headlight (optional extra)

Press the switch.
Additional headlight is switched on.
LED in switch illuminates.
Press switch again.
Additional headlight is switched off.
LED in the switch goes out.
S36 Special function 1 (optional extra)
Configuration and activation according to kit.

S41 Dome light

Press switch.
The interior lights are switched on.
Press switch again.
The interior lights are switched off.
S56 No function

S86 Mode selection, speed adjustment

Four 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: FINE mode (speed level 10)
E: ECO mode (speed level 8)
P: POWER mode (speed level 10)
P4 Engine speed display
The speed range of the diesel engine is displayed in 10 levels.

S228 Increase speed

Press switch.
Speed will be increased by one level.
A second LED to the right illuminates in display P4.
S229 Decrease speed
Press switch.
Speed will be decreased by one level.
A second LED from the right goes out in display P4.
S354 No function
LEC/en/Edition: 02 / 2015

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Control and operation Operating manual
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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
H122 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 Switch Quantum error code in/out
H92 Fire alarm
H94 Fuel valve closed Safety operation engine
S149 Ether control (cold starting aid) S74 Safety switch engine FLOW
P4 Engine RPM indicator S73 Safety switch engine POWER
P8 Service batteries voltmeter R6 Engine RPM adjustment
P9 Principal batteries voltmeter S23 Switch revolution
H6 Clock S178 Switch reset shutdown timer

H38_1Indicator empty level P2

H126 Indicator alarm driveway
S84_2Switch centralized lubrication
LEC/en/Edition: 02 / 2015

S126 Additional cabin lighting

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.

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 Operating manual Control and operation
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Monitoring system of the Diesel engine (QSK system)

Indicator lights H60, H61 and H62

Fig. 3-6 Diesel engine QSK 45

All the troubles appearing on the Diesel engine or in its monitoring circuit are centrally
indicated via the indicator lights H60, H61 and H62.
These 3 control lights are connected to the ECM (Electronic Control Module) of the
QSK system, which is mounted to the engine, next to the fuel pump.
Apart from its monitoring function, the QSK fuel system has been designed to control
the engine speed and fuel pressure so to optimise the exhaust emissions.
The red indicator light STOP (H60) lights up when an important fault which could
cause serious engine damage is detected.
If the stoplight comes on while the engine is running, it may be automatically stopped
LEC/en/Edition: 02 / 2015

by monitoring system in case an important trouble is detected.

For the other faults, the monitoring system protects the engine while reducing its
power or RPM.
Also in this case the engine has to be brought to low idle and stopped in a safe man-
ner as soon as possible.
Afterwards recognise the detected error(s) using the diagnostic switches S85, S82_1
and S82_2.
Depending on the kind and severity of the recognised trouble, the system may cause

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Control and operation Operating manual
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automatic engine shutdown, power or speed derating.

The yellow indicator light WARNING (H61) indicates an engine error, which does not
necessitate an immediate engine shutdown.
Recognise the detected error using the diagnostic switches, after stopping the en-
gine.
Get the cause of the problem remedied as soon as is convenient regarding the cause
of the problem. The detected error can result in a power loss.
The red indicator light PROTECTION (H62) shows that any parameter supervised by
the system has come out of its normal operation range.
The engine is automatically stopped by the monitoring system if one of the following
troubles is detected:
Low engine oil pressure.
High coolant temperature.
Low engine coolant pressure.
High intake air manifold temperature.
For some other parameters the monitoring system achieves protection by derating
the engine speed or torque correspondingly.
The engine may be kept in operation temporarily, (eventually the engine power is re-
duced by the monitoring system), the problem must be diagnosed via the switches
S85, S82_1 and S82_2.
Automatic torque derate will happen in case one of the following troubles is detected:
High fuel temperature.
High blow by pressure (= pressure in crankcase housing).
Low coolant pressure (first stage), also causes speed derate.
Low oil pressure (first stage).
High coolant temperature (first stage):
High intake air manifold temperature (first stage).

Diagnostic switches S82_1, S82_2 and S85 for engine monitoring sys-
tem

LEC/en/Edition: 02 / 2015

Fig. 3-7 Control board

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

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 Operating manual Control and operation
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There are two types of fault codes:

The engine electronic system fault codes which will light up the indicator lights
H60 and H61.
The engine protection system fault codes which will light up the indicator light
H62.
All fault codes recorded will either be active (fault code is presently active on the en-
gine) or inactive (fault code was active at some time, but is not presently active).
All active fault codes can be diagnosed as described below using both lamps H60
and H61.
Inactive fault codes can only be viewed with the optional equipment "Insite".
Diagnostic of the detected faults using the switches S82_1, S82_2 and S85.
If an indicator light H60, H61 and H62 is lighting, proceed as follows to recognise the
detected errors:
Turn the ignition key to "OFF" then to "contact" position.
Depress the switch S85 to position "ON", the indicator lamp inside the switch
lights up.
If no active fault codes are recorded, all three lights will come on and stay on.
If active fault codes are recorded, all three lights will come on momentarily and then...
First the yellow lamp H61 will flash one time.
Then the red indicator light H60 will blink, the sequence of blinking corresponds
to the code of the error detected by the system. Between two consecutive blinking
sequences for indication of the fault code, the yellow light H61 comes on.
Also see the section "Diagnostic fault codes" and the chart for diagnostic fault codes
in the Cummins operation and maintenance manual.
The sequence is repeated as long as the switch S85 remains on "ON" position,
the yellow indicator light H61 goes briefly on between two consecutive flashing
sequences.
Remaining errors, which are still detected, can be recognised on the same way,
using the switches S82_1 and S82_2. Briefly depressing the switch S82_1 "INC"
causes the blinking sequence of the error with the code directly above to be dis-
played on indicator light H60, depressing briefly S82_2 "DEC" will display the er-
ror with the code directly below.

Safety operation functions

For further information about correct use of these functions, refer to section
"Emergency operations" of this manual.
LEC/en/Edition: 02 / 2015

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Control and operation Operating manual
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3.1.5 Monitoring display

Fig. 3-8 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
LEC/en/Edition: 02 / 2015

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 Operating manual Control and operation
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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 C = 204F), 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.
LEC/en/Edition: 02 / 2015

H19 No function

H20 No function

H23 No function

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H24 No function

Area D: Menu control for screen

Fig. 3-9 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 operators 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) simultane-
ously.
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.
LEC/en/Edition: 02 / 2015

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. 3-10 Main screen

EC Cable error display SY Symbols

INF Information TI Time

Main screen design

SY field
The upper field of the monitor shows, on the one hand warning and indicator sym-
bols, 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 displayed 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.

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
codes are displayed simultaneously. If there are more than these 7 errors present,
an arrow which points to where the other error codes are located will be displayed
next to the error code window.
Press the Up or Down button.
The error code window will be shifted in the direction selected in the error code
list.

INF field
The INF field displays information temporarily, in both text and graphic form.
If more than 3 symbols are to be displayed, the symbols will shift one symbol to the
left approx. every 10 seconds.
LEC/en/Edition: 02 / 2015

The information is displayed in graphic or text form and indicates specific operating
states on the machine.

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.

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Control and operation Operating manual
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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 sustain-
ing 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 E 5xx.
Each error which occurs will be stored via the relevant error code.

E 501Low engine oil pressure

E 502Coolant 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.
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.
E 503 Engine coolant overheat
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 cool-
ant pressure is too low.
LEC/en/Edition: 02 / 2015

See Cummins Operation 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 man-
ifold temperature is too high (above 104C=220F).
See Cummins Operation Maintenance Manual.
Locate the reason for the trouble and get it repaired.

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 Operating manual Control and operation
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E 506 Oil in splitterbox is overheating

This symbol appears if the oil temperature in the splittebox exceeds 85C (185F)
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.
Turn the engine off.
Find and repair a possible leak.
Add oil until the level is correct.
E 564 High oil level in splitterbox
This symbol appears if the oil level in the splitterbox is above the maximum level.
Turn the engine off.
Find and repair the problem.
It is possible that too much oil has been added, or the oil level might have increased
due to hydraulic oil entering via a defective pump shaft seal.
E 591 Splitterbox oil pressure low
This symbol appears if the splitterbox oil pressure drops below 0.2 bar.
Stop operation and turn the engine off.
Find and correct the problem.
E 504 Low hydraulic oil level
This symbol appears if the oil level in the hydraulic tank drops below the minimum
level. At the same time, the pump are automatically returned to minimum flow.
Turn the engine off.
Find and repair the cause of the oil loss.
Add hydraulic oil via the service flap or via one of the return filters.
E 505 High hydraulic oil temperature
This symbol appears if the hydraulic oil temperature in the tank exceeds 98C
(208F).
Stop operation.
Continue to let the engine run in high idle and wait until the symbol disappears.
If necessary.
Turn the engine off.
Find and correct the problem (oil cooler dirty, blower or thermostat defective, ...).
LEC/en/Edition: 02 / 2015

E 566 - E 567 - E 568 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).
Stop operation and turn the engine off.
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).
Stop operation and turn the engine off.
Notify the maintenance personnel.
E 578 - E 579 - E 580 Main pumps overheat
This symbol appears if the temperature on one of the main pumps increases above
92C (198F) (the pump number appears in the top corner of the symbol).
Turn the engine off.
Find and correct the problem.
E 584 - E 585 Swing pumps overheat
This symbol appears if the temperature on one of the swing pumps increases above
92C (198F) (the pump number appears in the top corner of the symbol).
Turn the engine off.
Find and correct the problem.
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 lev-
el.
See Cummins Operation Maintenance Manual.
Full 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 104C=220F).
See Cummins Operation Maintenance Manual.
Locate the reason for the trouble and get it repaired.
E 594 High fuel rail pressure
This symbol appears simultaneously with the red indicator protection H62 if the fuel
rail pressure exceeds a normal limit .
See Cummins Operation Maintenance Manual.
Locate the reason for the trouble and get it repaired.
E 595 High blow-by pressure
This symbol appears simultaneously with the red indicator protection H62 if the blow-
by pressure exceeds a normal limit .
See Cummins Operation Maintenance Manual.
LEC/en/Edition: 02 / 2015

Locate the reason for the trouble and get it repaired.

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.
See Cummins Operation Maintenance Manual.
Full the engine oil tank.

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 Operating manual Control and operation
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E 598 Oil change required

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

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 (E5xx) has occurred and the buzzer sounds
simultaneously.

Getting information from the operators menu on the main

screen

Main screen menu selection

Fig. 3-11 Main screen

To change to the operators menu, the main screen must be visible.

Press the Menu button on the main screen.
The list of accessible menus is displayed.
LEC/en/Edition: 02 / 2015

Fig. 3-12 Menu selection in the operators menu.

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To select the operators menu:

Press arrow key Down or Up.
The following or previous operators menu will be displayed on screen with a
black background.
The selected menu is displayed with a black background, the Reset daily oper-
ating 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 Overview of menu options

Reset daily operating hours counter menu

The daily operating hours counter can be reset to 0 using this menu.
LEC/en/Edition: 02 / 2015

Fig. 3-13 Resetting the daily operating hours counter

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 Operating manual Control and operation
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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.
The submenu will be aborted.

Confirm service interval menu

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

Fig. 3-14 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.
The current operating hour will be confirmed as the last service interval carried
out.
Service work not carried out.
Press the Back button.
LEC/en/Edition: 02 / 2015

The submenu will be aborted.

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, quantity 2 is active if the specified attachment is serviced.

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Fig. 3-15 Work equipment quantity limitation menu

Press the Up or Down arrow key.

A different, predefined quantity (1-4) can be assigned (e g. when work equip-
ment is changed).
Press the Menu button.
The selection is confirmed. The arrow displays the current selection.

To exit the menu:

Press the Back button.
The submenu will be aborted.

Operating hours menu

Pages 1 to 2 provide an overview of the operating hours of individual units, process-
es and operating types.

Fig. 3-16 Engine service life menu (example)

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
LEC/en/Edition: 02 / 2015

Swing movements
Travel movements
Diesel at low idle

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 Operating manual Control and operation
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Fig. 3-17 Operating hours menu

Press the Menu button.

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

Fig. 3-18 Technical data

Press the Menu button again.

Page 3 is displayed.
The technical data menu, page 3, provides information on :
The excavator type, including type and serial number (type, series)
The design condition of the control which is currently built in (ver)
The current operating voltage (volt)
Press the Menu button again.
Page 1 is displayed.

To exit the menu:

Press the Back button.
The submenu will be aborted.
LEC/en/Edition: 02 / 2015

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Status of hydraulic pumps and electrical inputs and outputs menu

Fig. 3-19 Quantum system menu

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

Fig. 3-20 Quantity limitation menu

Press the Menu button again.

Page 2 is displayed.
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.
LEC/en/Edition: 02 / 2015

Fig. 3-21 LR magnet menu

Press the Menu button again.

Page 3 is displayed.

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 Operating manual Control and operation
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The present LR solenoid current (current value for power control) is showed on
screen 3.

Fig. 3-22 Fan speed current values menu

Press the Menu button again.

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

Fig. 3-23 Electrical inputs

Press the Menu button again.

Page 5 is displayed.
LEC/en/Edition: 02 / 2015

Press the Menu button again.

Page 6 is displayed.
Press the Menu button again.
Page 7 is displayed.
Pages 5, 6 and 7 provide an overview of the status of different electrical inputs.
A means "Input not active".
A means "Input active".

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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:

Press the Back button.
The submenu will be aborted.

Error menu (operating errors and electrical system errors)

Fig. 3-24 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 back-
ground.
Press the Menu button.
LEC/en/Edition: 02 / 2015

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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 Operating manual Control and operation
Operating and control elements

Machine error list Exxx:

Fig. 3-25 Error list (Fig. left) and Error occurrence (Fig. right) menu

Select list Exxx.

Press the Menu button.
The first page of the submenu appears.
All errors and their error codes are listed on the first page.
Use the Down or Up arrow key to select the error code desired.
Press the Menu button again.
The second page of the submenu appears.
Operating hours and the duration of the first and last ten occurrences of the error se-
lected will be listed on the second page.
Press the Back button.
The first page of the submenu appears.
Press the Back button again to select another error type or press the Down or Up
arrow key to select a new error code.
s*: Error was indicated by a buzzer and was acknowledged using the Back button.
The duration is given in seconds.
m*: Error was indicated by a buzzer and was acknowledged using the Back button.
The duration is given in minutes.

Note!
Only operating errors with an error code E 5xx will be displayed in the list Exxx
menu.

Cable error list E-elec.:

LEC/en/Edition: 02 / 2015

Fig. 3-26 Occurrence of electrical error (Fig. left) and Error statistics (Fig. right)

Select Cable error list E-elec.:

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Control and operation Operating manual
Operating and control elements

Press the Menu button.

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

Other errors list S-Exxx:

Fig. 3-27 Call up service operation error list menu

Selecting "list S-Exxx" also shows the errors according to the list in pages, 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.
LEC/en/Edition: 02 / 2015

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3 - 28 R 9250 / 10069862
MJFCIFSS
 Operating manual Control and operation
Operating and control elements

3.1.7 Monitoring cameras

Fig. 3-28 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
operators field of view with the operating environment:
camera 1: on the opposite side of the cab,
camera 2: on the counterweight.
LEC/en/Edition: 02 / 2015

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. 3-28).

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MJFCIFSS
Control and operation Operating manual
Operating and control elements

Full screen

Fig. 3-29 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!
LEC/en/Edition: 02 / 2015

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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3 - 30 R 9250 / 10069862
MJFCIFSS
 Operating manual Control and operation
The access and the outfit of the cab

3.2 The access and the outfit of the cab

Safely getting up
Proceed with the the same precautions to climb up or down onto the machine, as
to install yourself at the operators 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 partic-
ular, you should ensure that they are free of dirt, oil, ice and snow.
NOTE: To ensure that the doors open properly in all weather conditions, the door
seals must be dusted with talc or silicon at least every two months or more often
if required. The door hinges and locks should be greased regularly.
Face the machine when getting in or out and always use three-point support, i.e.
two hands and one foot or two feet and one hand must always be in contact with
the access system at the same time.
If you are able to reach the door handle with your free hand, open the doors 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 in-
stuctions 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
operators 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 operators seat and fasten the safety belt (if available) before tilt-
ing down the safety lever, and start the machine.

Safely getting down

Proceed with the the same precautions to climb up or down onto the machine, as
to instal yourself.
LEC/en/Edition: 02 / 2015

Stop the machine on level, horizontal ground. The upper structure should be po-
sitioned with the undercarriage in such a way that the steps and ladders are
aligned with each other.
Open and lock the door. Be sure of its 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

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Control and operation Operating manual
The access and the outfit of the cab

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
leaving the cab.
Always use the handholds provided for the purpose when entering or leaving the
machine.
Face the machine when getting in or out and always use three-point support, i.e.
two hands and one foot or two feet and one hand must always be in contact with
the access system at the same time.
Never use the control elements as handles.
Never jump from the machine.

LEC/en/Edition: 02 / 2015

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MJFCIFSS
 Operating manual Control and operation
The access and the outfit of the cab

Cab:

Fig. 3-30 Climb up using the handholds

LEC/en/Edition: 02 / 2015

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Control and operation Operating manual
The access and the outfit of the cab

Getting in

Fig. 3-31 Access ladder

If the ladder is in its lowest position and the excavator isnt running, you can climb up
on the machine.
Climb in with the ladders and with your face towards the ladders and use the pro-
LEC/en/Edition: 02 / 2015

vided handholds.
On the cabin catwalk, open the door.
Go in the cabin and sit in the operators seat
Adjust the seat if necessary.

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MJFCIFSS
 Operating manual Control and operation
The access and the outfit of the cab

Getting out

Caution!
Entering or leaving the cab incorrectly could lead to injury.
Proceed with the same attention on exit or entry of the cab, as while climbing the
machine.
Ensure that the safety lever is always in its highest position when entering or
leaving the cab.
Always use the handholds provided for the purpose when entering or leaving the
machine.
Face the machine when getting in or out and always use three-point support, i.e.
two hands and one foot or two feet and one hand must always be in contact with
the access system at the same time.
Never use the control elements as handles.
Never jump from the machine.

Switch off the machine and push the safety lever up.
Open the door fully.
Go out of the cabin on the cabin catwalk.
Close the door;
Go down with your face towards the ladders, and use the appropriate handholds.

Access ladder
LEC/en/Edition: 02 / 2015

Fig. 3-32 E1022-1 Control box / access ladder

H67Control light red / ladder not locked S155Push-button / access ladder up

H68Control light red / ladder not in S156Push-button / access ladder lock-
upper stop position ing

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Control and operation Operating manual
The access and the outfit of the cab

S125Switch / lighting of cab access S157Push-button / access ladder

unlocking
S141Switch / lighting of main ladder S158Push-button / access ladder down

Fig. 3-33 Control panel

The access ladder can be swung either into lower position to permit access to the
uppercarriage or into upper position during operation via an hydraulic cylinder.
Before operating the machine, the ladder must be fully raised to the uppercarriage
and locked in place.
The ladder can be extended and retracted from the uppercarriage via the control box
E1022-1, which is installed to the catwalk next to 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 S157 to unlock the ladder (the red indicator light H68 will go on).
Push the switch S158 to swing the ladder until it has reached the lowest position
(the red indicator H67 is on).
To bring the ladder into upper position (working position):
Push the switch S155 until the ladder has reached its top position (i.e. the red in-
dicator light H67 goes out).
Push the switch S156 to lock the ladder (when locked the red indicator light H68
goes out).
Caution!
LEC/en/Edition: 02 / 2015

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 but-
ton S122 at the right front of the control panel.
The ladder can only be locked after it has reached its upper stop position (H67 is off).
The ladder can only be swung up or down when the locking device is in unlocked po-

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 Operating manual Control and operation
The access and the outfit of the cab

sition (H68 is on).

3.2.2 Safety lever

Fig. 3-34 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 joy-
stick 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
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 operators seat.
LEC/en/Edition: 02 / 2015

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Control and operation Operating manual
The access and the outfit of the cab

3.2.3 Operators seat

Fig. 3-35 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 operators 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.

LEC/en/Edition: 02 / 2015

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3 - 38 R 9250 / 10069862
MJFCIFSS
 Operating manual Control and operation
The access and the outfit of the cab

Setting the armrests

Fig. 3-36 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

LEC/en/Edition: 02 / 2015

Fig. 3-37 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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MJFCIFSS
Control and operation Operating manual
The access and the outfit of the cab

Setting the horizontal seat position

Fig. 3-38 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, switch-

ing on the seat heating (air-cushioned operators seat, op-
tional extras)

Fig. 3-39 Switch bar on the air-cushioned operators seat

To set the vibration damping:

Press button 5 (+ or -) and set the vibration system according to body weight.
LEC/en/Edition: 02 / 2015

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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3 - 40 R 9250 / 10069862
MJFCIFSS
 Operating manual Control and operation
The access and the outfit of the cab

Putting on / releasing the safety belt

Fig. 3-40 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
regularly 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

LEC/en/Edition: 02 / 2015

Fig. 3-41 Auxiliary seat

The lever 1 serves to lock the auxiliary seat into position either beside the operators
seat or against the cabs wall.

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Control and operation Operating manual
The access and the outfit of the cab

To rotate the seat,

Pull the lever 1.
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 cabs wall.

3.2.5 Sunshade

Fig. 3-42 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.
LEC/en/Edition: 02 / 2015

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 - 42 R 9250 / 10069862
MJFCIFSS
 Operating manual Control and operation
The access and the outfit of the cab

3.2.6 Emergency exit

rear door

Fig. 3-43 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 weather-
LEC/en/Edition: 02 / 2015

strip 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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Control and operation Operating manual
The access and the outfit of the cab

3.2.7 Interior lightings

Fig. 3-44 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 be-
tween the two windows.

LEC/en/Edition: 02 / 2015

Fig. 3-45 Fire extinguisher fixing location

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3 - 44 R 9250 / 10069862
MJFCIFSS
 Operating manual Control and operation
The access and the outfit of the cab

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

LEC/en/Edition: 02 / 2015

When the ignition is switched on, pressing button S11 will activate the electric wind-
screen 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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MJFCIFSS
Control and operation Operating manual
The access and the outfit of the cab

Windscreen washing fluid container

Fig. 3-46 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

LEC/en/Edition: 02 / 2015

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3 - 46 R 9250 / 10069862
MJFCIFSS
 Operating manual Control and operation
The access and the outfit of the cab

3.2.10 Field of view

Fig. 3-47 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
operators 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
LEC/en/Edition: 02 / 2015

standing out of the hatched area illustrated on the fig. above.

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,

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Control and operation Operating manual
The access and the outfit of the cab

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 defined by the four checkpoints given on the fig.
above.

3.2.11 Lighting

Fig. 3-48 Arrangement of lighting

LEC/en/Edition: 02 / 2015

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 Operating manual Control and operation
The access and the outfit of the cab

Fig. 3-49 Arrangement of lighting for the uppercarriage

E1_1Fuel tank floodlight E6_3Cabin catwalk floodlight

E1_2Fuel tank floodlight (option, not E6_4Cabin catwalk floodlight (option,
represented) not represented)
E1_3Fuel tank floodlight E8_1Under uppercarriage floodlight
E1_4Fuel tank floodlight (option, not (option, not represented)
represented) E8_2Under uppercarriage floodlight
E2_1Equipment floodlight (option, not represented)
E2_2Equipment floodlight E18_1Counterweight floodlight (option)
E3_1Equipment floodlight
E3_2Equipment floodlight E18_2Counterweight floodlight (option)
E4_1Equipment floodlight (option, not E21Top of cabin floodlight
represented)
E4_2Equipment floodlight (option, not E23_1Counterweight floodlight (option)
represented)
E5_1Equipment floodlight (option, not E23_2Counterweight floodlight (option)
represented)
LEC/en/Edition: 02 / 2015

E5_2Equipment floodlight (option, not E58_1Top of cabin floodlight

represented) E58_2Top of cabin floodlight
E6_1Cabin catwalk floodlight E59Top of cabin floodlight
E6_2Cabin catwalk floodlight (option,
not represented)

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Control and operation Operating manual
The access and the outfit of the cab

Equipment lights, fuel tank lights, catwalk lights and top of

cabin lights
The fuel tank lights (E1_1, E1_2, E1_3 and E1_4), the catwalk lights (E6_1, E6_2,
E6_3 and E6_4) and the top of cabin lights (E58_1 and E58_2) are the driving lights.
The driving lights and the equipment headlights (E2_1, E2_2, E3_1, E3_2, E4_1,
E4_2, E5_1 and E5_2) are switched on by pressing switch S10.
Press the switch.
Driving lights are activated.
LED 1 in the switch illuminates.
Press switch again.
Driving light are deactivated.
LED 1 in the switch goes out.
Equipment headlights are activated.
LED 2 in the switch illuminates.
Press switch again.
Driving lights and equipment headlights are switched on.
LEDs 1 and 2 in the switch illuminate.
Press switch again.
Driving lights and equipment headlights are switched off.
LEDs 1 and 2 in the switch go out.

Counterweight headlights and under uppercarriage lights

(optional extra)
E8_1 and E8_2 are the under uppercarriage lights, and E18_1, E18_2, E23_1 and
E23_2 are the counterweight headlights.
Pressing switch S22 when the ignition is on switches on the Counterweight head-
lights and the under uppercarriage lights.
Press the switch.
Counterweight headlights and the under uppercarriage lights are switched on.
LED in switch illuminates.
Press switch again.
Counterweight headlights and the under uppercarriage lights are switched off.
LED in the switch goes out.

3.2.12 Heating/air conditioning system

A heater and an air conditioner are installed in the cab as standard equipment.
The heater is installed on the cab floor. The evaporator for the air conditioning sys-
tem is integrated in the roof of the cab, and the condenser is installed on the engine
cooling radiator.
LEC/en/Edition: 02 / 2015

Note!
Depending on the excavators, two types of heating / air conditioning system can be
installed:
A system with potentiometric control panel.
A system with push-button control panel.

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 Operating manual Control and operation
The access and the outfit of the cab

Fig. 3-50 Potentiometric and push-button control panels

1 Potentiometric control panel

2 Push button control panel

Potentiometric control unit

Front panel

Fig. 3-51 Control unit location on control board

LEC/en/Edition: 02 / 2015

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Control and operation Operating manual
The access and the outfit of the cab

Fig. 3-52 Potentiometric control unit

S1 Rotary switch / necessary airflow

S2 Rotary switch / necessary air temperature

Cab airflow

Fig. 3-53 Shut off valves

LEC/en/Edition: 02 / 2015

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 Operating manual Control and operation
The access and the outfit of the cab

Fig. 3-54 Airflow levers

Fig. 3-55 Heater button

Fig. 3-56 Air openings in the cab

The heater and the air conditioner can be used at the same time and independently
for the airflow of the cab.
LEC/en/Edition: 02 / 2015

To make the airflow through the heater:

For cab airflow during the summer time, the two coolant shut off valves 5 which
join the Diesel engine to the cab must be closed.
Push fully the lever 1 forward.
The water supply is closed.
Push button S12 to select necessary airflow.
The new air enters into the cab through openings on the steps and through the
vents on the left and right front.

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Control and operation Operating manual
The access and the outfit of the cab

Move the lever 2 to adjust the quantity of new air / recirculated air coming into the
cab.
If lever 2 is pushed forward, the fan recirculates the air in the cab.

To make the airflow through the potentiometric control unit:

The airflow in the cab is done through the evaporator in the cab roof.
Turn the air conditioner to off through button S2.
Turn the blower fans to on.
Set the necessary airflow through the rotary switch S1 and the vents of the evap-
orator.

Heater operating instructions

Open the coolant shut off valves 5 on the Diesel engine.
Move the lever 1:
The quantity of water running through the heat exchanger can be adjusted.
If the regulator is fully pushed to the rear, the maximum quantity of coolant
flows to the heater.
Set the necessary airflow through button S12.
Move the lever 2:
The quantity of new air recirculated and entering the cab is adjusted.

Note!
The best heating effect can be got when the air is recirculated, which means the
lever 2 must be fully pushed forward.
In this position, a small quantity of external air is mixed with the recirculating air in
the cab.

To quickly defrost the windshield:

Point the warm airflow through the vents to the front.
Fully push the sliding regulator 3 to the rear.
The maximum airflow is blown through the vents in the step onto the wind-
shield.
When the lever 3 is fully pushed forward, part of the warm airflow is blown against
the left side window. LEC/en/Edition: 02 / 2015

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3 - 54 R 9250 / 10069862
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 Operating manual Control and operation
The access and the outfit of the cab

Air conditioning operating instructions

Fig. 3-57 Vents on the evaporator unit

To adjust the air conditioner fan:

The Diesel engine is running.
Use button S1.

To turn on the air conditioning compressor and the condenser fan:

The air conditioning can only be turned on if the evaporator fan unit is turned on
through button S1.
Use button S2.

To set the necessary airflow:

Use the rotary switch S1.

To set the necessary air temperature:

Use the rotary switch S2.

To adjust the direction of the cold airflow:

Use the vents on the evaporator unit.

To operate the air conditioning during the summer time:

We recommend to close the coolant shut off valves on the Diesel engine.
Fully push the lever forward.
Turn the heater blower to off through button S12.
LEC/en/Edition: 02 / 2015

To dehumidify the air in the operators cab:

This procedure must be performed in case of very high humidity inside the cab
during the colder season.
The air conditioning can be operated for a short time at the same time with the
heater in order to remove the unwanted humidity and the condensation.
For best efficiency, set a high evaporator airflow through the rotary switch S1 and
operate the heater with recirculated air.

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Control and operation Operating manual
The access and the outfit of the cab

Push-button control unit

Front panel

Fig. 3-58 Control unit location on the left support

LEC/en/Edition: 02 / 2015

Fig. 3-59 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

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 Operating manual Control and operation
The access and the outfit of the cab

Manuel setting "downwards" 13 Blower manual speed bar

4 Control unit ON/OFF 14 Manual blower mode indicator
5 Evaporator blower speed manu/auto 15 Heating mode indicator
6 Reheat ON/OFF 16 Drivers cabin indicator
7 Heating ON/OFF 17 Temperature set value / error code
8 Fresh air / recirculated air mode 18 Temperature unit
19 LCD Display

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

Operating the heating/air-conditioning control unit

To switch 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.

To set the temperature:

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.

To switch ON/OFF the air conditioning unit:

Press button 1.
Air conditioning mode is operated.
Symbol 11 appears on display 19.
Press button 1 again.
Air conditioning mode is deactivated.
Symbol 11 disappears from display 19.
LEC/en/Edition: 02 / 2015

Note!
In case of high outside temperature, and especially if the cab has been heated up
by the sun, decrease the temperature inside the cab as far as possible before turn-
ing on the air conditioner.
Open the windows for a few minutes and adjust blower speed to maximum
speed via buttons 5 and 2.

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Control and operation Operating manual
The access and the outfit of the cab

To switch ON/OFF the reheat mode:

In order to achieve a quick dehumification of the cab when setting the machine into
operation, it may be advisable to briefly turn on the air conditioning operation when
the heater is already operative.
Press button 6.
Reheat mode is operated.
Symbol 10 appears on display 19.
The blower speed is raised to 100%. If necessary the control unit switches the
heating on, to hold ambient temperature at the desired value.
Press button 6 again.
Reheat mode is deactivated.
Symbol 10 disappears from display 19.

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

Reheat mode is automatically limited on 10 minutes.

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

To set the evaporator blower speed manually:

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

To switch ON/OFF the heating mode:

Press button 7.
Heating mode is operated.
Symbol 15 appears on display 19.
Press button 7 again.
LEC/en/Edition: 02 / 2015

Heating mode is deactivated.

Symbol 15 disappear from display 19.

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 Operating manual Control and operation
The access and the outfit of the cab

To set fresh air / recirculated air mode:

Press button 8.
Control unit switches from fresh air to recirculated air mode.
Fresh air flap is closed.
Symbol 9 appears on display 19.
Press button 8 again.
Control unit switches from circulated air to fresh air mode.
Fresh air flap is open.
Symbol 9 disappear from display 19.

To switch 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)

A dual air conditioning system can be installed on the excavator.
At the excavator starting up, the automatic dual air conditioning is activated by de-
fault. The two air conditioning units are working alternately every 6 hours.
LEC/en/Edition: 02 / 2015

Fig. 3-60 S26 button on control board

Press "Dual air conditioning" button S26 on control board.

Automatic air conditioning mode is deactivated.
First air conditioning unit is activated.
Second air conditioning unit is deactivated.

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Control and operation Operating manual
Setting the machine into operation

Press button again.

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

3.3 Setting the machine into operation

Bringing the machine safely into service

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

Adjusting the operators standing position

Before starting the machine, adjust the seat, mirrors, armrests and operators
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 seats damping action and adjustment mechanisms regularly and en-
sure that these seat characteristics remain as per the seat manufacturers in-
structions.

Utilisation in confined spaces

Only operate combustion engines and fuel-operated heaters in adequately venti-
LEC/en/Edition: 02 / 2015

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 operators 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 drivers seat.

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 Operating manual Control and operation
Setting the machine into operation

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.
Use the stop bolts to secure the upper structure facing the undercarriage, if avail-
able.
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 unpermitted use and vandalism.

3.3.1 Starting / stopping the machine

General information

Note!
When using the machine at a specific height above sea level and in connection with
certain outside temperatures, the performance and service life of the diesel engine
with turbocharging is decisively affected.
Under these conditions, there is also an increased risk of the coolant circuit and the
hydraulic oil overheating.
LEC/en/Edition: 02 / 2015

To avoid damaging CUMMINS diesel engines, the engines power must be reduced
when operating in the following environmental conditions (sea level and exterior tem-
perature):
see the Cummins operation and maintenance manual.

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Control and operation Operating manual
Setting the machine into operation

Activities before starting

Caution!
It is only possible to extinguish a source of fire if it is accessible.
Before starting, unlock all locks on the panelling of the hydraulic excavator.
In the event of fire, the doors can be opened immediately and the fire extin-
guished.

Arrangement of locks: see Maintenance chapter

Caution!
With the activities referred to below, a machine that is already warm from operating,
there is a risk of scalding or burning from hot coolant or oil.
Please ensure that you read the information provided in the Maintenance chap-
ter on carrying out these activities.

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 cool-
ing and combustion air intake.
* For how to carry out the activities, see the Maintenance chapter.

Starting the diesel engine

Ignition key switching positions

Fig. 3-61 Ignition switch

LEC/en/Edition: 02 / 2015

0 Off 2 Not used P Park position

1 Contact position 3 Start position

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 Operating manual Control and operation
Setting the machine into operation

Switching on the electrical system

Fig. 3-62 Main battery switch

The main battery switch S9_1 must be in position open. This battery switch is in
the motor room near the splitterbox.

Fig. 3-63

Turn the ignition key to contact position 1.

Immediately after turning the system on, the display and the control unit will
run through a self test.
Make sure all indicators function properly after turning the electrical system on,
i.e. the light emitting diodes (indicator lights and gauges) turn on for a short
time then the complete field of the LCD indicator 200 turns momentarily black
(the matrix indicator is energised completely for a short time).
Only the diode in the button S22 turns not on that time.

Note!
LEC/en/Edition: 02 / 2015

If no automatic check of the keypad and monitoring screen is carried out when the
ignition key is in the contact position, check that the main battery switch is set to on.

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Setting the machine into operation

Service interval display

Fig. 3-64 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 ser-
vice 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, be-
fore restarting the engine.
And repeat the starting procedure at 20 seconds intervals to allow the starter
motor to cool off.

According to the exterior temperature, the starting procedure is different.

Above 0C:
Refer to the chapter "Starting procedure when the exterior temperature is above
0C".
Between 0C and -18C:
Refer to the chapter "Starting procedure when the exterior temperature is below
0C".
Below -18C:
Refer to the chapter "Starting procedure when the exterior temperature is below
-18C".
LEC/en/Edition: 02 / 2015

Starting procedure when the exterior temperature is above 0 C

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 pre-lubrication pump stops and
the principal starter starts the Diesel engine.

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 Operating manual Control and operation
Setting the machine into operation

To start the engine:

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.

Starting procedure when the exterior temperature is below 0 C

Fig. 3-65 Control unit

A cold start system is standard equipment on the engine, which makes it easier to
start at low temperatures.

To actuate the cold start system:

Press the button SF1 (S36) on the control unit.
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 mani-
fold.
As soon as the engine turns over, release the button (once the engine is turning,
the button is automatically locked).

Engine after ignition

Turn the ignition key to position 2 as soon as the engine is running after the start-
ing procedure.
Symbol appears on the main screen.
Release the ignition key.

Note!
Do not preheat an engine which is at operating temperature.
LEC/en/Edition: 02 / 2015

Starting procedure when the exterior temperature is below -18 C

For starting at temperatures below -18 C, it is recommended to equip the machine
with a preheating system in accordance with LIEBHERR. The starting procedure with
this system is described further in this section.

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Setting the machine into operation

Speed adjustment and mode functions

Fig. 3-66 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 switch S86.

Performance selection (adjustment) using the mode button

Four different modes can be selected by pressing switch S86.
L: LIFT mode (speed level 5 sensitive lifting of loads)
F: FINE mode (speed level 10 skimming work)
E: ECO mode (speed level 8 economical work)
P: POWER mode (speed level 10)

Using the arrow keys to adjust speed

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:

LEC/en/Edition: 02 / 2015

Press switch S229.

Speed will be decreased by one level.
A second LED from the right goes out in display P4.
A flashing LED above switch S86 identifies an intermediate stage of the mode select-
ed.
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
flashing LED above switch S86 the next time the engine is started.

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 Operating manual Control and operation
Setting the machine into operation

The speed preselected after the diesel engine has been started will either be at level
1 (low idle on the diesel engine) or at level 3, if a warm-up phase is required for the
diesel engine.
Press the mode switch S86.
The mode selected will be used, with the corresponding speed and power.
The appropriate LED will illuminate permanently.
In mode E (maximum torque) and P, the diesel engine works at maximum power. In
mode L and F, the hydraulic power is reduced.

Warm-up procedure for Diesel engine and hydraulic circuit

If the excavator is started when the exterior temperature is below 0C, the operator
must do the warm-up procedure:
Make sure that the hydraulic oil temperature is sufficient (refer to lubricating sec-
tion in chapter 5) to do this procedure. If this temperature is not sufficient when a
preheating system is installed on the excavator, keep preheating.
With cold engine coolant (temperature below 20 C), the speed is automatically
set at level 3. This procedure lasts until the coolant has reached 20 C, but for a
maximum of 3 minutes.

Caution!
Idling for an extended period of time damages the engine.
Switch off the diesel engine if the machine is not being used.

Step 1 - Open louvers and tarpaulins (if installed).

Step 2 - Slowly increase the engine load until the coolant temperature reaches
40C, i.e. second green lighting diode goes on on the temperature gauge P2.
Step 3 - Carefully activate the working hydraulic circuits. Do not reach end posi-
tions of piston rod. Operate all movements at reduced speed:
Smoothly lift up attachment.
Slowly activate each cylinder of the attachment. Activate cylinder in order below
and repeat 10 times before moving to next cylinders:
Shovel flap cylinders (in case of shovel attachment)
Bucket tilt cylinders
Stick cylinders
Boom cylinders
Slowly swing clockwise and counterclockwise on approximately 1/2 turn. Repeat
4 times in each direction.
Step 4 - Repeat step 3 a second time.
Step 5 - Repeat step 3, with reaching end position of piston rod.
Step 6 - Repeat step 5 a second time.
Step 7 - Check oil temperature in hydraulic tank. If oil temperature is under 10C,
LEC/en/Edition: 02 / 2015

repeat step 5 until oil temperature reaches 10C. If oil temperature is above 10C,
move to step 8.
The step 8 that follows is applicable only to crawler excavators.
Step 8 - Start the travel hydraulic circuits very slowly forward and backward on
approximately 10 meters. Repeat 4 times.
During the warm-up procedure, the pump power is automatically limited when the hy-
draulic oil is cold (temperature below 10 C).
As soon the hydraulic oil temperature rises above 10 C, the machine can attain full

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Setting the machine into operation

power.
The excavator can now be operated.

Notes after starting the engine

Danger!
Danger of suffocation.
When operating in enclosed spaces, only run the engine in areas with sufficient
ventilation.
Open doors and windows to ensure sufficient supplies of fresh air.

Caution!
Bring the engine and hydraulic oil up to operating temperature. The controls op-
erate sluggishly at low oil temperatures.
Move the machine carefully in an open space to test the function of the chassis
and slewing gear brakes.
Check that the equipment is operating perfectly.

Switching off the diesel engine

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

First use arrow key S229 to set the engine speed to low idle.
Only the LED on the furthest left is now lit on display P4 (engine speed).
Allow the diesel engine to run continuously in low idle for another 2-3 minutes.
Now turn the ignition key to position 0 in order to switch off the engine.
Remove the ignition key.

3.3.2 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-
LEC/en/Edition: 02 / 2015

vices are supplied by an electric module (refer to section "Preheating components").

This module is installed in an additional electric box E1049 in the cabin elevation. In
order to be supplied externally, this cabin elevation has a socket for a generator set
(Gen-Set, not provided with the excavator).
When the Get-Set is connected, the module is supplied.

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 Operating manual Control and operation
Setting the machine into operation

Caution!
The Diesel engine can be started during the preheating but travel and swing move-
ments are not allowed.

The warning light H103 on the control board will come on when the preheating is ac-
tivated.

Preheating components

-30C low temperature kit

The Gen-Set must provide at least 35 kVA, 400 V, 50 Hz.
This kit must be activated every time the excavator is standing with external tem-
perature between -30C and 0C and weekend or service and maintenance day.
The module supplies the components that follows:
engine cooling water equipment
engine oil immersion heaters
hydraulic oil immersion heaters in suction pipe
splitterbox immersion heaters
battery heating blankets
electrical box preheater
electric cabin heater
hydraulic oil immersion heaters in hydraulic tank

-40C low temperature kit

The Gen-Set must provide at least 51 kVA, 400 V, 50 Hz or 51 kVA, 480 V, 60 Hz
according to the version installed.
This kit must be activated every time the excavator is standing with external tem-
perature between -40C and 0C and weekend or service and maintenance day.

Additionally to the -30C kit devices, the module supplies the added
components that follows:
heating and flushing unit
additional heater blower

Optional components
Following devices can be installed in addition to the previous kits:
grease tank heating
ether start aid
thermal insulation kit (including louvers, insulated PowerPack doors)
LEC/en/Edition: 02 / 2015

preheating pedal plate and footrests

snow protection for air filter

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Control and operation Operating manual
Setting the machine into operation

Preheating procedure

Note!
If the excavator is switched off and the ambient air temperature is above -10C, or
if the excavator is turned off less than one hour and the ambient air temperature is
below -10C (e.g. for daily maintenance):
Follow standard procedure to park the excavator.
Start the excavator by following the starting procedure when the exterior temper-
ature is below 0C.

Measures to be taken before Diesel engine stop or before to start the

preheating procedure

Fig. 3-67 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.
If installed, shut louvers.
If installed, use the snow protection for air filter.

Preheat the excavator

Plug Gen-Set into socket for the module on the cabin elevation.
Power supply indicator light comes on on the electric cabinet.
Preheating cycle for module starts.

Operate the excavator

Make sure Diesel engine coolant temperature is in good conditions.
Start the Diesel engine.
At this step, no travel or swing movement are possible. Attachment movements are
limited.
Do the warm-up procedure for Diesel engine and hydraulic circuit (given previous-
ly in this chapter).
LEC/en/Edition: 02 / 2015

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 Operating manual Control and operation
Setting the machine into operation

Note!
If the attachment is equipped with bypass valves and if the ambient temperature is
below -30C:
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.

Stop the preheating

Unplug Gen-Set from socket on cabin elevation.
Power supply indicator light on the electric cabinet goes off.

3.3.3 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
LEC/en/Edition: 02 / 2015

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.

3.3.4 Emergency operations

Engine shut down procedure

Fig. 3-68 Excavator keyboard

Do not suddenly turn the engine off when it is running at high idle.
Reduce the engine RPM to low idle via the arrow key S229.
Continue to run the engine for 3 - 5 minutes to lower temperature.
Then turn the ignition key to the "0" position to turn the engine off and remove the
key.

LEC/en/Edition: 02 / 2015

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 Operating manual Control and operation
Setting the machine into operation

Emergency shut down

Fig. 3-69 Cabin emergency off switch

For emergency shut down :

Turn the starter key to the "0" position or push one of the emergency off switches
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!
Use this shut off method only in emergencies. After an emergency shut down, it is
very important to let the engine run again for a short time at low idle after restarting.

Using one of the emergency off switches S100-1, S100-2, S100-3, S100-4 or
S100-5 will cause the hydraulic tank to be depressurised quickly.
After a shut down via an emergency off switch, you must unlock it before attempt-
ing to restart.
Caution!
You must wait at least ten minutes after an emergency shut down before attempting
to restart.
LEC/en/Edition: 02 / 2015

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Setting the machine into operation

Emergency operation of the Diesel engine

Fig. 3-70 Control board

If the engine can not be started, monitored or operated safety due to a functional
problem in the control electronic of the excavator, the Diesel engine operation can
be continued via the emergency control function.
To turn on the emergency control circuit for Diesel engine
Use button S23.
When the emergency control is turned on, the indicator light in the button is on.

Start the Diesel engine

Turn the throttle control knob R6 fully counterclockwise to low idle RPM.
Then the starting procedure is the same as during the normal starting procedure.
Release the key as soon as the engine starts.
Note!
The engine can not be cranked for more than 10 seconds.
If the engine does not start, wait 20 seconds before restarting.

When the emergency control circuit is turned on, the engine control switches S20,
S70 and S86 are not functioning.
All remaining switches on the control panel remain fully functional, if they are not
affected by existing problem.
LEC/en/Edition: 02 / 2015

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 Operating manual Control and operation
Setting the machine into operation

Monitoring the engine

Fig. 3-71 Indicator P4

In emergency function, the indicator P4 remains fully functional and must be moni-
tored regularly and carefully, because all remaining indicators and warning symbols
may no longer be reliable (depending on the problem) or fully functional.

Turn the Diesel engine off

Caution!
Do not suddenly turn the engine off when its running at high idle.

Reduce the engine RPM via the rotary switch R6 to low idle.
Continue to run the engine for 3-5 minutes to lower the temperature.
Then turn the ignition key to the "0" position to turn the engine off and remove the
key.

3.3.5 Driving

Driving straight ahead

LEC/en/Edition: 02 / 2015

Fig. 3-72 Driving straight ahead

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MJFCIFSS
Control and operation Operating manual
Setting the machine into operation

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).

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. 3-73 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).
LEC/en/Edition: 02 / 2015

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 Operating manual Control and operation
Setting the machine into operation

Turning with a crawler

Fig. 3-74 Turning with a crawler

Turning to the left (A):

Push the right pedal forwards (6a).

Turning to the right (B):

Push the left pedal forwards (5a).

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

Controlling the speed

The driving speed is influenced by switch S21. The travel motors can be operated in
two different positions:
Normal drive (position 1):
Maximum tensile force of both drive units at moderate speed.
Fast drive (position 2):
Reduced tensile force of both drive units at maximum speed.
Press switch S21.
Transfer from normal drive to fast drive is activated.
LED 1 in the switch illuminates.
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 switch S21.
Transfer from normal drive to fast drive is deactivated.
LED 1 in the switch goes out.
LEC/en/Edition: 02 / 2015

When switch 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
brake.
Disengage the pedals for the drive units.
The pedals will return to the neutral position.
The travelling mechanism will be stopped.

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Control and operation Operating manual
Working with the machine

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 approx. 5
seconds. The work equipment can, however, still be moved.

Caution!
Disengaging the pedals quickly causes the machine to halt abruptly.
Before starting the machine, always fasten the safety belt.

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 manufacturers guarantee.
Ensure that there is no one in the vicinity of the towing devices when towing.
Stretch safely and hold the towing devices. Avoid kinks on cables or ropes.
When towing, maintain the correct transport position, permitted speed and route,
and avoid lurching.
After towing, return the machine to correct operational status.
When restarting the machine, be sure only to proceed in accordance with the op-
erating instructions.

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
LEC/en/Edition: 02 / 2015

conditions.
Familiarize yourself with the location of power lines on the job site and take par-
ticular care when working near them. If necessary, inform the responsible author-
ities.
Maintain a safe distance from electrical aerial lines. Do not allow the 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,

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 Operating manual Control and operation
Working with the machine

do not leave the drivers cab,

warn any personnel in the vicinity not to come close to the excavator and
not to touch it,
instruct or initiate that someone turns off the voltage.
move the machine, if possible, from the danger zone to a sufficient distance,
Do not leave the machine until you are absolutely sure that voltage in the line,
which had been touched or damaged, has been turned off !
Before moving the machine, always ensure that any attachments are safely se-
cured.
When driving onto public roads, paths and squares, observe current traffic regu-
lations and if necessary, ensure that the machine has been made safe as per reg-
ulations beforehand.
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 drivers 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 81.
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 ma-
chine.
Always shift down to a lower running step before a slope. When doing this, the
diesel engine must run at maximal speed and the speed may only be reduced us-
ing the foot pedals.
Load an occupied truck only if all safety requirements are fulfilled, notably in order
to protect the truck operator.
LEC/en/Edition: 02 / 2015

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 operators sight or in radio contact
with him.
Depending on the equipment combination, there is a risk of collision between the

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Control and operation Operating manual
Working with the machine

work tool and the machine (uppercarriage and undercarriage). The greatest de-
gree of care must be taken to avoid damage.
Depending on the equipment combination, there is a risk of collision between the
work tool and the cab, the cab protection or the boom cylinders. The greatest de-
gree of care must be taken to avoid damage when the hoe teeth come within this
area.
Depending on the equipment combination, there is a risk of collision between the
work tool and the equipment parts. The greatest degree of care must be taken to
avoid damage.
Depending on the equipment combination, there is a risk of collision between the
lift ring of the attachment and the cab or the cab 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 oper-
ations with rocky material. This would prolong the work cycles and may lead to
damage to the bucket as well as further machine components.
With the 2x45 offset articulation, the offset position may only be employed if the
working tool or the attachment does not touch the material.
Operation of the offset articulation to drill into the material is not permitted.
Do not lift the machine during operation. Should this happen, lower the machine
slowly back to the ground.
Do not let the machine fall heavily on the ground and do not hold it back with the
hydraulics. This would damage the machine.
During operation with the attachment it is forbidden to raise the machine with the
dozing blade (e.g. carving at the ceiling when tunnelling).
Do not dig under the undercarriage. Take all necessary measures to prevent
LEC/en/Edition: 02 / 2015

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 struc-
tures 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 Min-

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 Operating manual Control and operation
Working with the machine

ing 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 ma-
chine 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.
Do not use the hydraulic hammer to lift objects

Safe use when loading and unloading (particularly when

loading and unloading wood)
According to use, it can be necessary when working with a grab to move with the
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 rotat-
ed the upper structure to the driving position.
There is a danger of possible swinging movement and dropping of the load
LEC/en/Edition: 02 / 2015

when the equipment is raised.

A protective grid (FOPS) in accordance with ISO 10262 must be attached to the
cab.
A protective roof (FOPS) in accordance with ISO 10262 must be attached if
there is a risk of objects falling from above.
Only the maximum permissible load may be taken up using the grab.
NOTE: The weight of absorbent materials, such as logs, is dependent on length,
diameter and specific weight. The influencing variables present in a natural prod-
uct, such as moisture, must be noted.

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Control and operation Operating manual
Working with the machine

Working procedures when using machines with grabs require the machine oper-
ator to receive special instruction and training.
Use as part of the work process is only permitted when the machine operator has
sufficient training and practical experience.

Safe use of machines with tower elevation

Due to the tower elevation, the centre of gravity of the machine will be displaced
upwards in the vertical direction. The driving and work characteristics of the ma-
chine will thus be influenced persistently, e.g. through reduction of the dynamic
stability.
Due to the heightened centre of gravity, the machine must be aligned horizontally
before use. In horizontal alignment, the centre of gravity of the upper structure is
over the centre of the undercarriage, which reduces the risk of tilting.
The machine can still sway and tilt despite being aligned!
The following instructions are therefore to be observed at all times:
When moving the machine:
Rotate the upper structure parallel to the undercarriage (transport position).
Draw the equipment as close as possible to the machine.
Only at this point may the support feet be retracted and the machine moved.
Moving with loads is not permitted.
Check the terrain to be covered to ensure that the ground is solid and even. Pot-
holes and uneven surfaces jeopardize the stability of the machine.
Adjust vehicle handling to suit the altered machine characteristics (high centre
of gravity) and environmental conditions.
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.
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 (slew-
ing) 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.
LEC/en/Edition: 02 / 2015

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 machines
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.

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 Operating manual Control and operation
Working with the machine

This means that there is a wide range of different vibrational loads for the same
machine type.
Whole-body vibrational load for the machine operator can be reduced if the following
recommendations are observed:
Select suitable machines, equipment parts and auxiliary devices for each part of
the job.
Use a machine that has a suitable seat (i.e. for earth-moving machinery such as
hydraulic excavators, this should be a seat which corresponds with EN ISO
7096).
Keep the seat in good condition and adjust it as follows:
The seat and its damping action should be adjusted depending on the weight
and height of the operator.
Check the seats damping action and adjustment mechanisms regularly and en-
sure that these seat characteristics remain as per the seat manufacturers in-
structions.
Check the maintenance status of the machine, particularly with respect to: tyre
pressure, brakes, steering, mechanical connections etc.
Do not steer, brake, accelerate, shift gears, move or load the machines 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 4.
LEC/en/Edition: 02 / 2015

Fig. 3-75 Rotating the uppercarriage

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Control and operation Operating manual
Working with the machine

Caution!
The joystick functions described below refer to the normal control, fitting out the
machine at delivery and according to ISO-standards,
On machines equipped 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 4 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.
The hydraulic swing brake
Let the left joystick 4 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 uppercar-
riage to a standstill rapidly.
Move the left joystick 4 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 "Swing brake" button S17.
Swing brake is applied.
LED in the button comes on.
Press the button again.
Swing brake is released.
LED in the button goes off.

Caution!
The brake only applies when the uppercarriage is near standstill and if no swing mo-
tion is actuated with the joystick.

To stop the uppercarriage when working on a slope:

Use the joystick to reduce the uppercarriage speed.
Press button S17 to operate the swing brake.
Move the joystick back to "0" position only after the brake operates.
LEC/en/Edition: 02 / 2015

To check the mechanical swing gear brake:

When the uppercarriage is stationary.
Press the touch S17 to apply the mechanical swing brake.
Push the left joystick 4 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.

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 Operating manual Control and operation
Working with the machine

Semi-automatic swing brake control (optional)

Press button S17 to release the swing brake.
LED in the button goes off.
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 LED beside the touch 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.

To stop the uppercarriage when working on a slope:

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

Emergency stop of the uppercarriage swing motion

The swing brake can be applied independently of the uppercarriage RPM by switch-
ing the "Swing brake" button S17 to position "applied".

Caution
Perform this braking via "Swing brale" button S17 only exceptionally, i. e. in emer-
gency cases, since it causes fast abrasion of the brake discs.

The positioning swing brake (optional)

The positioning swing brake is used for progressive and sensitive braking of the up-
percarriage.
LEC/en/Edition: 02 / 2015

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Control and operation Operating manual
Working with the machine

Fig. 3-76 Positioning swing brake pedal

Note!
Increased wear.
Do not use the positioning swing brake purely as a service brake, but only as a stop
and parking brake.
Using this brake to stop the uppercarriage running at the full swing RPM is not per-
missible since this would result in a quick abrasion of the brake discs.

In any case, first use the hydraulic braking to greatly reduce the speed of the up-
percarriage
Depress the pedal 10 when the uppercarriage is near standstill
The uppercarriage can be stopped precisely and progressively in the desired
position.

3.4.2 Working position

Fig. 3-77 Working position machine

LEC/en/Edition: 02 / 2015

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.

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 Operating manual Control and operation
Working with the machine

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.

Fig. 3-78 Operating the stick cylinder

Push the joystick back a.

Stick will be drawn in.
Push the joystick forwards b.
Stick will be extended.
LEC/en/Edition: 02 / 2015

Operating the boom cylinder

The boom cylinder is operated using the right joystick 3.

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Control and operation Operating manual
Working with the machine

Fig. 3-79 Operating the boom cylinder

Push the joystick back h.

Equipment will be raised.
Push the joystick forwards g.
Equipment will be lowered.

Operating the bucket

The bucket cylinder is operated using the right joystick 3. LEC/en/Edition: 02 / 2015

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 Operating manual Control and operation
Working with the machine

Fig. 3-80 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

LEC/en/Edition: 02 / 2015

Fig. 3-81 Operating the bottom dump shovel bucket

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

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Control and operation Operating manual
Working with the machine

Push pedal 7a.

Shovel bucket will be opened.
Push pedal 7b.
Shovel bucket will be closed.

Float position of boom cylinder for bucket operation (option-

al equipment)

Fig. 3-82 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.
LEC/en/Edition: 02 / 2015

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.

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 Operating manual Control and operation
General working methods

Fig. 3-83 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 units 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. Repeat-
edly hitting the work equipment against rock or other hard material will damage
steel parts and machine components.
With specific combinations of boom, stick and work tool, the work tool could hit or
break through into the cab. This could damage the cab and injure the machines
operator.
Do not attach buckets which are too big or side cutters when using the machine
LEC/en/Edition: 02 / 2015

in rocky material. This will extend the work cycles and could result in damage to
the bucket and other machine components.
Please contact your LIEBHERR contractual partner if special teeth are required
for heavy or special applications.
Operating the drag bearing to bore into material is not permitted.
Do not raise the machine when working. If this should occur, slowly lower the ma-
chine to the ground. Do not permit the machine to lower quickly and do not inter-
cept the falling movement using the hydraulics, since this could result in damage
to the machine.

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Control and operation Operating manual
General working methods

3.5.2 Preparatory activities

Danger!
Risk of fatal injury and damage to the machine when working.
Observe the safety information Notes for safe working at the start of these op-
erating instructions.

Fig. 3-84 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. 3-85 Hazard area

Danger!
LEC/en/Edition: 02 / 2015

Risk of fatal injury due to rotating the machine.

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

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 Operating manual Control and operation
General working methods

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

3.5.3 Positioning of the machine

Setting up properly is a pre-requisite to safe efficient loading, and helps maintain sta-
bility, power and bench levels. It will also reduce operator fatigue. Position the exca-
vator as close to the working face as safety permits.

Caution!
Always ensure there is sufficient clearance between the counterweight and the
face, including allowing for any rocks or material that may fall down.

Fig. 3-86 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

LEC/en/Edition: 02 / 2015

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 machines opera-
tor.
Ensure that nobody is standing within the hazard area of the backhoe bucket.

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R 9250 / 10069862 3 - 93
MJFCIFSS
Control and operation Operating manual
General working methods

Digging

Fig. 3-87 Optimal angle for digging

Fig. 3-88 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.
LEC/en/Edition: 02 / 2015

copyright by
3 - 94 R 9250 / 10069862
MJFCIFSS
 Operating manual Control and operation
General working methods

Fig. 3-89 Taking up grab material

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

Fig. 3-90 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 shouldnt exceed the length
LEC/en/Edition: 02 / 2015

of the shovel arm.

copyright by
R 9250 / 10069862 3 - 95
MJFCIFSS
Control and operation Operating manual
General working methods

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 drivers cab.

Fig. 3-91 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.
LEC/en/Edition: 02 / 2015

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
3 - 96 R 9250 / 10069862
MJFCIFSS
 Operating manual Control and operation
General working methods

Fig. 3-92 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 dont 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.
LEC/en/Edition: 02 / 2015

copyright by
R 9250 / 10069862 3 - 97
MJFCIFSS
Control and operation Operating manual
General working methods

Unload the bucket

Fig. 3-93 Unloading of the bucket

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

Attaching and removing 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 LIEBHERRs prior written consent.
LIEBHERR must be provided with the appropriate technical documentation nec-
essary 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-
LEC/en/Edition: 02 / 2015

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-

copyright by
3 - 98 R 9250 / 10069862
MJFCIFSS
 Operating manual Control and operation
Transport

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

3.6 Transport

3.6.1 Travelling procedures for mining machine

The life expectancy of undercarriage components is based on standard working con-
ditions with a maximum travel ratio of 5% per service meter unit. Working and / or
travelling on uneven ground and / or abrassive material will influence the lifetime of
the components and attract additional cost for the undercarriage components.
Downhill or uphill travel on a slope has also an effect on the life expectancy of under-
carriage components and on their wear rate. Indeed, even if the slope angle is below
the maximum permitted travelling angle, the increase of the slope angle causes the
increase of the force and of the contact pressures applied on all track components
(track pad assembly, sprocket, ...). On an indicative basis, the travel force applied on
the track components is multiplied by two from a slope angle of 5 (8,7%) and is mul-
tiplied by 2,5 from a slope angle of 10 (17,6%).
In general travel action has to be kept to the lowest level that is possible. Minimize
travelling with turning through a narrow turning circle and long distance travel.
To minimize the travel ratio, professional mine planning with longfront winning sec-
tions is preferred. If digging operations at various spots are necessary, a proper short
term and long term plan of winning operations has to be employed to guarantee long
term use of the excavator at one place before moving to another location.
However, if frequent machine movement is necessary, the following set of proce-
dures defined by LIEBHERR to minimize possible machine damage, downtime and
wear have to be taken into consideration.

General
In order to move the machine forwards : with the excavator in standard forward po-
LEC/en/Edition: 02 / 2015

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

Moving the machine during loading operations

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

copyright by
R 9250 / 10069862 3 - 99
MJFCIFSS
Control and operation Operating manual
Transport

ging and / or truck loading position of some meters.

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

Walking the machine over distance

Fig. 3-94 Hazard area r

Walking the machine distances means any movement of the machine of more than
100 m or for a time period longer than 3 minutes, whatever comes first.
In addition to above mentioned guidelines, when moving the machine during loading
operations, the following procedures apply:
Before the start of the travel movement, clean all very dirty parts of the undercar-
riage and remove the unwanted materials.
It is required to have somebody standby with a heat gun, to monitor the temper-
ature of the drive components, including the track and carrier rollers.

Danger!
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.
LEC/en/Edition: 02 / 2015

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 20C above ambiant tem-
perature, interrupt travel and only commence again after parts have sufficiently
cooled.
To prevent overheating during travelling or to speed up cooling procedure it is ad-
visable to have a water truck standby, to hose the heating components during
travelling or cooling break.

copyright by
3 - 100 R 9250 / 10069862
MJFCIFSS
 Operating manual Control and operation
Transport

Move with idler and attachment forwards. Whenever possible, and not to contra-
vene with mine safety regulations, swing whilst travelling to equally load track roll-
ers. However, always ensure that clear forward vision is maintained.

Travelling the machine down grades or upgrades

In addition to above mentioned guidelines, when moving the machine during loading
operations or when walking the machine distances, the following procedures apply :
When travelling down grades greater than 5,7 (10%), it would be better to walk
the machine down with the track motor first, i.e. the machine is moved backwards.
When travelling up an incline, the final drives must be at the rear of the excavator.
When walking down from a bench, firstly prepare a ramp. Respect the angle value
indicated in the "Technical data" section of this manual (machine must be able to
walk up unaided). When moving down the ramp never allow the machine to fall
down on the attachment. When walking up the ramp never use attachment to as-
sist the movement by pushing with the hydraulic power of the bucket, stick or
boom.

Travelling the machine first time

The slide bearing (friction bearing) of the track rollers needs some time for running-
in. If the bearing becomes hot at an early stage of machine life, this may cause lubri-
cation problems during further life. Therefore when travelling the machine the first
time aside from all above mentioned guidelines it is strongly recommended to move
carefully and at reduced speed.

Note!
Warranty may become void if failure to recognize and comply with the recommend-
ed travel operating procedures, as outlined in this document, is noted.

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 machines 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.
Attach the hand lever for fine-tune driving (crawler excavator) onto the accelerator
LEC/en/Edition: 02 / 2015

pedals.
Ensure that a spotter gives the machine operator the required signal.
Prepare the placing block to ensure against rolling back when the machine is driv-
ing up onto the flatbed.
Tilt the equipment up and drive up the loading ramp. While doing this, always hold
the equipment securely over the loading area, drive very carefully up the ramp
and onto the transportation vehicle.
Rotate the upper structure carefully to the rear and lower the equipment. Due to

copyright by
R 9250 / 10069862 3 - 101
MJFCIFSS
Control and operation Operating manual
Transport

restrictions during transport on hoe equipment, tilt the arm in and dismantle the
bucket during transportation.
After loading the machine onto the flatbed trailer, the upper structure must be se-
cured facing the undercarriage using the stop bolts (only A devices).
Secure the undercarriage and the remaining individual parts using chains and
blocks to prevent slipping.
Before you leave the machine, reduce pressure on all pressure lines, remove the
ignition key and tilt up the safety lever.
Lock all cab and panel doors.
Before transportation, find out all details about the route to be travelled, particu-
larly as they relate to width, height and weight restrictions.
Pay particular attention when driving under electrical lines and bridges and
through tunnels.
When unloading the machine, take the same amount of care as was taken when
it was loaded. Remove all chains and blocks. Start the engine as per the operating
instructions. Drive carefully off the trailers 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.

3.6.2 Excavator lifting and lashing operations

Danger!
For safety reasons, always consider the precautions given in this section.

Lifting precautions
Lift element:
always checking and respecting the lifting configuration indicated on the corre-
sponding transport drawing,
only with the provided lifting appliances,
with adequate and approved lifting devices of other kind (cables, chains, slings)
if necessary,
only after mounting the lifting appliances in accordance with the regulations,
only at the declared threads or lugs shown on the assembly drawing,
with the best possible equal load distribution,
only being sure that the lifted element has been already dismounted,
only after having drained tanks (hydraulic, fuel),
if no specific value is indicated on the corresponding transport drawing, always
respecting the angles given on the sticker for lifting and lashing operations (refer
to the description below).
LEC/en/Edition: 02 / 2015

Additional lifting precautions for backhoe buckets

When you lift the backhoe bucket, also obey the precautions that follow:
Only use the lifting points shown in the stickers placed on the bucket.
You can use the bucket teeth as lifting points.
Be careful about the position of the center of gravity of the bucket.
The bucket has two possible transport positions. The height B1 gives the correct
transport position as shown in the transport drawing.

copyright by
3 - 102 R 9250 / 10069862
MJFCIFSS
 Operating manual Control and operation
Transport

If the height B1 is more than 3,6 m, turn over the bucket safely.

Additional lifting precautions for shovel buckets

When you lift the shovel bucket, also obey the precautions that follow:
Only use the lifting points shown in the stickers placed on the bucket.
Do not use the bucket teeth as lifting points.
Do not use the welded beam to lift the bucket.
Be careful about the position of the center of gravity of the bucket.

Lashing precautions
Lash element:
always using necessary and appropriate devices or tools (e.g. elevating platform)
in order to ensure safe lashing,
always checking and respecting the lashing configuration indicated on the corre-
sponding transport drawing,
if no specific value is indicated on the corresponding transport drawing, always
respecting the angles given on the sticker for lifting and lashing operations (refer
to the description below),
always ensuring a sufficient coefficient of friction (0,6 or higher) between load and
supporting surface so as to avoid element to slip (e.g. using wooden parts, non-
slip mats...),
when using non-slip mats:
always ensuring that the coefficient of friction is guaranteed by manufacturer
certificates,
always positioning the non-slip mats between each contact surface (e.g. be-
tween the load and the support, between the support and the flatbed trailer),
always ensuring that the contact surfaces between the flatbed trailer and the load
carried are free of dirt, ice, snow, oil and grease.

Additional lashing precautions for backhoe buckets

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

Additional lashing precautions for shovel buckets

When you lash the shovel bucket, also obey the precautions that follow:
LEC/en/Edition: 02 / 2015

Only use the lashing points shown in the stickers placed on the bucket.
You can use the bucket teeth as lashing points.
Do not use the welded beam to lash the bucket.
Be careful about the position of the center of gravity of the bucket.
Wedge the bucket during transport.

Sticker for lifting and lashing operations

The following sticker is placed next to each transport drawing on the related part and

copyright by
R 9250 / 10069862 3 - 103
MJFCIFSS
Control and operation Operating manual
Transport

package. It shows rules and precautions which you must obey for transport opera-
tions.

Fig. 3-95 Sticker for lifting and lashing operations

The Lashing Capacity LC is the maximum force that the lashing ring can hold in ac-
cordance with the angles given on the transport drawing.
The Safe Working Load SWL is the maximum load that the lifting ring can hold in ac-
cordance with the angles given on the transport drawing.

Transport drawings
The following drawings indicate the different lashing and lifting points on the ele-
ments of the excavator. Weight (with and without transport tooling and packaging),
overall dimensions as well as center of gravity are also given.
The aim of these drawings is to ensure safe operation during transport, handling and
storage.

Note!
The lashing and lifting points are indicated on the concerned elements of the exca-
vator by specific labels (see "Signs on the machine"). To be easily recognized,
lifting points are painted in yellow (in red if excavator is yellow) as well.
LEC/en/Edition: 02 / 2015

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

copyright by
3 - 104 R 9250 / 10069862
MJFCIFSS
 copyright by

MJFCIFSS
 4 Malfunctions

Warning messages and fault messages:

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

Fig. 4-1 LIEBHERR service

If the cause of the fault cannot be recognised or rectified using the error codes
and fault charts, please consult LIEBHERR customer service.
LEC/en/Edition: 02 / 2015

copyright by
R 9250 / 10069862 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 subheading Emergency operations in the chapter Oper-
ating the machine 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 007 Coolant temperature B2 not Accidental ground Check coolant for contamina-
E 008 being monitored. Accidental + tion, consult LIEBHERR cus-
tomer service.
E 009 Broken wire
E 010 Hydraulic oil level B14 not be- Accidental ground Check hydraulic oil level, con-
E 011 ing monitored. Accidental + sult LIEBHERR customer
service.
E 012 Broken wire
E 013 Hydraulic oil temperature B67 Accidental ground Check coolant for contamina-
E 014 not being monitored. Accidental + tion, consult LIEBHERR cus-
tomer 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

4.1.2 Regulating circuit

Error code Effect Cause Measure / remedy

E 022 Diesel engine speed B12 not Accidental ground Consult LIEBHERR customer
LEC/en/Edition: 02 / 2015

E 023 being monitoring, Diesel en- Accidental plus service.

gine speed cannot be adjust-
E 024 ed using keyboard, reduced Broken wire
hydraulic power
E 027 Solenoid valve for power con- Cable defect Consult LIEBHERR customer
trol Y4 LR1 not being moni- service.
toring
E 030 Output ventilator oil Y10.2 not Cable defect Consult LIEBHERR customer
being monitoring service.

copyright by
4-2 R 9250 / 10069862
MJFCIFSS
 Operating manual Malfunctions
Error code charts

Error code Effect Cause Measure / remedy

E 033 Output ventilator water Y10.1 Cable defect Consult LIEBHERR customer
not being monitoring service.
E 036 Output Y3.1 EV1 not being Cable defect Consult LIEBHERR customer
monitoring service.
E 039 Output Y3.2 EV2 not being Cable defect Consult LIEBHERR customer
monitoring service.
E 042 Output Y3.3 EV3 not being Cable defect Consult LIEBHERR customer
monitoring service.

4.1.3 Keyboard

Error code Effect Cause Measure / remedy

E 302 Coding plug missed in key- No coding plug Consult LIEBHERR customer
board service.
E 303 No CAN 1 connection be- Error detected also if BST is Consult LIEBHERR customer
tween control unit S2 and cir- not operative : no power sup- service.
cuit board BST ply, ...)
E 305 No CAN 2 connection be- Error detected also if ESP01 Consult LIEBHERR customer
tween control unit S2 and cir- is not operative service.
cuit board ESP01
E 312 No CAN 1 connection be- No CAN bus connection Consult LIEBHERR customer
tween control unit S2 and service.
E1036 (connection box pump
transmitters)
E 313 No CAN 1 connection be- No CAN bus connection Consult LIEBHERR customer
tween control unit S2 and service.
A1020 (FSG plate)

4.1.4 Display

Error code Effect Cause Measure / remedy

E 308 No CAN 2 connection be- No CAN bus connection Consult LIEBHERR customer
tween control unit S2 and dis- service.
play or no function of the
control unit
LEC/en/Edition: 02 / 2015

4.1.5 Coding error

Error code Effect Cause Measure / remedy

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.

copyright by
R 9250 / 10069862 4-3
MJFCIFSS
Malfunctions Operating manual
Error code charts

Error code Effect Cause Measure / remedy

E 322 Unknown hardware coding Coding error Consult LIEBHERR customer
from BST service.

4.1.6 Connection box pump transmitters

Error code Effect Cause Measure / remedy

E 311 No CAN 1 connection on Consult LIEBHERR customer
E1036 (connection box pump service.
transmitters)
E 320 No CAN 1 connection be- Consult LIEBHERR customer
tween E1036 (connection box service.
pump transmitters) and trans-
later J1939

4.1.7 Error due to warning symbols in SY field

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

Error code Effect Cause Measure / remedy

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
E 504 Symbol appears Hydraulic oil level low See symbol description
E 505 Symbol appears Hydraulic oil overheating See symbol description
E 506 Symbol appears Splitterbox oil temperature See symbol description
too high
E 540 Symbol appears Coolant pressure 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 567 Symbol appears Pump 2 clogged See symbol description
E 568 Symbol appears Pump 3 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
LEC/en/Edition: 02 / 2015

E 579 Symbol appears Overheat pump 2 See symbol description

E 580 Symbol appears Overheat pump 3 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 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

copyright by
4-4 R 9250 / 10069862
MJFCIFSS
 Operating manual Malfunctions
Error code charts

Error code Effect Cause Measure / remedy

E 594 Symbol appears Fuel pressure See symbol description
E 595 Symbol appears Blow by 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

4.1.8 Heating / air conditioning system

Error code Affected elements Description / possible Possible effects /

cause measures
F0 Room temperature sensor Short circuit or disconnection Control function no longer op-
of cable, connector or control erational
unit.
Defective sensor
F1 Exhaust air temperature sen- Short circuit or disconnection Control function no longer op-
sor of cable, connector or control erational
unit.
Defective sensor
F2 Exhaust air temperature sen- Short circuit or disconnection Control function no longer op-
sor (head area) of cable, connector or control erational
unit.
Defective sensor
F3 Outside temperature sensor Short circuit or disconnection Control function no longer op-
of cable, connector or control erational
unit.
Defective sensor
F4 High-/Low pressure switch Failure on condenser fan, Control function no longer op-
evaporator blower, expansion erational
valve, compressor or refriger-
ant circuit
LEC/en/Edition: 02 / 2015

copyright by
R 9250 / 10069862 4-5
MJFCIFSS
Malfunctions Operating manual
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 0C For operation under specific climatic
conditions, see operating instruc-
tions
Starter motor not drawing through Check line connections, overhaul
starter motor
Batteries have no power Charge / replace
Engine starts but stops immediately Fuel tank empty (low pressure in Fill tank and vent fuel system
after or runs irregularly tank)
Fuel filter dirty Clean or change filter and vent fuel
system (tank)
Particularly in winter: too viscous Use engine oil suitable for the out-
engine oil used side temperature
Dry-air filter dirty Clean or change main filter element
Air in fuel system Bleed fuel system
Ventilation in fuel tank obstructed Clean
Fuel line bent Check line and repair if required
Diesel engine emitting grey or black Dry-air filter dirty Clean or change filter
smoke
Diesel engine continually emitting Water in combustion chamber Consult customer service
white smoke (steam)
Diesel engine does not reach full Speed adjustment not set to maxi- Set speed adjustment to maximum
speed mum value value
Injection system is set incorrectly Consult customer service
Dry-air filter dirty Clean or replace filter
Bad fuel supply Clean or change fuel filter, check
lines, drain water from tank
Diesel engine becomes too hot Too little coolant Fill coolant, check for leaks
Water pump defective Repair
LEC/en/Edition: 02 / 2015

Thermostats do not work Change thermostats

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

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4-6 R 9250 / 10069862
MJFCIFSS
 Operating manual Malfunctions
Faults and remedies

Fault / error Cause Solution

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

4.2.2 Hydraulic system

Fault / error Cause Solution

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 immediate- check intake lines for leaks
ly
Hydraulic oil temperature too high Coolant contaminated Clean coolant
Fan or fan control defective Rectify error / consult customer ser-
vice
Hydraulic oil level too low Oil loss Repair leaks, exchange hoses, refill
oil via return-line filter
Cannot drive Push the safety lever up Push the safety lever down
Swing gear not functioning No servo control Push the safety lever down
Switch on servo control
Swing gear brake activated Push the safety lever down
Release swing gear brake
No working movement No servo control Push the safety lever down
Switch on servo control
No servo pressure present Consult customer service
No pump high pressure present Consult customer service

4.2.3 Transmission

Fault / error Cause Solution

Oil flowing out on track rollers, sup- Seal defective Replace seal
port rollers or leading wheel
Insufficient crawler tracking on lead- Leading wheel tracking on track roll- Adjust the leading wheel tracking
LEC/en/Edition: 02 / 2015

ing wheel er mounting has too much play play

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

copyright by
R 9250 / 10069862 4-7
MJFCIFSS
Malfunctions Operating manual
Faults and remedies

4.2.4 Electrical system

Fault / error Cause Solution

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

4.2.5 Heating/air-conditioning system

Fault / error Cause Solution

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

Fault / error Cause Solution

LEC/en/Edition: 02 / 2015

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

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4-8 R 9250 / 10069862
MJFCIFSS
 Operating manual Malfunctions
Fuses and relays

4.3 Fuses and relays

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

4.3.1 Power electrical box E1003

The power electrical box E1003 is located under the cab, in the cab elevation.
LEC/en/Edition: 02 / 2015

copyright by
R 9250 / 10069862 4-9
MJFCIFSS
Malfunctions Operating manual
Fuses and relays

LEC/en/Edition: 02 / 2015

Fig. 4-2 Power electrical box E1003

F119 8A Fuse / S1/Kl30 F20_4 Fuse / Kl30 floodlight

copyright by
4 - 10 R 9250 / 10069862
MJFCIFSS
 Operating manual Malfunctions
Fuses and relays

F12_1 25A Fuse / attachment flood- F20_4 Reserve

light
F12_2 25A Fuse / attachment flood- F20_5 Reserve
light
F12_3 35A Fuse / fuel tank floodlight F20_6 100A Fuse / engine
F12_4 35A Fuse / hydraulic tank F20_7 7,5A Fuse / Camera
floodlight
F12_5 25A Fuse / counterweight F37 25A Fuse / ether
floodlight
F12_6 25A Fuse / counterweight K11 Relay current charging
floodlight
F120 50A Fuse / air conditionning K110 Relay for M10
F121 50A Fuse / air conditionning K112 Relay for M11
F122 15A Fuse / optional windshield K113 Relay lightening
wiper
F123 50A Fuse / supply A1020 K133 Relay lightning
F131 15A Fuse / Evaporator engine K137 Relay reserve
1
F137 8A Fuse / Quantum K141_1 Relay fuel valve control
F138 100A Fuse / service circuit K141_2 Relay fuel valve control
supply
F139 100A Fuse / M10 supply K141_3 Relay fuel valve control
F140 15A Fuse / board K16_1 Startrelay E1003
F141 15A Fuse / E14 K16_2 Startrelay E1003
F142 15A Fuse / lighting K19_1 Relay Kl15
F143 25A Fuse / lighting K19_2 Relay Kl15
F144 15A Fuse / ladder / trap door K19_3 Relay Kl15
F145 Reserve K19_4 Relay Kl15
F147 100A Fuse / M11 supply K20_1 Relay attachment flood light
F152 25A Fuse / Quantum K20_2 Relay attachment flood light
F166 Reserve K20_3 Relay fuel tank flood light
F167 25A Fuse / elevation pressure K20_4 Relay hydraulic tank flood light
fan
F169 15A Fuse / charging K20_5 Relay counterweight flood light
F170 Reserve K20_6 Relay counterweight flood light
F20_1 100A Fuse / supply cabin Kl15 K20_7 Relay reserve
F20_2 100A Fuse / supply E1005 K20_8 Relay camera lightning
Kl15
F20_3 100A Fuse / charging current KT9 Relay timer lightening
LEC/en/Edition: 02 / 2015

4.3.2 Cab connection box E1005

The cab connection box E1005 is located in the cab, behind the operators seat.

copyright by
R 9250 / 10069862 4 - 11
MJFCIFSS
Malfunctions Operating manual
Fuses and relays

Fig. 4-3 Fuses and relays of cab connection box E1005

F29 8A Fuse / reserve cameras F161 15A Fuse / A1036

F30 8A Fuse / attenuation plate K22_1 Relay option windshield wiper
supply reserve
F31 15A Fuse / A1020 boom / K22_2 Relay option windshield wiper
shovel tilt
F32 15A Fuse / A1020 stick / swing K23 Relay second air conditioned
F33 15A Fuse / A1020 travel / trap K98 Relay travel alarm
door
F34 15A Fuse / A1020 FSG K99 Relay supply A1020
F35 15A Fuse / A1020 controller K139 Relay fire alarm
FSG
LEC/en/Edition: 02 / 2015

F124 15A Fuse / S7, A1001 K183 Relay engine stop

F125 15A Fuse / A1019, U16 K184 Relay power reduced
F126 15A Fuse / A1001 K193 Relay / reserve
F127 15A Fuse / greasing K385 Relay / Horn right
F128 15A Fuse / board KT10 Relay timer emergency stop
F129 15A Fuse / cabin KT17 Relay timer fire alarm
F130 8A Fuse / A1001 KT51 Relay timer engine stop

copyright by
4 - 12 R 9250 / 10069862
MJFCIFSS
 Operating manual Malfunctions
Fuses and relays

F148 15A Fuse / A1019

4.3.3 Heating / air conditioning electrical box E1006

Heating / air conditioning electrical box E1006 is located behind the operator seat, in
the roof.

Fig. 4-4 Fuses and relays of heating / air conditioning electrical box E1006

F131 15A Fuse /Evaporator engine 1 F190 15A Fuse / Air conditioning
F132 15A Fuse /Evaporator engine 2 K23A Relay second air conditioning
F133 15A Fuse /Evaporator engine 3 K121 Relay air conditioning
F134 25A Fuse / Reserve E1006 K273 Relay second air conditioning
switch
F136 8A Fuse / Reserve E1006 KT52 Relay control unit AC switch
LEC/en/Edition: 02 / 2015

copyright by
R 9250 / 10069862 4 - 13
MJFCIFSS
Malfunctions Operating manual
Fuses and relays

LEC/en/Edition: 02 / 2015

copyright by
4 - 14 R 9250 / 10069862
MJFCIFSS
 5 Maintenance

5.1 Servicing the machine safely

General safety instructions

Maintenance and repair work may only be carried out by specially trained person-
nel.
Observe statutory timetables or intervals given in the operating instructions for re-
peat tests / inspections. It is imperative that a suitably equipped workshop is avail-
able in order to carry out maintenance work.
The inspection and maintenance schedule given at the end of these operating in-
structions defines precisely who is required / permitted to carry out what work.
Jobs listed as daily / weekly work may be carried out by the machine's driver or
maintenance personnel when they have received appropriate instruction.
The remaining work may only be carried out by specialist personnel with appro-
priate training.
Replacement parts must correspond to the technical requirements determined by
the manufacturer. Original replacement parts are always guaranteed to meet
these criteria.
Always wear safe work clothes when carrying out maintenance work. Avoid the
wearing of rings, wrist watches, ties, scarves, open jackets, baggy clothing etc...
There is a risk of injury from, for example, getting caught up or being drawn in.
Protective goggles, safety helmets, safety shoes and gloves, reflective vests and
ear protection etc. are required for specific jobs.
Do not remain in direct proximity of the diesel engine while the diesel engine is
running.
Persons with pacemakers should not approach within 20 cm of the running diesel
engine.
Do not touch voltage-carrying parts on the electrical connection of the individual
solenoid injection pumps (Unit Pumps UP) while the diesel engine is running.
Do not permit unauthorised persons to approach the machine during mainte-
nance work.
Cordon off a wide maintenance area if required.
Inform operational personnel before starting to carry out any special work and re-
pair work. Designate persons in charge of supervision.
In the absence of any other information in the operating instructions, carry out all
maintenance work on the machine on level, firm ground with the working equip-
ment set aside and the engine switched off.
For some machines, the only one position which enables a secured access to
every maintenance locations on the uppercarriage, is when the uppercarriage is
aligned with the undercarriage so that the sprockets locate at the back-end.
LEC/en/Edition: 02 / 2015

The ladder situated on the undercarriage only corresponds with the uppercar-
riages 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
R 9250 / 10069862 5-1
MJFCIFSS
Maintenance Operating manual
Servicing the machine safely

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

Cleaning
Clean oil, fuel or care products off the machine before starting maintenance or re-
pair work and pay particular attention to connections and screw fittings.
Do not use aggressive cleaning products and use lint-free cleaning cloths.
Do not use aggressive cleaning products or steam jet devices to clean the ma-
chine for the first two months after initial set-up of the machine (or after repaint-
ing).
Do not use combustible liquids to clean the machine.
Before cleaning the machine with water or steam jets (high pressure cleaner) or
other cleaning materials:
lubricate all bearing points, bolt connections and the rim bearing to prevent wa-
ter or steam entering the bearing points.
cover or glue shut all openings into which for safety or functional reasons water
or steam may not be permitted to enter.
Electric motors, electrical components, control boxes, plug connections and air
filters are particularly at risk.
Ensure that the fire warning systems and fire extinguishers of the engine compart-
ments temperature sensor do not come into contact with hot cleaning products
during cleaning work.
The fire extinguisher could start.
If you use a high pressure cleaner with steam or hot water to clean the machine,
observe following recommendations :
the distance between the nozzle and the surface to be cleaned must be no low-
er than 20 inches
the water temperature should not exceed 60c (140F)
limit the water pressure to 80 bar maximum (1160 PSI)
if you employ cleaning fluid, only use neutral cleaning agents such as custom-
ary car shampoos diluted to 2 or 3 percent maximum
After cleaning:
remove all covers completely.
check all fuel, engine oil and hydraulic lines for leakage, loosened connections,
chafing and damage.
rectify any defects found immediately.
lubricate all bearing points, bolt connections and the rim bearing to displace any
water or cleaning products that may have entered.

Corrosion protection
LEC/en/Edition: 02 / 2015

The corrosion protection of the machine must be inspected and renewed at reg-
ular intervals. For further information, refer to the Maintenance manual for corro-
sion protection.

Field of view
Mirrors and cameras, which were possibly removed for the transport, must be in-
evitably reinstalled and correctly adjusted before the initial set-up of the machine.
Regularly check that the interior and exterior mirrors as well as the cameras are

copyright by
5-2 R 9250 / 10069862
MJFCIFSS
 Operating manual Maintenance
Servicing the machine safely

correctly adjusted.
Control the surroundings, and particularly the nearness area of the machine, dur-
ing operation or when travelling.
Mirrors are installed on the machine:
on the left to check the left side of the machine.
on the front to check the front side of the machine.
on the right to check the right side of the machine.
above the counterweight to check the rear side of the machine.
On some machines, some mirrors may be replaced with cameras.
At each extension, construction or change on the machine, the sight conditions
must be maintained. These conditions must otherwise be checked according to
ISO 5006.
Mirrors 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 mainte-
nance plan:
every 250 operating hours by the machine owners maintenance personnel.
every 500 operating hours by authorised specialist personnel.
It is advisable to carry out these tests: supported, on firm, horizontal substrate,
with the equipment in longitudinal and cross direction for variable loads. Current
accident prevention regulations must be adhered to.
Especially check the supporting components, in particular :
framed construction undercarriage with axle and gearbox storage, support out-
riger, lower slewing ring support with tower and slewing ring.
framed construction uppercarriage with bearing for boom and hoist cylinder, up-
per slewing ring support, cab suspension, mounting for slewing gear and coun-
ter weight.
framed construction components of attachments, e.g. boom, stick, quick
change adapter, digging tool and grapple.
hydraulic cylinders, axles, steering, pins and pin connections, ascents, ladders
and mounting elements.
The crack test should be carried out visually. If a crack is suspected, the dye pen-
etration test should be carried out as a crack test on areas which do not have
LEC/en/Edition: 02 / 2015

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.

copyright by
R 9250 / 10069862 5-3
MJFCIFSS
Maintenance Operating manual
Servicing the machine safely

Welding, drilling, firing and grinding work

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

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

Repair work
Do not attempt to lift heavy parts. Use devices which are suitable for this purpose
and which have sufficient load capacity. When replacing single parts and larger
subassemblies, carefully secure them on lifting devices so that they do not pre-
sent a risk. Only use suitable and correctly functioning lifting devices and load
take-up devices with adequate load capacity.
Do not stand or work under swinging loads.
Do not use lifting devices which are damaged or do not have sufficient load car-
rying capacity.
Wear work gloves when working with wire cables.
Authorize only experienced people to attach load and to give indications to the
crane operator. This people must be in the operators sight or in radio contact with
him.
When working above body height, use safe climbing devices and working plat-
forms which are appropriate for the job.
Do not use machine parts as climbing devices if they are not designed for this pur-
LEC/en/Edition: 02 / 2015

pose.
When working at height, wear a harness to prevent falling.
Ensure that all grips, steps, rails, platforms and ladders are free of dirt, snow and
ice.
Pneumatic cylinders do not have to be used as handles. Open doors and covers
carefully, so that pneumatic cylinders do not hit their stops, because this could
cause mechanical damages.
Make sure the equipment on which you will operate is securely supported before
working (e.g. replacing teeth). Prevent metal touching metal when doing this.

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5-4 R 9250 / 10069862
MJFCIFSS
 Operating manual Maintenance
Servicing the machine safely

For safety reasons, never open and remove a track chain unless having previous-
ly totally released the pretension of the chain tensioning unit.
Never lay under the machine if it is raised with work equipment and has not been
securely supported with appropriate supports.
Always jack the machine up in such a way that any weight displacement does not
jeopardize stability and prevent metal touching metal while doing this.
Work on the suspension, brake and steering systems may only be carried out by
trained specialist personnel.
If the machine has to be repaired on a slope, secure the crawler with chocks and
connect the upper structure to the chassis using stop bolts.
Only personnel with special training and experience may work on hydraulic equip-
ment.
When searching for leakage, wear protective gloves. A fine jet of liquid under
pressure can penetrate the skin.
Do not unscrew any lines or connections before you have set aside the equip-
ment, switched off the engine and depressurized the hydraulic system. After
switching off the engine, with the start key in contact position and with the safety
lever down into its lowest position, you must operate all pilot control devices (joy-
stick and pedals) in all directions in order to reduce the actuating and dynamic
pressures in the work circuits. You must then reduce the internal tank pressure
as described in these operating instructions.

Electrical system
Check the electrical system regularly.
Have all faults, such as loose connections, blown fuses and lamps and clogged
or abraded cables rectified by personnel.
Only use original fuses with approved current strength.
For machines with electrical neutral and high tension leads:
switch the machine off immediately in the event of malfunctions in the power
supply.
Work on the machines electrical equipment may only be carried out by skilled
electrical personnel or by trained personnel under the supervision of an electri-
cian in accordance with electrical regulations.
When working on live parts, ensure that a second person is available to operate
the emergency-off or the main switch and overvoltage release. Cordon off the
working area with a red and white safety chain and a warning sign. Only use in-
sulated tools.
When working on neutral and high tension subassemblies, after releasing the
voltage, briefly disconnect the supply cable at earth and electronic devices such
as capacitors using an earthing rod.
First test the released parts to make sure that they are off circuit, earth them and
then disconnect them briefly. Insulate adjacent live parts.
Disconnect the battery before working on the electrical system or carrying out any
electric arc welding on the machine.
LEC/en/Edition: 02 / 2015

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-

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R 9250 / 10069862 5-5
MJFCIFSS
Maintenance Operating manual
Servicing the machine safely

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

Hydraulic lines and hoses

It is forbidden to carry out repair work on hydraulic lines and hoses!
All lines, hoses and bolt connections must be checked regularly for externally vis-
ible damage and any possible damage must be immediately checked for leakage.
Never check for leaks with your bare hands, use a sheet of paper or something
else.
Any damaged parts must be removed immediately! Spurting oil can lead to injury
and burns.
Even with correct storage and permitted load, lines and hoses are subject to the
natural aging process. This restricts their duration of use.
Incorrect storage, mechanical damage and unauthorized load are the most
common causes of failure.
In relation to duration of use, current norms, regulations and guidelines pertain-
ing to lines and hoses at place of use must be adhered to.
Use at the limit range of permissible load can shorten duration of use (e.g. high
temperatures, frequent movement cycles, extremely high pulse frequencies,
multiple shift usage).
Lines and hoses should be replaced if the following are found during inspection:
Damage to the outer sheath as far as the liner (e.g. chafing, cuts and cracks);
Brittleness of the outer sheath (fracture formation in hose material);
Deformations which do not correspond to the natural form of the line or hose,
whether in a unpressurized or pressurized state or on bends e.g. sheath sepa-
ration, blistering;
Unsealed areas;
Non-adherence to requirements during installation;
Damage or deformations to the hose fittings which reduce the tightness of the
fittings or the hose / fitting connection;
LEC/en/Edition: 02 / 2015

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,

copyright by
5-6 R 9250 / 10069862
MJFCIFSS
 Operating manual Maintenance
Maintenance access doors

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

5.2 Maintenance access doors

5.2.1 Overview of access doors

The machine has 5 access doors for maintenance. The locks integrated in the han-
dles 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.
LEC/en/Edition: 02 / 2015

copyright by
R 9250 / 10069862 5-7
MJFCIFSS
Maintenance Operating manual
Maintenance access doors

Engine room

LEC/en/Edition: 02 / 2015

Fig. 5-1 Access doors for the engine room

These doors permit to accede to the engine room.

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5-8 R 9250 / 10069862
MJFCIFSS
 Operating manual Maintenance
Maintenance access doors

Cab elevation and hydraulic tank installation

Fig. 5-2 Access doors for the cab elevation and for the hydraulic tank installation

The access door for the cab elevation permit to access to the windshield washer tank
and to the power connection box E1003.
The access door of the hydraulic tank installation permit to accede to the service bat-
teries.
LEC/en/Edition: 02 / 2015

copyright by
R 9250 / 10069862 5-9
MJFCIFSS
Maintenance Operating manual
Maintenance access doors

Left catwalk

LEC/en/Edition: 02 / 2015

copyright by
5 - 10 R 9250 / 10069862
MJFCIFSS
 Operating manual Maintenance
Maintenance access doors
LEC/en/Edition: 02 / 2015

Fig. 5-3 Access door for the left catwalk

The access door for the left catwalk permit to access to the main pumps of the exca-
vator, to the splitterbox, to the engine, to the counterweight and to the radiator.

copyright by
R 9250 / 10069862 5 - 11
MJFCIFSS
Maintenance Operating manual
Maintenance access doors

Radiator

Fig. 5-4 Access door for the radiator

To access to the radiator :

Unscrew the screw 1.
Open the door 2.
LEC/en/Edition: 02 / 2015

copyright by
5 - 12 R 9250 / 10069862
MJFCIFSS
 Operating manual Maintenance
Maintenance access doors

Main pumps and splitterbox

Fig. 5-5 Access for main pumps and splitterbox

This access permit to get main pumps or the splitterbox out.

LEC/en/Edition: 02 / 2015

copyright by
R 9250 / 10069862 5 - 13
MJFCIFSS
Maintenance Operating manual
Lubricants and operating fluids

5.3 Lubricants and operating fluids

5.3.1 General information on changing lubricants and operating

fluids

Note
The quantities given in the lubrication and operating material chart and on the lubri-
cation chart in the cab are only guide values.
After each oil change or refill, check the level in the relevant unit.

Note!
Adhering to regulations for lubrication, level checks and operating material changes
guarantees a high degree of reliability and a long service life for the machine.
It is particularly important to adhere to the oil change intervals and use the specified
type of lubricant.
Observe the following when using and checking lubricants and operating fluids:
see "Lubricants and operating fluids"
see "Inspection and maintenance schedule"

Note!
Cleanliness is of the utmost importance when changing oil.
Clean all filler plugs, filler covers and drain plugs and their surroundings before
opening.
For preference, drain off oil when it is at operating temperature.
Ensure that old oils are collected and disposed of in an environmentally accept-
able manner using the removable oil filter cartridges.

Danger!
When checking and changing lubrication and operating materials, ensure that the
following precautions are adhered to:
Unless otherwise indicated, carry out all work on the machine on level, solid
ground and with the engine switched off.
Whenever you reach into the engine compartment, always secure the cover and
side doors against accidentally falling back or closing.
Only refuel the machine when the engine is switched off, do not smoke and
avoid naked flame.
Turn the main battery switch to position 0 (off) and remove the ignition key.
LEC/en/Edition: 02 / 2015

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5.3.2 Lubrication chart

LEC/en/Edition: 02 / 2015

Fig. 5-6 Lubrication chart - R9250

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Symbol Display
Diesel engine

Engine coolant

Hydraulic system

Swing gear

Travel gear

Lifetime sealing interspace (optional)

Splitterbox

Fuel

Grease / Swing ring teeth

Grease

Windshield washer

Check oil level

Oil change

First oil change

Oil analysis

Tab. 5-1 Lubrication chart key

5.3.3 The service trap

To simplify the oil change and the refilling procedure, the drain of major components
are centrally connected to a service trap.
The Diesel engine system.
The splitterbox.
The fuel tank.
LEC/en/Edition: 02 / 2015

The hydraulic oil tank.

The windshield washer fluid tank.
The grease tank for general lubrication.
The grease tank for swing ring teeth lubrication

Component Adapter WIGGINS Flow max.

Splitterbox C-1807 50 l/min

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Component Adapter WIGGINS Flow max.

Engine oil OSP 2 50 l/min
Hydraulic oil 6600 B12 100-200 l/min
Fuel ZZ 9A1 400 l/min
Windshield washer EC 280 B8 25 l/min
Principal grease OSP 2
15-30 l/min
Pmini 100 bar
Teeth ring grease 6000 B12

Tab. 5-2 Major components of the service trap

LEC/en/Edition: 02 / 2015

Fig. 5-7 Major components of the service trap

D: draining the hydraulic oil

R: refilling the hydraulic oil

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5.3.4 Lubricant chart

Designation Medium Symbol Classification Viscosity Quantity*

Diesel engine Engine oil See the Operation and Maintenance Manual 245 l
for CUMMINS engine.

Hydraulic tank Hydraulic oil See section "Lubricating and operating materi- 2500 l in
al specifications". hydraulic
tank
4050 l in
whole cir-
cuit

Swing gear Transmission See section "Lubricating and operating materi- 2 x 39 l

oil al specifications".

Travel gear Transmission See section "Lubricating and operating materi- 2 x 52 l

oil al specifications".

Lifetime travel gear Transmission See section "Lubricating and operating materi- 2 x 58 l
(optional) oil al specifications".

Lifetime sealing Hydraulic oil Use same oil as used for hydraulic tank. 2 x 6,8 l
interspace (optional)

Splitterbox Transmission API-GL-5 SAE 90 60 l

oil MIL-L 2105 B, C or D SAE 80W-90

Swing ring roller bear- Lubricating Multupurpose grease KP2k Consistency 2 200 l
ing races and general grease or EP2 (extreme pressure NL GI N2
lubrication points N2 grade) grade

For optional cold climate systems, see section

"Lubricating and operating material specifica-
tions".

Swing ring teeth Lubricating See section "Lubricating Special grease 15 l

grease and operating material
specifications".
LEC/en/Edition: 02 / 2015

Track roller Pordoi - 30G ISO 100 18 x 2700

(ITT) Agip Diesel Sigma S30 SAE 30 cc

Carrier roller 90% Agip Rotra LSX + 10% Agip Rocol ASO R 4 x 1,4 kg
(Berco) (1565 cc)

Idler wheel Tests in accordance with: 2 x 3300

(ITT) MIL-L-2105D / API GL-5 cc

VARIAX-EP / 80W90
Mobilube HD 80W90

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Designation Medium Symbol Classification Viscosity Quantity*

Hinges, joints, locks Engine oil - - - -

Rubber seal on doors Silicon spray - - - -

and trim panels or talc

Tab. 5-3 Lubricant chart

* The given quantities are only guidelines. Check fluid level after each change or refilling.

5.3.5 Operating material chart

Designation Medium Symbol Quantity*

Fuel tank See the Operation and Maintenance Manual for CUM- 5440 l
MINS engine.

Engine coolant See the Operation and Maintenance Manual for CUM- 280 l
MINS engine.

Windshield washer system Commercially available windshield washer fluid or dena- 75 l

tured alcohol

Standard air conditioning Refrigerating agent: - 7,5 kg

system R134a

Refrigerant oil in a new compressor: - 0,207 l

PLANETELF PAG SP 20

Refrigerant oil to add in the system after a compressor re- - 0,504 l

placement:
PLANETELF PAG SP 20

Refrigerant oil in the full system: - 0,711 l

PLANETELF PAG SP 20

Additional air conditioning Refrigerating agent: - 5 kg

system (optional) R134a

Refrigerant oil in a new compressor: - 0,207 l

PLANETELF PAG SP 20

Refrigerant oil to add in the system after a compressor re- - 0,265 l

LEC/en/Edition: 02 / 2015

placement:
PLANETELF PAG SP 20

Refrigerant oil in the full system: - 0,472 l

PLANETELF PAG SP 20

Tab. 5-4 Operating material chart

* The given quantities are only guidelines. Check fluid level after each change or refilling.

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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
However, these components are also equipped with oil drain valves, see description
for oil change procedure of these components.

To lower and lift the service trap

Fig. 5-8 Control box E1022_2 and control board

When the service trap is lowered, the service plate is accessible from the ground lev-
el.
The service trap can be moved up and down via the four push buttons on the control
box E1022_2 at the lower end of the access ladder.
The service trap can also be operated with the engine stopped.
It must only be moved out if the uppercarriage and the undercarriage are aligned.

To lower the service trap from its uppermost position:

Push the button S161 to unlock the trap,
Push the button S162 to move the trap downward.

To lift the trap:

Push the button S159 until the red warning light H69 goes off on,
Push the button S160 to lock the trap until the lock pin get its stop position.
The lighting of the red warning light H70 shows that the locking pin of the trap is not
in end (locked) position.
The lighting of the red warning light H69 shows that the trap is not in upper end po-
LEC/en/Edition: 02 / 2015

sition.
The locking of the trap through the button S160 is possible only when light H69 goes
off.

Caution!
For safety reasons, the excavator can only be operated if the service trap is locked
in its uppermost position. If not, the red warning light H70 comes on.
This means that the swing and travel movements stay locked.

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This safety measure can be bypassed as long as the button S122 on the right front
instrument panel is activated.

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
See the Operation and Maintenance Manual for CUMMINS engine.

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 LIEB-
HERR.
LIEBHERR recommends maintaining the hydraulic oil to a cleanliness level that
meets contaminant code 20/18/15 according to ISO 4406.
Maximum water content of hydraulic oil : <0,1%.

Caution!
According to the oil type used for the hydraulic system, the fans speed regulation
must be set specifically ("STANDARD", "COLD" or "EXTRA-COLD").

If the excavator is delivered without arctic kit, it is set to "STANDARD" at

LEC/en/Edition: 02 / 2015

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. 5-9 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
LEC/en/Edition: 02 / 2015

Fig. 5-10 Engine oils for hydraulic system

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A Ambient air temperature

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

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

Fans speed regulation settings

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
LEC/en/Edition: 02 / 2015

Fig. 5-11 Hydraulic oil for hydraulic system

A Ambient air temperature

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

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warm-up instruction)

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 50C according to DIN ISO 9120

Fans speed regulation settings

Hydraulic oil fans speed regulation setting

ISO VG68 "STANDARD"

ISO VG100 "STANDARD"

ISO VG46 "COLD"

ISO VG32 "EXTRA-COLD"

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

Biodegradables hydraulic oils

The use of biodegradables hydraulic oils must in any case be discussed with LIEB-
LEC/en/Edition: 02 / 2015

HER MINING EQUIPMENT COLMAR SAS.

Do not mix biodegradable hydraulic oils from different suppliers and never mix
with mineral oils.
Do not use vegetable oils as they do not possess the necessary thermal stability.
Depending on the temperature range, LIEBHERR recommends its poly-alpha-olefin
(PAO, HEPR) oils, that are biodegradable according to CEC-L-103-12 (21 days, >
60%, primary decomposition):

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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.
Oils pourpoint temperature must be at least 5 K below the minimal air ambient tem-
perature.
Oils flash point temperature > 160C (recommended > 200C).
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 +20C, the oil viscosity at
+50C (oil temperature) must be over 16 cst.
In this case, the fans speed regulation "EXTRA-COLD" must be selected.
If the maximal ambient air temperature stays below +30C, the oil viscosity at
+60C (oil temperature) must be over 16 cst. In this case, the fans speed regula-
tion "EXTRA-COLD" or "COLD" must be selected.
If the maximal ambient air temperature stays below +40C, the oil viscosity at
+70C (oil temperature) must be over 16 cst. In this case, the fans speed regula-
tion "COLD" must be selected.
Contact LIEBHERR Customer Service for additional questions about oil selection.

Oil mixing
In principle, oil mixing between two different oil types must be avoided. Mixing two
different oil types leads to an unknown lubricant with resultant unknown physical
properties (viscosity, pourpoint, flash point, ageing behaviour, lubricity, reaction with
additives...).
LEC/en/Edition: 02 / 2015

However, if mixing is absolutely necessary, respect the following maximum mix-

ing proportions:
Mixing LIEBHERR oils with hydraulic oils, or LIEBHERR oils with mineral oils, or
hydraulic oils with mineral oils, or two different mineral oils together, or two differ-
ent hydraulic oils together:
max. 10%
Mixing HEES oils with hydraulic oils or mineral oils or LIEBHERR oils:
max. 2%

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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. 5-12 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
separately (Id. No. 8145666). LEC/en/Edition: 02 / 2015

Fig. 5-13 Taking an oil sample

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5.4.4 Swing and travel gear oils

Note!
For a given machine operating temperature range, and if different viscosity grades
are approved according to the following specifications, always choose the lubricant
with the highest viscosity grade.

Use gear oil meeting following viscosity classes and specifications (depending on the
ambient temperature):

Fig. 5-14 Gear oils for use as swing and travel gear oils

* COB-1: Gear oil according to DIN 51517, part 3, CLP-HC(1)

(1)
HC / Synthetic carbon hybrid (poly-alpha-olefin PAO)
TEST / REQUIREMENT STANDARD / REFER- REQUIRED LEVEL /
ENCE PERFORMANCE
Relative scuffing load-carrying capacity A/8.3/90 DIN ISO 14635-1 >14
Relative scuffing load-carrying capacity A/16.6/140 DIN ISO 14635-1 >12
FVA-FZG micro-pitting load capacity GT-C/8.3/90 FVA Information sheet GT-High
no. 54/I-IV
FE-8 roller bearing wear tests 7.5/80/80 and 7.5/100/80 DIN 51819-3 Pass (excellent)
FLENDER AG approval - Approved
LEC/en/Edition: 02 / 2015

Tab. 5-5

FVA = Forschungsvereinigung Antriebstechnik e.V. ("Research association for drive technologies")

FZG = Forschungsstelle fr Zahnrder und Getriebebau der TU Mnchen ("Gear Research Center
of the Technical University of Munich")

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** COB-2: Gear oil according to DIN 51517, part 3, CLP

TEST / REQUIREMENT STANDARD / REFER- REQUIRED LEVEL /

ENCE PERFORMANCE
FVA-FZG micro-pitting load capacity GT-C/8.3/90 FVA Information sheet GT-High
no. 54/I-IV
FE-8 roller bearing wear tests 7.5/80/80 and 7.5/100/80 DIN 51819-3 Pass (excellent)
FLENDER AG approval - Approved
Pour point temperature ISO 3016 VG220: TPour point < -15C
VG320: TPour point < -15C
VG460: TPour point < -10C
VG680: TPour point < -5C
Tab. 5-6

*** COB-3: Gear oil according to API classification GL5

TEST / REQUIREMENT STANDARD / REFER- REQUIRED LEVEL /

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

**** COB-4: Gear oil according to API classification GL5

TEST / REQUIREMENT STANDARD / REFER- REQUIRED LEVEL /

ENCE PERFORMANCE
API classification GL 5 -
Scuffing load capacity FZG test A/8.3/90 DIN ISO 14635-1 >12
MIL-L 2105 D, PRF-2105E -
MAN 342 type N -
ZF Friedrichshafen TE-ML 05A, 07A, 16D, -
21A
Tab. 5-8
LEC/en/Edition: 02 / 2015

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.

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Fig. 5-15 Gear oils for use as splitterbox oil

5.4.6 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 ac-
points cordance 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 0C and -15C Use a grease with consistency classification 1 NL

(32F and 5F) GI or EP1 grease.

Between -15C and -40C Only employ synthetic greases. We recommand

(5F and -40F) 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
LEC/en/Edition: 02 / 2015

Lubricant for pistons, piston Gleitmo 800

nuts and piston bearing in-
stallations on the hydraulic
cylinders
Special anti-corrosive materi- Castrol-Tarp
al for installation areas of
sealingelements on hydraulic
cylinders

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Lubricant Description / manufacturer

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

Tab. 5-9 Lubricating grease and other lubricants

5.4.7 Coolant

See the Operation and Maintenance Manual for CUMMINS engine.

5.4.8 Lubricants specifications for -40C

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 -40C to +30 (if the excavator is equipped with a preheating
the temperature range can start at -50C instead of -40C).

Hydraulic oil
See the part hydraulic oils

Gear oil
SAE 75W90 API GL5 : Purpoint < -54C
Like BP gear oil SHXM 75W90 :
Ident-Nr. 8503299, drum 20 l
Ident-Nr. 10033025, drum 208 l
From -50C to +40C
Like AVIA Gear oil Synthogear FE 75W90 EP from -50C to +40C

Grease : general lubepoint

Low temperature grease : Liebherr universal grease Artic
LEC/en/Edition: 02 / 2015

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. 10296824 container 25 kg
Ident-Nr. 10296823 container 50 kg
Ident-Nr. 10296822 drum 180 kg
Grease BP Energrease SY PM drum 165 kgfrom -30C to +30C,
Ident-Nr.8503731

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Diesel engine

Grease BP Energrease SY PM drum 45 kgfrom -30C to +30C,

Ident-Nr.10279983
Grease Liebherr Spezialfett 1026 LS drum 180 kgfrom -30C to +60C,
Ident-Nr.10113698
Grease Petro-Canada Multiflex Moly EP1from -50C to +20C,
Fuchs Urethym HGOfrom -55C to +0C,

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
Ident-Nr. 10296825 container 10 kg
Ident-Nr. 10296824 container 25 kg
Ident-Nr. 10296823 container 50 kg
Ident-Nr. 10296822 drum 180 kg
from -50C to +20C
Grease Petro-Canada Vulcan Synthetic Arctic from -55C to -20C.

5.5 Diesel engine

Refer to the CUMMINS Operation and Maintenance Manual for detailed descrip-
tion of maintenance work to be performed.
In addition, accurately observe the following items and perform all maintenance
work according to the intervals given in the maintenance schedule.

5.5.1 Check of engine oil level

Danger !
Risk of burning.
The engine oil is hot when it is at operating temperature.
Avoid contact with hot oil and components containing oil, since it could cause
severe burns.

The machine must be standing level.

Switch off the engine.
LEC/en/Edition: 02 / 2015

Wait for a few minutes for the oil to collect in the oil pan.

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Fig. 5-16 Oil level markings on the dipstick

Check the oil level in the engine.

The oil must be between the min and max marks on the dipstick 1.

5.5.2 Diesel engine oil change

Note !
Only carry out the oil change when the engine is warm.

Fig. 5-17 Filler neck and service trap

To drain the oil:

Drain the engine oil sump.
LEC/en/Edition: 02 / 2015

Bring the engine to operating temperature.

Drain the oil via the quick change coupling in the service center (pos. 6).
As a help way, the oil can also be drained via the drain valve on the oil pan of the
Diesel engine.
To do so, remove the cap of the drain valve, attach the drain hose (supplied in the
toolbox) to the drain valve and drain the oil into a suitable container.
Remove the hose, reinstall the cap on the drain valve and add oil via the filler neck

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Diesel engine

2.

To replace the oil filter elements:

Fig. 5-18 Oil filter elements

Unscrew and remove the 3 filter elements, pos. 3.

Each filter element is a combination oil filter comprising a full flow element and a
by-pass element.

Danger !
Risk of burning.
When removing the engine oil filters, be careful to avoid contact with hot oil, it
could cause severe burns.

Clean the sealing surfaces on the filter mounts.

Lightly lubricate the rubber seal on the new filters with oil.
Install and tighten the filters with both hands (see also enclosed CUMMINS en-
gine operation and maintenance manual).
Check after every oil change or after adding oil to ensure that the oil level has
reached the upper mark on dipstick 1.

To refill the oil:

LEC/en/Edition: 02 / 2015

Fig. 5-19 Filler neck and service trap

Refill via the quick change coupling 6 until the max. mark is reached on dipstick 1.

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Maintenance Operating manual
Diesel engine

A small amount of oil can also be refilled via the filler neck 2, or via the Centinel
valve if the excavator is equipped with Centinel system.
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.

5.5.3 Mounting screws

Fig. 5-20 Engine mounting screws

Torque
1 Hexagonal head screw M20x130 560 Nm
2 Hexagonal head screw M16x80 280 Nm
3 Socket head screw M16x110 280 Nm
LEC/en/Edition: 02 / 2015

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.

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 Operating manual Maintenance
Diesel engine

Caution!
Loctite nr. 243 must be applied on mounting screws 1, 2 and 3 when installing in
order to avoid possible damages on the parts.

The screws 1, 2 and 3 must only be tightened after the engine and the splitterbox
has been positioned on the PowerPack frame as a complete unit, to avoid a preten-
tioning of the rubber mounting.

5.5.4 Elastic bedding

Fig. 5-21 Engine elastic bedding

The two rubber buffers 4 at the front face of the engine must be checked and re-
placed at regular intervals.
For maintenance intervals, see control and maintenance chart.
LEC/en/Edition: 02 / 2015

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Maintenance Operating manual
Splitterbox

5.5.5 Belt for the 24 V alternator of the Diesel engine

Fig. 5-22 Belt

Please refers to the enclosed CUMMINS Operation and Maintenance Manual.

5.6 Splitterbox

5.6.1 Splitterbox mounting screws

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

LEC/en/Edition: 02 / 2015

Fig. 5-23 Splitterbox mounting screws

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 Operating manual Maintenance
Splitterbox

Torque
1 Hexagonal head screw M20x130 460 Nm
2 Hexagonal head screw M16x80 280 Nm
3 Socket head screw M16x110 280 Nm

Check the mounting screws on the splitterbox brackets regularly for tightness, re-
torque if necessary.
For maintenance intervals, see control and maintenance chart.

Caution!
Loctite nr. 243 must be applied on mounting screws 1, 2 and 3 when installing
in order to avoid possible damages on the parts.
The screws 1, 2 and 3 must only be tightened after the engine and the splitterbox
has been positioned on the PowerPack frame as a complete unit, to avoid a pre-
tentioning of the rubber mounting.

Fig. 5-24 Mounting screws

LEC/en/Edition: 02 / 2015

Torque
1 Hexagonal head screw M12x90 115 Nm

Check the tightness of mounting screws 1 from the splitterbox to the Diesel en-
gine housing regularly, retorque if necessary.
For maintenance intervals, see control and maintenance chart.

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Maintenance Operating manual
Splitterbox

5.6.2 Elastic bedding

Fig. 5-25 Elastic bedding

The two rubber buffers 1 at the splitterbox side must be checked and replaced at
regular intervals.
For maintenance intervals, see control and maintenance chart.

LEC/en/Edition: 02 / 2015

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 Operating manual Maintenance
Splitterbox

5.6.3 Breather filter

Fig. 5-26 Breather filter on splitterbox

The breather filter 1 on the splitterbox must be checked, cleaned and replaced reg-
ularly.

To clean the breather filter:

Open breather filter 1 by pushing it and turning it 1/4 turn.
Remove the filter element 2 from the breather housing.
Check filter condition and clean it with fuel.
Reinstall the filter element in the breather housing.
Close breather 1.
For check, clean and change intervals, see maintenance and control chart.
LEC/en/Edition: 02 / 2015

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Maintenance Operating manual
Cooling system

5.7 Cooling system

5.7.1 Checking and cleaning the cooling system

Fig. 5-27 expansion tank

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
7 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.
LEC/en/Edition: 02 / 2015

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 Operating manual Maintenance
Cooling system

5.7.2 Checking the coolant level

Fig. 5-28 expansion tank

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.
Turn the cap 6 slowly to release pressure.

Check the coolant level when the engine coolant is cold.

When cold, the coolant level should not drop below the bottom end of the filler
neck under the cap 6 of the expansion tank 7.
LEC/en/Edition: 02 / 2015

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Maintenance Operating manual
Cooling system

5.7.3 Coolant antifreeze and anti-corrosion fluid

Fig. 5-29 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).
Volume: see lubricant chart
The coolant filters installed on the engine contain a corrosion protector.
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.

5.7.4 Changing the coolant

Danger!
Risk of burning due to hot coolant.
Only change the coolant when the engine is cold.

LEC/en/Edition: 02 / 2015

Fig. 5-30 Coolant filters

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

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 Operating manual Maintenance
Cooling system

er corrosion protection properties of the coolant.

The filters must be replaced every 250 operating hours
Turn the shut off valve on the filter head to the OFF position,
Unscrew and remove the filter elements,
Lightly oil the seal rings on the new filter element,
Screw on the new elements until the seal ring touches the filter 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 maintenance
manual.

Draining the coolant

Fig. 5-31 Draining the coolant

For coolant change interval, see CUMMINS Operation and Maintenance Manual.

To drain the coolant

The drain plug is located under the radiator (pos. 1).
For the procedure to drain and refill the engine cooling system refer to the CUMMINS
engine operation and maintenance manual.

Important!
When refilling the system, make sure that the coolant level should not drop below
the bottom end of the filler neck under the cap 6 of the expansion tank 7.
LEC/en/Edition: 02 / 2015

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Maintenance Operating manual
Fuel system

5.8 Fuel system

Danger!
Risk of explosion!
Avoid naked flame when working on the fuel system and when refuelling.
Do not smoke.
Only work on the diesel engine when it is switched off.

5.8.1 Refuelling

Fuel filler cap

LEC/en/Edition: 02 / 2015

Fig. 5-32 Fuel filler cap

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 Operating manual Maintenance
Fuel system

Unscrew fuel filler cap 17

Add fuel via the filler sieve.

Service trap

Fig. 5-33 Service trap

Add fuel via the service trap (pos. 110).

LEC/en/Edition: 02 / 2015

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Maintenance Operating manual
Fuel system

5.8.2 Draining the fuel tank

Fig. 5-34 Draining the fuel tank

LEC/en/Edition: 02 / 2015

To drain the fuel tank and the fuel system daily:

Place a suitable container underneath.
Turn the drain plug 1 on the drain valve 55 found on the underside of the fuel tank,
on the valve by two turns counterclockwise.
Drain off the water until clean fuel starts to come out.
Screw drain plug 1 closed again.
If conditions of use and fuel quality permit, the maintenance interval can be increased

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 Operating manual Maintenance
Fuel system

to one week.

Note!
To reduce the formation of condensate in the tank, keep the fuel level as high as
possible.

Display P3 indicates the fuel level.

When the red bar P3.1 illuminates, a low reserve quantity is still in the tank.
In the event of a low fuel level, refill the tank before starting to work.
LEC/en/Edition: 02 / 2015

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Maintenance Operating manual
Fuel system

5.8.3 Emptying and cleaning the fuel tank

LEC/en/Edition: 02 / 2015

Fig. 5-35 Fuel tank

The tank floor is fitted with a drain valve 55.

Place a suitable container underneath.
To drain off the water, unscrew the drain plug 1 on the drain valve 55 by two turns
until fuel which contains no water comes out.
Retighten the plug.

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Fuel system

To empty, remove the cover 3 and the drain valve 55 and collect the fuel in a suit-
able container.
Check the fuel tank.
Wash out the fuel tank.

5.8.4 Draining and changing fuel filter cartridges

Fig. 5-36 Fuel filter cartridges

Unscrew and remove the 3 filter elements (pos. 3).

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.
Lightly lubricate the rubber seal on the new filters with oil.
Install and tighten the filters with both hands (see also enclosed CUMMINS en-
gine operation and maintenance manual).
LEC/en/Edition: 02 / 2015

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Maintenance Operating manual
Fuel system

5.8.5 The air pressure system

Fig. 5-37 Air pressure system

During operation, the pressure on both pressure gauges 15 must be between 6,2 and
7,25 bar.

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 drain valve 12 until the air pressure drops to approx. 6,2 bar.
The pressure regulator 2 must now shift the compressor into the working cycle.
LEC/en/Edition: 02 / 2015

Continue to run the engine at low idle. When the pressure reaches 7,25 bar, the
regulator shifts the compressor to the neutral cycle.
Adjust the pressure regulator if necessary until both, pressures are correct.
For maintenance intervals, refer to the maintenance schedule and to the CUMMINS
Operation and Maintenance Manual.

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Fuel system

The air dryer

Fig. 5-38 The air dryer

The air dryer 4 in the air pressure circuit dries and filters the pressurised air.
The air filter element must be replaced at intervals specified in the maintenance
schedule.
LEC/en/Edition: 02 / 2015

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Maintenance Operating manual
Fuel system

To replace the air cleaner element

Fig. 5-39 The air cleaner element

Relieve the pressure in the air system via the drain valve 12.
Disconnect the air pressure line 5 on the outlet 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; turn the cartridge back and forth if nec-
essary.
Lubricate the o-rings 9 and 10 with oil.
Push in the new air filter cartridge, using a turning motion and make sure that the
LEC/en/Edition: 02 / 2015

o-ring 9 on the upper end of the cartridge is inserted into the filter housing.
Reinstall spring 7, the centering piece 6, o-ring 10, cover 2 and tighten nuts 1.

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Fuel system

To drain the air tank

Fig. 5-40 Drain valve

We still recommend to drain condensation manually by opening the drain valve 12,
regularly as specified in maintenance schedule.
LEC/en/Edition: 02 / 2015

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Maintenance Operating manual
Dry air filter

5.9 Dry air filter

Fig. 5-41 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
safety element are designed to give maximum protection at long maintenance inter-
vals.
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.
LEC/en/Edition: 02 / 2015

The primary filter elements 3 must be replaced:

Immediately when the maximum vacuum pressure has been reached.
At the intervals specified in the control and maintenance chart, if the maximum
vacuum pressure has not been reached first.
To reset the vacuum indicator, press the "Reset" button 19.
If the elements 3 are removed and installed too often, the seals between the filter el-
ements and the filter housing may be damaged.

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Dry air filter

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

5.9.1 To change the primary filter element

Fig. 5-42 Primary filter element

Turn the engine off.

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.
LEC/en/Edition: 02 / 2015

Tighten nuts 2.

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Maintenance Operating manual
Dry air filter

5.9.2 Changing the safety element

Fig. 5-43 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.
LEC/en/Edition: 02 / 2015

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 Operating manual Maintenance
Dry air filter

5.9.3 To clean the air channels for the precleaner

Fig. 5-44 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.

5.9.4 Check the air intake system, hoses, elbows, clamps

LEC/en/Edition: 02 / 2015

Fig. 5-45 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

Do a visual check of the air intake system at the intervals given in the control and
maintenance chart.
Do a sealing control of the air intake system at the intervals given in the control
and maintenance chart.
Do also a sealing control of the air intake system each time you replace a com-
ponent of the air intake duct.
Use the sealing control tool ID. 11480004 to do the sealing control of the air intake
system.

5.10 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.

5.10.1 Preparatory activities

LEC/en/Edition: 02 / 2015

Fig. 5-46 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.

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Hydraulic system

Turn the engine off.

5.10.2 Checking the oil level in the hydraulic tank

Fig. 5-47 Hydraulic tank oil level

When the machine is in the check position, the level must not lie below the central
marking on the inspection window.
LEC/en/Edition: 02 / 2015

If this is not the case, add oil via the service plate 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 drawn
in.
The lower marking MINI shows the minimum oil level if all cylinders are fully extend-
ed.
If the oil level drops below the lower marking MINI, the symbol appears on screen
when the lowest quantity is reached.

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Hydraulic system

5.10.3 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.
Switch off the engine.
Move the pilot control devices (joystick and pedals) in all directions (with the igni-
tion key in the contact position).
The hydraulic tank is depressurised automatically thank to the air filter.

Danger!
The hydraulic oil is hot when at operating temperature.
Do not allow the hot oil or oil-bearing parts to touch the skin.

5.10.4 Emptying and refilling the hydraulic tank

Fig. 5-48 Front plate

We recommend to add and to drain the hydraulic oil to the tank only via the cou-
pling 13 and 14 in the service center.

To drain the oil:

LEC/en/Edition: 02 / 2015

Use the coupling 14.

To refill the hydraulic oil:

Use the coupling 13.

Caution!
After each hydraulic oil change, vent the hydraulic pumps.

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Hydraulic system

Fig. 5-49 Covers of the return filter

As a help way, or for small quantities oil can also be added via the cover 21 of the
return filter :
Remove one of the covers 21 of the return filters.
Add oil via the return filter until the level is exactly at the center mark of the sight
gauge.
Reinstall the cover 21.

5.10.5 Return-line filters and air filter

The return-line filters and the air filter are located on the top of the hydraulic tank.
LEC/en/Edition: 02 / 2015

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Fig. 5-50 Return-line filter

1 Cover 5 Filter insert

2 Magnetic rod 8 O-ring
3 Hexagon bolt 10 Air filter

The magnetic rods 2 of the return-line filter must be cleaned at fixed intervals (see
maintenance chart) and the glass fibre filter insert 5 replaced.

To clean the magnetic plug and replace the filter element:

LEC/en/Edition: 02 / 2015

Unscrew the screws on the filter cover and lift out cover 1 and magnetic rod 2.
Carefully clean off any dirt sticking to the magnetic rod.
Remove the used filter cartridge 5 on the bracket.
Insert the new filter cartridge on the bracket vertically into the tank and press
down lightly. Then lay the clamp to the side on the tank ring.

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Caution!
Ensure that the filter cartridge is standing vertical in the tank.

Centre the cover unit on the filter insert 5 and position. When doing this, ensure
that the sealing 8 is positioned correctly and is in good condition.

Note!
The filler aperture of the hydraulic tank is fitted with a return pipe. This prevents ob-
jects getting into the hydraulic tank. The protective cylinder can be removed from
the filler aperture if required.

Note!
Each time you replace the filter insert 5, also replace the pressure filter cartridge
that is integrated in the control oil unit.

5.10.6 Servo oil filter

LEC/en/Edition: 02 / 2015

Fig. 5-51 Control oil unit

4 Filter element 6 Filter head

5 Filter housing 7 O-ring

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Hydraulic system

Note!
It is not permitted to clean the filter element.
Change the filter element each time you open the filter housing.

Three hydraulic filters ensure filtration of the auxiliary circuits :

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

To replace the filter element:

Remove the filter housing 5,
Take out the filter element 4,
Clean the filter head 6 and the filter housing 5.
Insert a new filter element 4,
Lightly lubricate the threads of the housing,
Reinstall the filter housing,
Making sure the O-ring 7 is positioned correctly,
Tighten the filter housing by hand.

5.10.7 Control circuit

LEC/en/Edition: 02 / 2015

Fig. 5-52 Accumulator

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

Danger!
Before working on the control circuit, the control pressure must be depressurized
as follows:
Lay the work equipment on the ground.
Switch off the engine.
Operate both joysticks (with ignition key in contact position).

5.10.8 Bleeding the main pumps

Fig. 5-53 Working pump

After working on the pump or after changing oil in the hydraulic system, the hydraulic
pump must be bled.
Unscrew the leakage oil hose slightly and allow the air to escape.
As soon as hydraulic oil flows out densely, close the leakage 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.
LEC/en/Edition: 02 / 2015

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Hydraulic system

5.10.9 Bleeding the swing pumps

Fig. 5-54 Swing pumps

After working on the pump or after changing oil in the hydraulic system, the hydraulic
pump must be bled.
Unscrew the plugs slightly and allow the air to escape.
As soon as hydraulic oil flows out densely, close the plugs again.
Before starting the pump for the first time after repairing or replacing the pump, the
pump housing must be filled with hydraulic oil via the same hole.

5.10.10 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.

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
LEC/en/Edition: 02 / 2015

might explode (Diesel effect).

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Hydraulic system

5.10.11 Unscrew the intake hoses to the pump

Fig. 5-55 Pumps aspiration (intake hoses)

LEC/en/Edition: 02 / 2015

Fig. 5-56 Shut off valves

The shut off valves on the hydraulic tank to the intake hose has two positions:
a open

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Hydraulic system

b closed
If the intake hose 10 has to be unscrewed at the pump or at the hydraulic tank,
close the shut off valves (position b) on the hydraulic tank.
Unscrew the intake hoses 10 or one of the intake hoses 10.
Drain the hydraulic oil out of the pump and intake hose 10.
Once the repair work is completed, turn the shut off valves back to its starting po-
sition a and engage.

5.10.12 High pressure filters in working circuit

Fig. 5-57 High pressure filter

These filters are installed 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.

To clean the filter element :

Caution!
Risk of oil spilling when removing the filter housing. Oil spilling could be reduced by
using a vacuum pump.

Remove the filter housing 1.

LEC/en/Edition: 02 / 2015

Remove the filter element 2 and clean it with non flammable cleaning fluid, or re-
place it with a new element,
Clean the filter housing 1 and the filter head and reinstall, making sure the o-rings
4 and 5 are seated properly.

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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.

5.10.13 Oil cooler protection filters (optional)

Fig. 5-58 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.
For maintenance intervals, see control and maintenance chart.

Caution!
If filters maintenance isnt correctly carried out, filters clogging due to regular oper-
ation of the excavator could lead to following risks:
cooling capacity drop,
LEC/en/Edition: 02 / 2015

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.

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Hydraulic system

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 sev-
eral 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.

5.10.14 Servicing the hydraulic cylinder

Checking the condition of the piston rod mount

Fig. 5-59 Piston rod mount

Note
When a leak appears on the piston rod mount of a hydraulic cylinder (see arrow),
the sealing kit must be replaced by a LIEBHERR dealer.

Protecting the piston rods

LEC/en/Edition: 02 / 2015

Fig. 5-60 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.

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 Operating manual Maintenance
Hydraulic system

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
hydraulic oil (eg. cylinder on slewing arm when working over ground).
Check the condition of hydraulic cylinders which are not moved a great deal reg-
ularly.

5.10.15 Replacing hydraulic hoses

Danger!
The service life of a hose assembly, including a storage time of the hose assembly,
must not be more than six years. The storage time must not be more than two
years.
When you check a hose assembly or you install a new one, refer to the date of
assembly marked on the hose assembly nipple.
For hoses maintenance, refer to the control and maintenance chart.
LEC/en/Edition: 02 / 2015

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Maintenance Operating manual
Hydraulic system

General information

Fig. 5-61 SAE flanges

1 Flat single-part flange 4 Half flange with boss

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

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.
LEC/en/Edition: 02 / 2015

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:

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 Operating manual Maintenance
Hydraulic system

Size of screw Thread pitch Valid for flange Valid for flange Bolt/screw with Oil/grease on
(grade 10.9) (mm) size CODE 61 size CODE 62 thread bolt/screw or
completely dry inside the
(Nm) thread (Nm)
M8 1,25 1/2" 1/2" 25 20
M10 1,5 3/4", 1", 1"1/4 3/4" 55 45
M12 1,75 1"1/2, 2" 1" 100 80
M14 2 1"1/4 140 110
M16 2 1"1/2 230 180
M20 2,5 2" 430 340
Tab. 5-10

Tab. 5-11 Tightening torques for SAE flanges

Note!
These tightening torque values are also applicable to the mounting screws of the
sealing flanges and hydraulic blocks.

Fig. 5-62 Sealing flange 1 and hydraulic block 2

SAE half flanges installation

LEC/en/Edition: 02 / 2015

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.

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Maintenance Operating manual
Hydraulic system

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.

5.10.16 Progressive criss-cross tightening procedure

Note!
Always use this procedure to install the following flanges types:
half flanges,
single-part flanges,
conical flanges,
monobloc flanges (welded).

Fig. 5-63 Criss-cross tightening

Make sure that all mounting surfaces have no damage, grease or contamination.
Install the O-ring without grease in the groove of the hose fitting.
Put the hose in position onto the mounting surface (be careful that you do not
cause damage to the O-ring or remove the O-ring).
Pre-install the flange and pre-tighten the mounting screws by hand.
Tighten the screws progressively in a criss-cross pattern:
first to 50% of the prescribed torque value,
then to 100% of the prescribed torque value.
LEC/en/Edition: 02 / 2015

Check the tightening torque clockwise.

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 Operating manual Maintenance
Oil changes on components

5.11 Oil changes on components

5.11.1 General information

The machine must be standing level.
Switch off the engine.
Wait briefly until the oil has collected in the oil sump.
Drain off the oil (preferably when oil is at operating temperature)
Add the oil.
Check the oil level.
Oil quality and quantity: see lubricant chart.
Change intervals: see lubrication and maintenance chart.
LEC/en/Edition: 02 / 2015

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Oil changes on components

5.11.2 Swing gear transmission oil change

Fig. 5-64 Changing the oil on the slewing gear transmission

1 Drain valve 7 Expansion reservoir

3 Filler tube 8 Hose
4 Sealing cap 9 Hose
6 Drain hose
LEC/en/Edition: 02 / 2015

Note!
The oil in the swing gears must be changed at operating temperature.

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 Operating manual Maintenance
Oil changes on components

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

To drain the oil :

Remove the sealing cap 4.
Unscrew the cover of the drain valve 1.
Screw the drain hose provided 6 to the drain valve and let the oil flow out into a
suitable container.
Remove the hose 6.
Screw the cover of the drain valve 1 back on.
Put the sealing cap 4 on the expansion reservoir 7.

To add the oil :

For small quantities :
Remove the caps 4.
The oil refilling may be done via the filler tubes 3.
Each expansion reservoir is connected to the upper section of a swing gear via
two hoses 8 and 9.
When there is more oil to add :
Unscrew the hoses 8 and 9 of the swing gear.
Add oil in the swing gear via the two holes who were screwed the hoses 8 and 9.
When the oil level is sufficient, screw the hoses 8 and 9 on the swing gear.

The oil level :

The oil level must reach the middle of the lower sight glass "L" of the expansion res-
ervoir 7 when the oil is cold, and must not overpass the sight gauge "H" when the oil
is hot.

Note!
If at operating temperature the oil level is lower than the sight glass "L", oil must be
refilled.
LEC/en/Edition: 02 / 2015

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Oil changes on components

5.11.3 Oil change on travel gear and Lifetime travel gear (optional)

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.

Oil change on travel gear

LEC/en/Edition: 02 / 2015

Fig. 5-65 Travel gear - adding and draining oil

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

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

To drain the oil:

Ensure that you have a suitable oil drainage container to hand.

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

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

To add the oil:

With the drain plugs 3 and 5 installed,
Slowly add oil via bore 2 until oil runs out.
Reinstall plug 2.
For oil specification and oil quantity, refer to the lubrication chart. For oil change in-
tervals, refer to the Maintenance Schedule.

Oil change on Lifetime sealing interspace (optional)

Fig. 5-66 Interspaces oil expansion tank

9 Filler tube 11 Expansion tank

10 Sealing cap
LEC/en/Edition: 02 / 2015

Caution!
For the Lifetime sealing interspaces, always use the same oil as used to fill the hy-
draulic tank.

To drain the oil:

Make sure you have a suitable oil drain container at your disposal.
Remove sealing cap 10.
Remove drain plug 3.

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Oil changes on components

Drain the oil into a suitable container.

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.

Make sure you have a suitable oil drain container at your disposal.
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.
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 in installed on the travel gear.

Remove sealing cap 10.
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.

5.11.4 Swing gears and travel gears flushing

Caution!
LEC/en/Edition: 02 / 2015

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.

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Oil changes on components

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.

5.11.5 Splitterbox oil change

LEC/en/Edition: 02 / 2015

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Oil changes on components

Fig. 5-67 Oil change on the splitterbox

1 Drain valve 3 Oil inlet cap

2 Dipstick 4 Splitterbox oil change coupling

To check the oil level in the splitterbox:

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.
Drain the oil into a suitable container.
LEC/en/Edition: 02 / 2015

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.

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 Operating manual Maintenance
Track components

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.

5.12 Track components

The track components are maintenance-free until the regeneration of the treads or
the cylinder or until all running gear parts are completely worn.
The lifetime design of the support rollers, track rollers and leading wheels increases
the track components lifetime and metal sealing make it insensitive to dirt.

5.12.1 Checking the track components mountings

LEC/en/Edition: 02 / 2015

Fig. 5-68 Running gear component mountings

2 Travel gear 17 Screw M 24 960 Nm

3 Screw M 30x2 1940 Nm 20 Sprocket
4 Washer 21 Screw M 30x2 1940 Nm
6 Travel motor 22 Washer
7 Screw M 20 560 Nm 25 Travel motor protection
8 Washer 31 Bracket

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Track components

10 O-ring 32 Washer
15 Cover 33 Screw M 30 1900 Nm
16 Washer

Fig. 5-69 Track components

3 Side frame 28 Screw M 20 390 Nm

6 Screw M 42 4810 Nm 35 Cover
7 Screw M 42 4810 Nm 36 Screw M 10 68 Nm
8 Washer 37 Washer
13 Travel drive 51 Screw M 30 1900 Nm
14 Hyd. instal. motor-rot. 52 Washer
25 Travel motor cover 56 Screw M 24 960 Nm
27 Washer 57 Washer

Carry out regular checks for loose mounting screws on the base plates and trav-
elling mechanisms.
LEC/en/Edition: 02 / 2015

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 Operating manual Maintenance
Track components

5.12.2 Monitoring the track tension

Fig. 5-70 Monitoring the track tension

Relieve the tracks by driving the machine forwards and backwards.

Place the measuring rod 1 in the area between the leading wheel and the carrier
roller
Measure distance A between the measuring rod lower edge.
The track should, under operating conditions, sag 25 to 30 mm between the
carrier roller and the sprocket.
Retension the tracks if necessary.

5.12.3 Retensioning the track

Fig. 5-71 track when insufficiently (A) and correctly (B) tensioned.

With normal wear on the sprocket and on the track chain, it is necessary to check the
track tension regularly and retension the track if necessary.
LEC/en/Edition: 02 / 2015

Fig. 5-72 Retensioning the track

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Track components

Remove the cover 6 on the side frame of the undercarriage.

Screw high pressure hose 2 onto the manual grease gun 1.
Through the opening in the side frame, connect the high pressure hose 2 to the
lubricating nipple 3 of the grease tensioner 4.
Inject grease until the track is sufficiently tensioned.
Check the track tension as described above.
Remove the grease gun 1, the pressure hose 2 and reattach the cover 6.

Danger!
When adjusting the chain tension, keep your head clear of the access hole. The
grease cylinder is under high pressure and the chain will sag.
Grease is under high pressure and might squirt out. Also make sure that the track
tension cylinder is out!

5.12.4 Releasing the track tension

Danger!
Risk of injury due to sudden dropping of the crawler or to a jet of grease under high
pressure.
Because of the risk of grease jet, always wear protective gloves and glasses
when releasing the chain tension
When releasing the tension of the chain, keep your head away from the opening
5 in the track side frame. Never touch the grease nipple 3 with your hand but
always use an appropiate tool to unscrew or screw it in.
To screw the grease nipple 3 in or out, always catch it at its rear part 3.1 with a
wrench and never at its front part.

Before attempting to release the chain tension, loosen and remove every item
which may be stucked in the chain while driving forward and backward or doing
as described in the section "Cleaning the track components" thereafter.
Carefully unscrew lubricating nipple 3 (see Fig. 5-72) by several thread pitches
until the grease escapes out of the releasing groove of the nipple.
Tighten lubricating nipple 3 as soon as the desired track tension is obtained.
After the adjustment procedure, drive the machine forwards and backwards and
check the track tension again as described above.

5.12.5 Cleaning the travel gear

LEC/en/Edition: 02 / 2015

Do not operate the machine if larger stones, pieces of wood or metal, wires or cables
are trapped in the running gear.
Dried or frozen mud and stones or other foreign bodies in the travel gear parts could
result in considerable damage to the machine if the machine is operated or an at-
tempt is made to free the machine using engine power.

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Note!
All the chain pins of the travel gear must be greased with black grease (Ident Nb.
8503279).

5.13 Electrical system

5.13.1 Notes on the electrical system

Danger!
Risk of injury due to formation of sparks.
Avoid sparks and naked flame when charging batteries or working on the batter-
ies.
Always wear protective goggles and gloves.

Check that the machines 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 or when carrying
out electric arc welding on the machine.

Danger!
Risk of injury due to formation of sparks.
Disconnect the negative terminal (-) first and connect it last.

5.13.2 Main battery switch

Caution!
Take particular care with machines with built-in independent heating.
Only switch off the main battery switch when the independent heatings run-on
is over.
LEC/en/Edition: 02 / 2015

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Maintenance Operating manual
Electrical system

Fig. 5-73 Main battery switch

Before starting any work on the electrical system, including welding work on the
machine, switch the main battery switch to position 0.
When washing the machine, cover the electrical units (particularly the alternator,
generator, cabling, electronic components and measured value sensor) to pre-
vent water penetrating.
When cleaning the engine with a water / steam jet, do not subject electrical meas-
ured value sensors such as oil pressure switches to any direct jets.
If this happens, moisture could penetrate and lead to contact corrosion and the
failure of the measuring function.
Oil pressure switches are not watertight due to the necessary presence of
membrane ventilation.

Note!
Batteries can become flat if the machine is out of service for longer periods.
Before laying up the machine for longer periods, switch the main battery switch
to position 0 (off).

5.13.3 Battery care

The battery 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 A reg-
ularly and to then cover them with a thick layer of acidproof grease (see Fig. 5-74).

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.
LEC/en/Edition: 02 / 2015

Check the condition of the hoses regularly, particularly after installing a battery
(see Fig. 5-74).

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.

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Fig. 5-74 Battery care

From time to time, measure the acid concentration C using an acid tester.
When the battery is fully charged, the unit weight is 1.28 kg/l (31.5 B).
If the acid tester displays a lower value, the batteries is virtually flat and should be
charged if necessary.
LEC/en/Edition: 02 / 2015

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Electrical system

5.13.4 Electrical components location

LEC/en/Edition: 02 / 2015

Fig. 5-75 Electrical components location

E1003Power connection box E1022_1Connection box / ladder control

E1005Cabin connection box
E1006Cabin connection box / air condi- E1022_2Connection box / trap control
tioner H1 Monitoring display

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E1010Cabin connection box / greasing S2 Control unit

S9_1Engine battery switch
S100_1, 2, 3, 4 and 5Emergency stop

5.13.5 Electrical boxes and cab pressurization

Fig. 5-76 Aeration device

This aeration device is located on the rear top of the cab.

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 replace the main element and the safety element of the air filter system
of this device.
For maintenance interval, refer to the control and maintenance chart.
LEC/en/Edition: 02 / 2015

5.14 Heating/air-conditioning system

The excavator has a heating and an air conditioning system as standard.

The heating system operates with a heater under the cab floor.
The air conditioning system has the elements that follow:
A compressor installed on the Diesel engine.

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Heating/air-conditioning system

An evaporator located in the roof of the cab.

A filter/dryer/receiver unit located in the cab elevation.
A condenser installed on the Diesel engine cooler.

Note!
An optional dual air conditioning system can be installed. In this case, a second air
conditioning unit is installed on the side of the cab. This second unit has:
A compressor (hydraulically operated by an additional pump installed on the
splitterbox).
A condenser battery.
A filter/dryer/receiver unit.

Note!
In case of repair at condenser or receiver, the refrigerant must be removed and col-
lected in an applicable receiver. The collected refrigerant can be cleaned and re-
prepared by refrigerant manufacturers.

For maintenance intervals, see control and maintenance chart.

5.14.1 Heating system

The heater and the air conditioner can be used at the same time or independently of
each other to ventilate the cab.

LEC/en/Edition: 02 / 2015

Fig. 5-77 Heater and evaporator locations

50 Heater 60 Evaporator
70 Air grid

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Heating/air-conditioning system

Fig. 5-78 Heating system

2 Heat exchanger of the heater 3 New air filter of the heater

5 Shut-off valves

The airflow in the heating system is reduced if the filters are dirty and this frequently
causes frost and shut down of the system.
Remove and clean the heat exchanger 2 and the new air filter 3 at intervals spec-
ified in the control and maintenance chart.
Do not operate the machine, even briefly, without the filters 3 because, in this
case, the heat exchanger 2 will quickly become blocked.

Note!
Independently from weather conditions, the two coolant shut-off valves 5 located on
the Diesel engine must always remain open.

To clean and change the new air filter:

Remove the new air filter 3.

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.

To check the heat exchanger:

Check the plates of the heat exchanger 2 annually for damage.
LEC/en/Edition: 02 / 2015

5.14.2 Air-conditioning system

Switch on the air conditioning system for approximately 10 minutes every 2 or 3
weeks, regardless of the season.

During the warm season, perform checks or maintenance works that follow.

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Condenser check:

Fig. 5-79 Condenser

Check the heat exchanger of the condenser 6 located on the engine cooler box 2.
If necessary, blow it out with pressurised air or steam from the inner (fan side) to
outside.

Filter check:
Check and clean the recirculating air filter 70 on the evaporator 60 in the cab.

Filter/dryer/receiver unit check:

LEC/en/Edition: 02 / 2015

Fig. 5-80 Filter/dryer/receiver unit

5 Receiver 6 Filter/dryer
7 Sight glass

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Heating/air-conditioning system

Check condition of receiver 5 and filter/dryer 6.

If corrosion, rust or mechanical damage formation is seen on the receiver 5 (on
mounting consoles, connecting parts, ...), so it must be replaced immediately by
reasons of explosions. While replacing, take care of the mounting direction. The
exit is marked with an "A" and the top side is marked with "OBEN".
The filter/dryer 6 must be replaced at regular intervals, at least once a year. It
must be also replaced after each opening of the refrigerant circuit. The arrow sym-
bols on the filter/dryer must be located in the direction 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 filter/dryer/receiver while the air condi-
tioner is operating. Bubbles or foam in the sight glass 7 indicate an insufficient
refrigerant charge.
In this case, the system must be checked and refilled by a trained specialist.
Check the colour 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/dryer 6 must
be replaced immediately by a trained specialist.

Compressor check:

Fig. 5-81 Compressor on Diesel engine

Check for possible damages on the compressor 3 installed on the Diesel engine.
Check compressor fastening.
Check condition, alignment and tension of the related V-belt.
LEC/en/Edition: 02 / 2015

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Heating/air-conditioning system

5.14.3 Dual air conditioning system (optional)

Fig. 5-82 Location of the optional air conditioning system

LEC/en/Edition: 02 / 2015

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 Operating manual Maintenance
Drive unit brakes and swing gear brakes

Fig. 5-83 Components of the optional air conditioning system

5 Receiver 8 Compressor
6 Filter/drier 9 Condenser battery
7 Sight glass 10 Fan

If installed, switch on the second air conditioning system for approximately 10

minutes every 2 or 3 weeks, regardless of the season.
During the warm season, perform the same check and maintenance works as for
the standard air conditioning:
Filter/dryer 6 and receiver 5.
Compressor 8.
Condenser battery 9.
LEC/en/Edition: 02 / 2015

Check conditions of fans 10 and replace if necessary (defective fan).

The fans must be free of dirt and damages.

5.15 Drive unit brakes and swing gear brakes

Both the drive unit brakes and the swing gear brakes are spring-applied, pressure-

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Maintenance Operating manual
Check mounting bolts for tightness

released multi-plate brakes. They are ventilated hydraulically and are fully sealed
and integrated in the travel gear or swing gear transmission.
Their usage purely as parking brakes makes them wear-free and therefore mainte-
nance free.

5.16 Check mounting bolts for tightness

The mounting bolts listed below must be regularly checked and retighten if nec-
essary.
See maintenance schedule for checks intervals.

Note!
When installing bolts of size bigger than M40 the thread of the screw must be slight-
ly coated with a MoS2 based grease. Also grease the bolt head supporting surface,
unless hereafter otherwise specified.

Danger!
Due to their size, most of the below listed mounting bolts require, to be tensioned
to the prescribed torque, the use of a special, hydraulic or electric actuated tension-
ing device.
These high torque tensioning devices are power tools, which must be operated by
trained mechanics, knowing the safety precautions edicted by the tool manufacturer
and that must be observed to avoid accidents or personal injury.
In particular, pay attention to chose a solid and secure reaction point for the tool and
position the reaction arm during operation. Keep clear of the reaction arm during
operation; if it must be held or steaded during operation, use alternative means of
securing the tool during operation.

Caution!
The mounting bolts of the main components (especially the bolts listed below), of
the hydraulic hoses and of the counterweight must be replaced after every removal.

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 Operating manual Maintenance
Check mounting bolts for tightness

5.16.1 Mounting bolts of the counterweight

Fig. 5-84 Counterweight bolts

The eight mounting bolts 5 (M42) must be torqued to 4810 Nm.

Note!
Grease the head and thread of the screw and the two sides of the washer with Mo-
biltac 81s grease (ID. 8503279).

5.16.2 Threaded studs of the swing ring

Fig. 5-85 Threaded studs of the swing ring

The threaded studs 4 (M36) for the mounting of the swing ring 10 to the uppercar-
LEC/en/Edition: 02 / 2015

riage 11 must be tensioned to 707,5 kN.

The threaded studs 3 (M36) for the mounting of the swing ring 10 to the undercar-
riage 12 must be tensioned to 707,5 kN.
Torque the lock nuts 5 on the studs 3 and 4 to 600 100 Nm.
To get the correct stud tension, you must use the special tensioning procedure and
tool (LIEBHERR recommends that you use the special tensioning cylinder ID.
5617448 at the required hydraulic pressure of 1350 bar, or that you use the tool ID.
10444128 at the required pressure of 1500 bar).

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Check mounting bolts for tightness

Danger!
The special tool must 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 concern-
ing this tool.
Use appropriate working platforms and lifting devices to install and hold in position
the special tool while tensioning the studs.

5.16.3 Mounting bolts of fuel tank

Fig. 5-86 Fuel tank bolts

The six mounting bolts 2 (M30) of the fuel tank must be torqued to 1900 Nm.

5.16.4 Mounting bolts of hydraulic tank

The four mounting bolts M30 of the hydraulic tank must be torqued to 1900 Nm.
LEC/en/Edition: 02 / 2015

5.16.5 Mounting bolts of Powerpack

The mounting bolts M20 of the Powerpack must be torqued to 560 Nm.

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 Operating manual Maintenance
Check mounting bolts for tightness

5.16.6 Mounting bolts of the swing gear and motor

Fig. 5-87 Swing gear and motor bolts

The mounting bolts 7 (M30) of the swing gear must be torqued to 1900 Nm.
The mounting bolts 8 (M24) of the swing motor must be torqued to 960 Nm.

5.16.7 Mounting bolts of hydraulic pumps

Fig. 5-88 Hydraulic pumps bolts

The mounting bolts M20 of the main working pumps (P1 and P2) must be torqued to
LEC/en/Edition: 02 / 2015

560 Nm.
The mounting bolts M20 of the main working pump (P3) must be torqued to 560 Nm.
The mounting bolts M20 of the water cooler fan pump (120) and the oil cooler fan
pump (140) must be torqued to 560 Nm.
The mounting bolts M12 of the control oil pump (110) and the splitterbox lube oil
pump (130) must be torqued to 117 Nm.

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General maintenance points

5.16.8 Connection of central piece and side frames

The lower bolts M42 must be torqued to 4810 Nm.
The upper bolts M42 must be torqued to 4810 Nm.

5.16.9 Drivers cab mounting bolts

Fig. 5-89 Drivers cab bolts

Torque Quantity
12 Hexagonal head screw M16x70 280 Nm 12
21 Socket head screw M16x45 280 Nm 12
26 Hexagonal head screw M16x70 280 Nm 16

5.17 General maintenance points

LEC/en/Edition: 02 / 2015

5.17.1 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.

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 Operating manual Maintenance
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It should be noted that only original LIEBHERR replacement parts are to be used.
This is particularly relevant for hoses and hydraulic lines, which must be preassem-
bled at the works. For all other repairs, particularly when dismounting the counter-
weight, works and dealership fitters are to be consulted.

5.17.2 Welding work on the machine

Welding work on all main components serving the power transmission (such as the
chassis frame, rotating platform, equipment parts etc.) may only be carried out by the
manufacturer or by an authorized workshop.
Disconnect the batteries before starting any electric arc welding work on the ma-
chine.
Disconnect the connectors of the engine control unit.
Always disconnect the negative terminal (-) first and reconnect it last.
Switch off the main battery switch!
Nevertheless if welding repair should be done on components which may contain in-
flammable gases (welded counterweight, hydraulic tank, fuel tank, ...) these compo-
nents must be previously and sufficiently ventilated with pressurized air to avoid all
fire or explosion hazard.

Caution!
If high currents flow through the bearings or sealing elements, these could be burnt.
Move the earthing cable of the welding tool as close as possible to the welding
surface so that the welding current cannot flow over parts like the swing ring, ro-
tary connection, gears, bushings, bearings, hinges, joints, hydraulic hoses,
sockets, rubber parts or seals.

5.18 Control and maintenance chart

Caution!
Careful maintenance can only be carried out when the machine is clean. Visual
checks such as crack testing are only applicable on a clean machine.
Clean the machine before you start maintenance work (see also the chapter
Servicing the machine safely, sections Cleaning" and "Crack testing).

Caution!
You must do the weekly additional maintenance tasks. Liebherr recommends that
LEC/en/Edition: 02 / 2015

you schedule this maintenance interval carefully.

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Control and maintenance chart

Note!
If you find damage(s) on structural components (boom, stick, bucket, central part,
side frames, rotating deck, hydraulic tank, fuel tank or cabin) please fill out the
"Structural Inspection" form in Service Manual - Chapter 4.
In addition:
- a visual inspection is required every 500 hours,
- a detailed inspection is required every year or at least every 7500 hours.

5.18.1 General information

The following maintenance chart will help you to do the adequate maintenance on
your excavator.
It is mandatory to follow these maintenance charts, to keep your excavator into best
and safe condition.
The pre-requisite to any claim to Liebherr for operation issues or warranty, is that
these maintenance charts are strictly followed and recorded.
It is mandatory to follow these requirements in order to keep your excavator safe, ef-
ficient and also for warranty reason. Liebherr is not responsible in case of damage if
the maintenance requirements are not correctly followed. Moreover, your machine
may not be running as efficiently and productively as it could be.

For lubricants and operating fluids, refer to the Operating Manual chapter 5.3.

Two types of inspection

Visual Check
A visual examination of an interior or exterior area, installation or assembly to de-
tect obvious damage, failure or irregularity. This level of inspection is made from
within touching distance unless otherwise specified. A mirror may be necessary
to ensure visual access to all surfaces in the inspection area. This level of inspec-
tion is made under normally available lighting conditions such as daylight, hangar
lighting, flashlight or drop-light and may require removal or opening of access
panels or doors. Stands, ladders or platforms may be required to have safe ac-
cess to the area being checked.

Detailed Check
An intensive examination of a specific item, installation or assembly to detect
damage, failure or irregularity. This examination may require the use of special-
ized inspection techniques and/or equipments. Surface cleaning and elaborate
access may also be required.
LEC/en/Edition: 02 / 2015

5.18.2 How to use the maintenance chart

The following maintenance chart is split in 5 individual check lists:
a daily,
a 250 hours,
a 500 hours,
a 1000 hours,
and a 2000 hours.

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Intervals:
daily,
250 hours, 750 hours, 1250 hours, 1750 hours, ...
500 hours, 1500 hours, 2500 hours, 3500 hours, ...
1000 hours, 3000 hours, 5000 hours, 7000 hours, ...
2000 hours, 4000 hours, 6000 hours, 8000 hours, ...

Examples:
At 750 hours you must follow the 250 hours maintenance chart.
At 2500 hours you must follow the 500 hours maintenance chart.
At 3000 hours, you must follow the 1000 hours maintenance chart.
At 6000 hours, you must follow the 2000 hours maintenance chart.

Fig. 5-90 How to use the check lists (in addition to the daily maintenance)
LEC/en/Edition: 02 / 2015

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Control and maintenance chart

5.18.3 Daily Maintenance Schedule - R9250

Serial Number: Completed by :
Fleet Number:
SMU HOURS:
Travel Hours: Date and Signature :

WORK TO BE PERFORMED DAILY

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

GENERAL HYDRAULIC SYSTEM

Do a visual check of all hoses, pipes and fittings for any external damage
or leakage

Do a visual check of the hydraulic components for leaks and/or damages

Do a visual check of the hydraulic cylinder rods for leaks and good condi-
tion

GENERAL FASTENING

General hydraulic: Do a visual check for missing, broken or loosen

mounting screws of all hoses, pipes, fittings and clamps, tighten if neces-
sary

Track components: Do a visual check for missing, broken or loosen

mounting screws of the sprockets, rollers, idlers, track guides and track
pads, protection covers and final drives, tighten if necessary

Undercarriage: Do a visual check for missing, broken or loosen mounting

screws of the side frames, tighten if necessary

Undercarriage: Do a visual check for missing, broken or loosen mounting

screws of all parts, tighten if necessary

Attachment: Do a visual check for missing, broken or loosen mounting

screws of the pin covers fastening and greases connections, tighten if
necessary

Uppercarriage: Do a visual check for missing, broken or loosen mounting

screws of the counterweight, tanks, Powerpack, control valve console,
cab, catwalks, grease box, ladder, tighten if necessary

Swing gear: Do a visual check for missing, broken or loosen mounting

bolts of the swing gear and hydraulic motors, tighten if necessary

Diesel engine: Do a visual check for missing, broken or loosen mounting

screws of the thermic protection on exhaust manifold fastening, tighten if
necessary

LEC/en/Edition: 02 / 2015

Diesel engine: Do a visual check for missing, broken or loosen mounting

bolts of the starter motors, alternator and AC compressor, tighten if nec-
essary

TRACK COMPONENTS

Clean track chains (after the end of each shift)

Do a visual check of the tensioning cylinders, idler, carrier and track rollers
for leaks

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WORK TO BE PERFORMED DAILY

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Do a visual check of the track chains tension

TRAVEL GEAR

Do a visual check of the gear for leaks, if there are leaks, check oil level

UNDERCARRIAGE

Do a visual check of all parts for damages and cracks

If necessary fill out the "Structural Inspection" form in Service Manual -
Chapter 4

ATTACHMENT

Do a visual check of the bucket teeth and wear kit for wear

Do a visual check of the grease supply at each lube point

Do a visual check of cable harness and sensors for damage

UPPERCARRIAGE

Do a visual check of the service trap for leaks or damage

Do a visual check of oil, grease or fuel for leaks

SWING GEAR

Do a visual check of the swing gears for leaks and oil level in expansion
tanks

CENTRALIZED LUBRICATION SYSTEM

Perform a complete daily maintenance given in the LINCOLN Operating

Instructions Manual

Do a check of the grease tank level

DIESEL ENGINE AND SPLITTERBOX

Do a visual check in and around the engine compartment for leaks, con-
tamination and damage

Check engine oil level

Check coolant level

Do a visual check of the engine and external pipework for leaks

LEC/en/Edition: 02 / 2015

Do a visual check of the exhaust gas system connections for leaks

Do a visual check of the oil supply / return pipework for leaks

Do a visual check of the water separator on fuel filters, drain if necessary

Do a visual check of the vacuum indicators for air filters clogging, clean or
replace if necessary and reset the indicator

Check oil level in the splitterbox

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WORK TO BE PERFORMED DAILY

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Do a visual check of the splitterbox input shaft seal or engine main rear
seal for leaks

Do a visual check of the starter motors, alternator and AC compressor for

cables, and brackets

Do a visual check of the coolers for clogging and damage, clean or replace
if necessary

Perform the complete "Daily" Maintenance Echelon given in the CUM-

MINS Operating and Maintenance Manual

HYDRAULIC SYSTEM

Check oil level in hydraulic tank

Clean magnetic rods of the leak oil filter (daily during the first 250 hours)

ELECTRICAL SYSTEM

Press to open dust discharge valve on aeration devices for cabin and elec-
trical boxes

FIRE FIGHTING SYSTEM

Do a visual check of the fire fighting system condition (refer to the fire fight-
ing system documentation)
- If any issue contact fire fighting local dealer

Follow the inspection intervals recommended by the specific Health and

Safety rules existing in country and/or on mine site

START THE ENGINE TO CHECK THE FOLLOWING ACTIONS

General: Maintenance work must include the check of the correct func-
tions of hydraulic and electric systems before starting operation

Attachment: Check function of the working attachment lubrication system

during operation

Attachment: Check if the damping system on equipment is working cor-

rectly

Uppercarriage: Check position of the hydraulic shut-off valve

Uppercarriage: Check that the swing movement of the uppercarriage is

locked when the access ladder is lowered

Swing Gear: Check function and operation of the swing brake

LEC/en/Edition: 02 / 2015

Swing Ring: Check function of the swing ring bearing lubrication system
during operation

Swing Ring: Check function of the swing ring teeth lubrication system
during operation

Diesel engine: Check speed on RPM gauge

Diesel engine: Check running noises

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WORK TO BE PERFORMED DAILY

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Diesel engine: Check exhaust gas colour

Diesel engine: Check oil pressure and coolant temperature during oper-
ation

Diesel engine: Check if the prelub system is working properly

Electrical system: Clean and check LCD screen of the display for proper
function when starting

Electrical system: Check indicator lights and gauges on the control panel
when starting

Electrical system: Check for warning and fault messages on display

(monitoring, grease, air conditioning, ...). If necessary refer to chapter 4 in
the Operating Manual to identify and rectify faults and errors.

Air pressure system: Do a visual check of cut in and cut out pressure of
air pressure regulator

Cabin: Check if the safety lever is working properly

Cabin: Check the horn

Cabin: Check for green flash light on control module if fire fighting system
is installed

WEEKLY CHECK THESE STEPS IN ADDITION TO THE DAILY REQUIREMENTS

UPPERCARRIAGE

Check level in reservoir for windshield washer, refill if necessary

CENTRALIZED LUBRICATION SYSTEM

Perform the complete weekly maintenance given in the LINCOLN Operat-

ing Instructions Manual

DIESEL ENGINE AND SPLITTERBOX

Do a visual check of the air channels in precleaner, clean if necessary

Do a visual check of the air intake hose for condition and leaks

Do a visual check and clean the radiator core and fan

Do a visual check of the radiator cap for leaks, replace if necessary

LEC/en/Edition: 02 / 2015

Drain off water and sediment at fuel tank

HYDRAULIC SYSTEM

Clean magnetic rods of all return filters (weekly during the first 250 hours)

Do a visual check of the hydraulic tank air filter, clean if necessary

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Control and maintenance chart

WORK TO BE PERFORMED DAILY

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

ELECTRICAL SYSTEM

Do a visual check of the head and floodlight, clean if necessary

Do a visual check of the wiring system for damage

AIR PRESSURE SYSTEM

Drain air tanks

CABIN, CABIN ELEVATION AND HEATER AIR/CONDITIONER

Operate air conditioner every week for 10 minutes

Visual check condenser unit and evaporator filter

Check refrigerant level, if necessary refill circuit

Do a detailed check of the V-belt tension for air conditioner

LEC/en/Edition: 02 / 2015

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Control and maintenance chart

WORK TO BE PERFORMED DAILY

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

General comments:
LEC/en/Edition: 02 / 2015

Tab. 5-12 Daily maintenance schedule - R9250

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Control and maintenance chart

5.18.4 250 Hours Maintenance Schedule - R9250

Serial Number: Completed by :
Fleet Number:
SMU HOURS:
Travel Hours: Date and Signature :

WORK TO BE PERFORMED AT 250, 750, 1250 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

GENERAL HYDRAULIC SYSTEM

Do a visual check of all hoses, pipes and fittings for any external damage or leak-
age

Do a detailed check for good condition of pipes, hoses, clamps and fittings for
damage and leakage

Do a visual check of the hydraulic components for leaks and/or damages

Do a visual check of the hydraulic cylinder rods for leaks and good condition

GENERAL FASTENING

General hydraulic: Do a visual check for missing, broken or loosen mounting

screws of all hoses, pipes, fittings and clamps, tighten if necessary

Track components: Do a visual check for missing, broken or loosen mounting

screws of the sprockets, rollers, idlers, track guides, track pads, protection cov-
ers and final drives, tighten if necessary

Undercarriage: Do a visual check for missing, broken or loosen mounting

screws of the side frames, tighten if necessary

Undercarriage: Do a visual check for missing, broken or loosen mounting

screws of all parts, tighten if necessary

Attachment: Do a visual check for missing, broken or loosen mounting screws

of the pin covers fastening and greases connections, tighten if necessary

Uppercarriage: Do a visual check for missing, broken or loosen mounting

screws of the counterweight, tanks, Powerpack, control valve console, cab, cat-
walks, grease box, ladder, tighten if necessary

Swing gear: Do a visual check for missing, broken or loosen mounting bolts of
the swing gear and hydraulic motors, tighten if necessary

Diesel engine: Do a visual check for missing, broken or loosen mounting screws
of the thermic protection on exhaust manifold fastening, tighten if necessary

Diesel engine: Do a visual check for missing, broken or loosen mounting bolts
of the starter motors, alternator and AC compressor, tighten if necessary
LEC/en/Edition: 02 / 2015

TRACK COMPONENTS

Clean track chains (after the end of each shift)

Do a visual check of the tensioning cylinders, idler, carrier and track rollers for
leaks

Do a visual check of the track chains tension

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WORK TO BE PERFORMED AT 250, 750, 1250 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

TRAVEL GEAR

Do a visual check of the gear for leaks, if there are leaks, check oil level

UNDERCARRIAGE

Do a visual check of all parts for damages and cracks

If necessary fill out the "Structural Inspection" form in Service Manual - Chapter 4

ATTACHMENT

Do a visual check of the bucket teeth and wear kit for wear

Do a visual check of the grease supply at each lube point

Do a visual check of cable harness and sensors for damage

Do a visual check of all parts for damages and cracks

If necessary fill out the "Structural Inspection" form in Service Manual - Chapter 4

Do a visual check of the fastening of pin covers

UPPERCARRIAGE

Do a visual check of the service trap for leaks or damage

Do a visual check of oil, grease or fuel for leaks

SWING GEAR

Do a visual check of the swing gears for leaks and oil level in expansion tanks

CENTRALIZED LUBRICATION SYSTEM

Perform a complete daily maintenance given in the LINCOLN Operating Instruc-

tions Manual

Do a check of the grease tank level

DIESEL ENGINE AND SPLITTERBOX

Do a visual check in and around the engine compartment for leaks, contamina-
tion and damage

Check engine oil level

Sample and analyse engine oil

Change oil in Diesel engine

LEC/en/Edition: 02 / 2015

Replace engine oil filters

Check coolant level

Do a visual check of the engine and external pipework for leaks

Do a visual check of the exhaust gas system connections for leaks

Do a visual check of the oil supply / return pipework for leaks

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Control and maintenance chart

WORK TO BE PERFORMED AT 250, 750, 1250 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Drain off water and sediment at fuel tank

Do a visual check of the water separator on fuel filters, drain if necessary

Replace all fuel filters

Do a visual check of the vacuum indicators for air filters clogging, clean or replace
if necessary and reset the indicator

Do a visual check of the air channels in precleaner, clean if necessary

Replace primary element of the air cleaner (if necessary or at least once a year)

Replace safety element of the air cleaner if indicated (if necessary or at least
once a year)

Check oil level in the splitterbox

Change oil in splitterbox, if BOSCH splitterbox is installed

Do a visual check of the splitterbox input shaft seal or engine main rear seal for
leaks

Do a visual check of the starter motors, alternator and AC compressor for cables,
and brackets

Do a visual check of the air intake hose for condition and leaks

Do a visual check of the coolers for clogging and damage, clean or replace if nec-
essary

Do a visual Check of the radiator core and fan, clean if necessary

Do a visual check of the radiator cap for leaks, replace if necessary

Perform the complete "Daily" Maintenance Echelon given in the CUMMINS Op-
erating and Maintenance Manual

Every 250hours or 6 months, perform a complete Maintenance Echelon given in

the CUMMINS Operating and Maintenance Manual

See CUMMINS Operation and Maintenance Manual for other maintenance

(Eliminator, Centinel, Fleetguard, valves and injectors adjustment)

HYDRAULIC SYSTEM

Check oil level in hydraulic tank

Clean magnetic rods of the leak oil filter

Clean magnetic rods of all return filters

LEC/en/Edition: 02 / 2015

ELECTRICAL SYSTEM

Press to open dust discharge valve on aeration devices for cabin and electrical
boxes

Do a visual check of the head and floodlights, clean if necessary

Do a visual check of electric harness, sensors for damage and/or rubbing zone

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WORK TO BE PERFORMED AT 250, 750, 1250 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Do a detailed check of fuses and circuit breakers

AIR PRESSURE SYSTEM

Drain air tanks

CABIN

Do a detailed check of the V-belt tension for air conditioner

Do a visual check of the cabin for oil/fluids leaks

FIRE FIGHTING SYSTEM

Do a visual check of the fire fighting system condition (optional equipment, refer
to the fire fighting system documentation)
- If any issue contact fire fighting local dealer

Follow the inspection intervals recommended by the specific Health and Safety
rules existing in country and/or on mine site

START THE ENGINE TO CHECK THE FOLLOWING ACTIONS

General: Maintenance work must include the check of the correct functions of
hydraulic and electric systems before starting operation

Attachment: Check function of the working attachment lubrication system dur-

ing operation

Attachment: Check if the damping system on equipment is working correctly

Uppercarriage: Check position of the hydraulic shut-off valve

Uppercarriage: Check that the swing movement of the uppercarriage is locked

when the access ladder is lowered

Swing Gear: Check function and operation of the swing brake

Swing Ring: Check function of the swing ring bearing lubrication system during
operation

Swing Ring: Check function of the swing ring teeth lubrication system during op-
eration

Diesel engine: Check speed on RPM gauge

Diesel engine: Check running noises

Diesel engine: Check exhaust gas colour

LEC/en/Edition: 02 / 2015

Diesel engine: Check oil pressure and coolant temperature during operation

Diesel engine: Check if the prelub system is working properly

Electrical system: Clean and check LCD screen of the display for proper func-
tion when starting

Electrical system: Check indicator lights and gauges on the control panel when
starting

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Control and maintenance chart

WORK TO BE PERFORMED AT 250, 750, 1250 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Electrical system: Check for warning and fault messages on display (monitor-
ing, grease, air conditioning, ...). If necessary refer to chapter 4 in the Operating
Manual to identify and rectify faults and errors.

Air pressure system: Do a visual check of cut in and cut out pressure of air
pressure regulator

Cabin: Check if the safety lever is working properly

Cabin: Check the horn

Cabin: Check for green flash light on control module if fire fighting system is in-
stalled

LEC/en/Edition: 02 / 2015

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WORK TO BE PERFORMED DAILY

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

General comments:
LEC/en/Edition: 02 / 2015

Tab. 5-13 250 Hours maintenance schedule - R9250

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Control and maintenance chart

5.18.5 500 Hours Maintenance Schedule - R9250

Serial Number: Completed by :
Fleet Number:
SMU HOURS:
Travel Hours: Date and Signature :

WORK TO BE PERFORMED AT 500, 1500, 2500 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

GENERAL HYDRAULIC SYSTEM

Do a visual check of all hoses, pipes and fittings for any external damage or leak-
age

Do a detailed check for good condition of pipes, hoses, clamps and fittings for
damage and leakage

Do a visual check of the hydraulic components for leaks and/or damages

Do a visual check of the hydraulic cylinder rods for leaks and good condition

GENERAL FASTENING

General hydraulic: Do a visual check for missing, broken or loosen mounting

screws of all hoses, pipes, fittings and clamps, tighten if necessary

Track components: Do a visual check for missing, broken or loosen mounting

screws of the sprockets, rollers, idlers, track guides, track pads, protection covers
and final drives, tighten if necessary

Undercarriage: Do a visual check for missing, broken or loosen mounting

screws of the side frames, tighten if necessary

Undercarriage: Do a visual check for missing, broken or loosen mounting

screws of all parts, tighten if necessary

Attachment: Do a visual check for missing, broken or loosen mounting screws

of the pin covers fastening and greases connections, tighten if necessary

Uppercarriage: Do a visual check for missing, broken or loosen mounting

screws of the counterweight, tanks, Powerpack, control valve console, cab, cat-
walks, grease box, ladder, tighten if necessary

Swing gear: Do a visual check for missing, broken or loosen mounting bolts of
the swing gear and hydraulic motors, tighten if necessary

Diesel engine: Do a visual check for missing, broken or loosen mounting screws
of the thermic protection on exhaust manifold fastening, tighten if necessary

Diesel engine: Do a visual check for missing, broken or loosen mounting bolts
of the starter motors, alternator and AC compressor, tighten if necessary
LEC/en/Edition: 02 / 2015

Hydraulic: Do a detailed check for missing, broken or loosen mounting screws

of pumps, motors, clamps, ..., tighten the screws

TRACK COMPONENTS

Clean track chains (after the end of each shift)

Do a visual check of the tensioning cylinders, idler, carrier and track rollers for
leaks

copyright by
5 - 118 R 9250 / 10069862
MJFCIFSS
 Operating manual Maintenance
Control and maintenance chart

WORK TO BE PERFORMED AT 500, 1500, 2500 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Do a visual check of the track chains tension

TRAVEL GEAR

Do a visual check of the gear for leaks, if there are leaks, check oil level

Sample and analyse gear oil, change oil if necessary

Change gear oil (if filled with COB-1 gear oil)

Change gear oil (if filled with COB-2, COB-3 or COB-4 gear oil)

Sample and analyse lifetime sealing interspace oil, change oil if necessary (op-
tional equipment)

Change lifetime sealing interspace oil (optional equipment)

UNDERCARRIAGE

Do a visual check of all parts for damages and cracks

If necessary fill out the "Structural Inspection" form in Service Manual - Chapter 4

ATTACHMENT

Do a visual check of the bucket teeth and wear kit for wear

Do a visual check of the grease supply at each lube point

Do a visual check of cable harness and sensors for damage

Do a visual check of all parts for damages and cracks

If necessary fill out the "Structural Inspection" form in Service Manual - Chapter 4

Do a visual check of the fastening of pin covers

UPPERCARRIAGE

Do a visual check of the service trap for leaks or damage

Do a visual check of oil, grease or fuel for leaks

Do a detailed check of all structural parts for damages and cracks

If necessary fill out the "Structural Inspection" form in Service Manual - Chapter 4

Do a detailed check of the dust separator on air filter (cyclone) and hoses for
damage

Do a visual check if the fan guards are in place and secured

SWING GEAR
LEC/en/Edition: 02 / 2015

Do a visual check of the swing gears for leaks and oil level in expansion tanks

Sample and analyse gear oil, change oil if necessary

Change gear oil (if filled with COB-1 gear oil)

Change gear oil (if filled with COB-2, COB-3 or COB-4 gear oil)

copyright by
R 9250 / 10069862 5 - 119
MJFCIFSS
Maintenance Operating manual
Control and maintenance chart

WORK TO BE PERFORMED AT 500, 1500, 2500 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

SWING RING

Do a detailed check of the grease supply (outlet of new grease around the swing
ring)

CENTRALIZED LUBRICATION SYSTEM

Perform a complete daily maintenance given in the LINCOLN Operating Instruc-

tions Manual

Do a check of the grease tank level

DIESEL ENGINE AND SPLITTERBOX

Do a visual check in and around the engine compartment for leaks, contamina-
tion and damage

Check engine oil level

Sample and analyse engine oil

Change oil in Diesel engine

Replace engine oil filters

Check coolant level

Do a visual check of the engine and external pipework for leaks

Do a visual check of the exhaust gas system connections for leaks

Do a visual check of the oil supply / return pipework for leaks

Drain off water and sediment at fuel tank

Do a visual check of the water separator on fuel filters, drain if necessary

Replace all fuel filters

Do a visual check of the vacuum indicators for air filters clogging, clean or replace
if necessary and reset the indicator

Do a visual check of the air channels in precleaner, clean if necessary

Replace primary element of the air cleaner (if necessary or at least once a year)

Replace safety element of the air cleaner if indicated (if necessary or at least
once a year)

Check oil level in the splitterbox

LEC/en/Edition: 02 / 2015

Sample and analyse splitterbox oil

Change oil in splitterbox, if LIEBHERR splitterbox is installed

Do a visual check of the splitterbox breather for clogging, replace if necessary

Do a visual check of the splitterbox input shaft seal or engine main rear seal for
leaks

copyright by
5 - 120 R 9250 / 10069862
MJFCIFSS
 Operating manual Maintenance
Control and maintenance chart

WORK TO BE PERFORMED AT 500, 1500, 2500 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Do a visual check of the starter motors, alternator and AC compressor for cables,
and brackets

Do a visual check of the air intake hose for condition and leaks

Do a visual check of the coolers for clogging and damage, clean or replace if nec-
essary

Do a visual Check of the radiator core and fan, clean if necessary

Do a visual check of the radiator cap for leaks, replace if necessary

Perform the complete "Daily" Maintenance Echelon given in the CUMMINS Op-
erating and Maintenance Manual

Every 250 hours or 6 months, perform a complete Maintenance Echelon given in

the CUMMINS Operating and Maintenance Manual

See CUMMINS Operation and Maintenance Manual for other maintenance

(Eliminator, Centinel, Fleetguard, valves and injectors adjustment)

HYDRAULIC SYSTEM

Drain water sediment from hydraulic tank

Check oil level in hydraulic tank

Sample and analyse hydraulic oil and change oil if necessary

Clean magnetic rods of the leak oil filter

Clean magnetic rods of all return filters

Replace filter element of the return filters

Replace filter element of the leak oil filter

Replace control oil filter element

Replace swing pumps replenishing oil filter elements

Do a visual check of the oil cooler protection filters, clean or replace if necessary
(optional equipment)

ELECTRICAL SYSTEM

Press to open dust discharge valve on aeration devices for cabin and electrical
boxes

Replace main element on aeration devices for cabin and electrical boxes (at least
LEC/en/Edition: 02 / 2015

once a year)

Replace safety element on aeration devices for cabin and electrical boxes, after
3 services of main element

Do a visual check of the head and floodlights, clean if necessary

Do a visual check of electric harness, sensors for damage and/or rubbing zone

Do a detailed check of fuses and circuit breakers

copyright by
R 9250 / 10069862 5 - 121
MJFCIFSS
Maintenance Operating manual
Control and maintenance chart

WORK TO BE PERFORMED AT 500, 1500, 2500 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Do a visual check of wiring system damage

Check battery electrolyte level (refill if necessary) and clean battery terminals

AIR PRESSURE SYSTEM

Drain air tanks

CABIN

Do a detailed check of the V-belt tension for air conditioner

Do a visual check of the cabin for oil/fluids leaks

Operate air conditioner every week for 10 minutes

Do a visual check of the condenser unit and evaporator filter

Do a visual check of the refrigerant level, if necessary refill circuit

Replace if necessary the air conditioner filter/dryer (at least once a year)

Yearly check condition of the refrigerant receiver, if necessary replace it

Perform maintenance for the second air-conditioning system (optional equip-

ment)

Lubricate all doors seals with silicone or talc (before cold season)

Do a visual check of the AC for leaks or rubbing hoses or pipes

FIRE FIGHTING SYSTEM

Do a visual check of the fire fighting system condition (optional equipment, refer
to the fire fighting system documentation)
- If any issue contact fire fighting local dealer

Follow the inspection intervals recommended by the specific Health and Safety
rules existing in country and/or on mine site

START THE ENGINE TO CHECK THE FOLLOWING ACTIONS

General: Maintenance work must include the check of the correct functions of
hydraulic and electric systems before starting operation

Attachment: Check function of the working attachment lubrication system during

operation

Attachment: Check if the damping system on equipment is working correctly

LEC/en/Edition: 02 / 2015

Uppercarriage: Check position of the hydraulic shut-off valve

Uppercarriage: Check movement and locking of the access ladder

Uppercarriage: Check that the swing movement of the uppercarriage is locked

when the access ladder is lowered

Swing Gear: Check function and operation of the swing brake

Swing Ring: Check function of the swing ring bearing lubrication system during
operation

copyright by
5 - 122 R 9250 / 10069862
MJFCIFSS
 Operating manual Maintenance
Control and maintenance chart

WORK TO BE PERFORMED AT 500, 1500, 2500 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Swing Ring: Check function of the swing ring teeth lubrication system during op-
eration

Diesel engine: Check speed on RPM gauge

Diesel engine: Check running noises

Diesel engine: Check exhaust gas colour

Diesel engine: Check oil pressure and coolant temperature during operation

Diesel engine: Check if the prelub system is working properly

Electrical system: Clean and check LCD screen of the display for proper func-
tion when starting

Electrical system: Check indicator lights and gauges on the control panel when
starting

Electrical system: Check for warning and fault messages on display (monitor-
ing, grease, air conditioning, ...). If necessary refer to chapter 4 in the Operating
Manual to identify and rectify faults and errors.

Air pressure system: Do a visual check of cut in and cut out pressure of air pres-
sure regulator

Cabin: Check if the safety lever is working properly

Cabin: Check the horn

Cabin: Check for green flash light on control module if fire fighting system is in-
stalled
LEC/en/Edition: 02 / 2015

copyright by
R 9250 / 10069862 5 - 123
MJFCIFSS
Maintenance Operating manual
Control and maintenance chart

WORK TO BE PERFORMED DAILY

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

General comments:

LEC/en/Edition: 02 / 2015

Tab. 5-14 500 Hours maintenance schedule - R9250

copyright by
5 - 124 R 9250 / 10069862
MJFCIFSS
 Operating manual Maintenance
Control and maintenance chart

5.18.6 1000 Hours Maintenance Schedule - R9250

Serial Number: Completed by :
Fleet Number:
SMU HOURS:
Travel Hours: Date and Signature :

WORK TO BE PERFORMED AT 1000, 3000, 5000 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

GENERAL HYDRAULIC SYSTEM

Do a visual check of all hoses, pipes and fittings for any external damage or leak-
age

Do a detailed check for good condition of pipes, hoses, clamps and fittings for
damage and leakage

Do a visual check of the hydraulic components for leaks and/or damages

Do a visual check of the hydraulic cylinder rods for leaks and good condition

GENERAL FASTENING

General hydraulic: Do a visual check for missing, broken or loosen mounting

screws of all hoses, pipes, fittings and clamps, tighten if necessary

Track components: Do a visual check for missing, broken or loosen mounting

screws of the sprockets, rollers, idlers, track guides, track pads, protection covers
and final drives, tighten if necessary

Track components: Do a detailed check for missing, broken or loosen mounting

screws of the rollers, pins locking and track guides, tighten the screws

Track components: Do a detailed check for missing, broken or loosen mounting

screws of the idler axis locking keys, tighten the screws

Track components: Do a detailed check for missing, broken or loosen mounting

screws of the track pads, tighten the screws

Travel gear: Do a detailed check for missing, broken or loosen mounting screws
of the gears, sprocket wheels and hydraulic motors, tighten the screws

Undercarriage: Do a visual check for missing, broken or loosen mounting

screws of the side frames, tighten if necessary

Undercarriage: Do a detailed check for missing, broken or loosen mounting

screws of the side frames, tighten the screws

Undercarriage: Do a visual check for missing, broken or loosen mounting

screws of all parts, tighten if necessary
LEC/en/Edition: 02 / 2015

Attachment: Do a visual check for missing, broken or loosen mounting screws

of the pin covers fastening and greases connections, tighten if necessary

Uppercarriage: Do a visual check for missing, broken or loosen mounting

screws of the counterweight, tanks, Powerpack, control valve console, cab, cat-
walks, grease box, ladder, tighten if necessary

Swing gear: Do a visual check for missing, broken or loosen mounting bolts of
the swing gear and hydraulic motors, tighten if necessary

copyright by
R 9250 / 10069862 5 - 125
MJFCIFSS
Maintenance Operating manual
Control and maintenance chart

WORK TO BE PERFORMED AT 1000, 3000, 5000 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Swing ring: Do a detailed check for missing, broken or loosen mounting screws
and protective nuts of swing ring, tighten the bolts

Diesel engine: Do a visual check for missing, broken or loosen mounting screws
of the thermic protection on exhaust manifold fastening, tighten if necessary

Diesel engine: Do a visual check for missing, broken or loosen mounting bolts
of the starter motors, alternator and AC compressor, tighten if necessary

Diesel engine: Do a detailed check for missing, broken or loosen mounting

screws of the splitterbox, tighten the screws

Hydraulic: Do a detailed check for missing, broken or loosen mounting screws

of pumps, motors, clamps, ..., tighten the screws

TRACK COMPONENTS

Clean track chains (after the end of each shift)

Do a visual check of the tensioning cylinders, idler, carrier and track rollers for
leaks

Do a visual check of the track chains tension

TRAVEL GEAR

Do a visual check of the gear for leaks, if there are leaks, check oil level

Sample and analyse gear oil, change oil if necessary

Change gear oil (if filled with COB-2, COB-3 or COB4 gear oil)

Sample and analyse lifetime sealing interspace oil, change oil if necessary (op-
tional equipment)

Change lifetime sealing interspace oil (optional equipment)

UNDERCARRIAGE

Do a visual check of all parts for damages and cracks

- If necessary fill out the "Structural Inspection" form in Service Manual - Chapter
4

ATTACHMENT

Do a visual check of the bucket teeth and wear kit for wear

Do a visual check of the grease supply at each lube point

LEC/en/Edition: 02 / 2015

Do a visual check of cable harness and sensors for damage

Do a visual check of all parts for cracks

- If necessary fill out the "Structural Inspection" form in Service Manual - Chapter
4

Do a visual check of the fastening of pin covers

UPPERCARRIAGE

Do a visual check of the service trap for leaks or damage

copyright by
5 - 126 R 9250 / 10069862
MJFCIFSS
 Operating manual Maintenance
Control and maintenance chart

WORK TO BE PERFORMED AT 1000, 3000, 5000 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Do a visual check of oil, grease or fuel for leaks

Do a detailed check of all structural parts for cracks

- If necessary fill out the "Structural Inspection" form in Service Manual - Chapter
4

Do a detailed check of the dust separator on air filter (cyclone) and hoses for
damage

Do a detailed check and lubricate the covers, doors hinges, locks as well as ser-
vice trap, access ladder cylinders bushings and swivel pins

Do a visual check if the fan guards are in place and secured

SWING GEAR

Do a visual check of the swing gears for leaks and oil level in expansion tanks

Sample and analyse gear oil, change oil if necessary

Change gear oil (if filled with COB-2, COB-3 or COB-4 gear oil)

SWING RING

Do a detailed check of the grease supply (outlet of new grease around the swing
ring)

CENTRALIZED LUBRICATION SYSTEM

Perform a complete daily maintenance given in the LINCOLN Operating Instruc-

tions Manual

Do a check of the grease tank level

Every 1000 hours, perform a complete 1000 hours Maintenance Echelon given
in the LINCOLN Operating Instructions

DIESEL ENGINE AND SPLITTERBOX

Do a visual check in and around the engine compartment for leaks, contamina-
tion and damage

Check engine oil level

Sample and analyse engine oil

Change oil in Diesel engine

Replace engine oil filters

LEC/en/Edition: 02 / 2015

Check coolant level

Do a visual check of the engine and external pipework for leaks

Do a visual check of the exhaust gas system connections for leaks

Do a visual check of the thermic protection on the exhaust manifold fastening

Do a visual check of the oil supply / return pipework for leaks

Drain off water and sediment at fuel tank

copyright by
R 9250 / 10069862 5 - 127
MJFCIFSS
Maintenance Operating manual
Control and maintenance chart

WORK TO BE PERFORMED AT 1000, 3000, 5000 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Do a visual check of the water separator on fuel filters, drain if necessary

Replace all fuel filters

Do a visual check of the vacuum indicators for air filters clogging, clean or replace
if necessary and reset the indicator

Do a visual check of the air channels in precleaner, clean if necessary

Replace primary element of the air cleaner (if necessary or at least once a year)

Replace safety element of the air cleaner if indicated (if necessary or at least
once a year)

Check oil level in the splitterbox

Sample and analyse splitterbox oil

Change oil in splitterbox, if LIEBHERR splitterbox is installed

Do a visual check of the splitterbox breather for clogging, replace if necessary

Replace filter in splitterbox breather

Do a visual check of the splitterbox input shaft seal or engine main rear seal for
leaks

Do a detailed check of the engine and the splitterbox rubber buffers (replace if
necessary and at least every 10000 hours)

Do a visual check of the starter motors, alternator and AC compressor for cables,
and brackets

Do a visual check of the air intake hose for condition and leaks

Do a visual check of the coolers for clogging and damage, clean or replace if nec-
essary

Do a visual Check of the radiator core and fan, clean if necessary

Do a visual check of the radiator cap for leaks, replace if necessary

Perform the complete "Daily" Maintenance Echelon given in the CUMMINS Op-
erating and Maintenance Manual

Every 250hours or 6 months, perform a complete Maintenance Echelon given in

the CUMMINS Operating and Maintenance Manual

See CUMMINS Operation and Maintenance Manual for other maintenance

(Eliminator, Centinel, Fleetguard, valves and injectors adjustment)
LEC/en/Edition: 02 / 2015

HYDRAULIC SYSTEM

Drain water sediment from hydraulic tank

Check oil level in hydraulic tank

Sample and analyse hydraulic oil and change oil if necessary

Clean magnetic rods of the leak oil filter

Clean magnetic rods of all return filters

copyright by
5 - 128 R 9250 / 10069862
MJFCIFSS
 Operating manual Maintenance
Control and maintenance chart

WORK TO BE PERFORMED AT 1000, 3000, 5000 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Replace filter element of the return filters

Replace filter element of the leak oil filter

Replace the hydraulic tank air filter

Replace control oil filter element

Replace swing pumps replenishing oil filter elements

Do a visual check of the oil cooler protection filters, clean or replace if necessary
(optional equipment)

Check and adjust primary and secondary pressure relief valves

ELECTRICAL SYSTEM

Press to open dust discharge valve on aeration devices for cabin and electrical
boxes

Replace main element on aeration devices for cabin and electrical boxes (at least
once a year)

Replace safety element on aeration devices for cabin and electrical boxes, after
3 services of main element

Do a visual check of the head and floodlights, clean if necessary

Do a visual check of electric harness, sensors for damage and/or rubbing zone

Do a detailed check of fuses and circuit breakers

Do a visual check of wiring system damage

Check battery electrolyte level (refill if necessary) and clean battery terminals

AIR PRESSURE SYSTEM

Drain air tanks

CABIN

Do a detailed check of the V-belt tension for air conditioner

Do a visual check of the cabin for oil/fluids leaks

Operate air conditioner every week for 10 minutes

Do a visual check of the condenser unit and evaporator filter

Do a visual check of the refrigerant level, if necessary refill circuit

LEC/en/Edition: 02 / 2015

Replace if necessary the air conditioner filter/dryer (at least once a year)

Yearly check condition of the refrigerant receiver, if necessary replace it

Perform maintenance for the second air-conditioning system (optional equip-

ment)

Lubricate all doors seals with silicone or talc (before cold season)

Do a visual check of the AC for leaks or rubbing hoses or pipes

copyright by
R 9250 / 10069862 5 - 129
MJFCIFSS
Maintenance Operating manual
Control and maintenance chart

WORK TO BE PERFORMED AT 1000, 3000, 5000 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Do a visual check of the locks and hinges on doors and windows (lubricate if nec-
essary)

Do a detailed check of the cabin rubber mounts

FIRE FIGHTING SYSTEM

Do a visual check of the fire fighting system condition (optional equipment, refer
to the fire fighting system documentation)
- If any issue contact fire fighting local dealer

Follow the inspection intervals recommended by the specific Health and Safety
rules existing in country and/or on mine site

START THE ENGINE TO CHECK THE FOLLOWING ACTIONS

General: Maintenance work must include the check of the correct functions of
hydraulic and electric systems before starting operation

Attachment: Check function of the working attachment lubrication system during

operation

Attachment: Check if the damping system on equipment is working correctly

Uppercarriage: Check position of the hydraulic shut-off valve

Uppercarriage: Check movement and locking of the access ladder

Uppercarriage: Check that the swing movement of the uppercarriage is locked

when the access ladder is lowered

Swing Gear: Check function and operation of the swing brake

Swing Ring: Check function of the swing ring bearing lubrication system during
operation

Swing Ring: Check function of the swing ring teeth lubrication system during op-
eration

Diesel engine: Check speed on RPM gauge

Diesel engine: Check running noises

Diesel engine: Check exhaust gas colour

Diesel engine: Check oil pressure and coolant temperature during operation

Diesel engine: Check if the prelub system is working properly

Electrical system: Clean and check LCD screen of the display for proper func-
LEC/en/Edition: 02 / 2015

tion when starting

Electrical system: Check indicator lights and gauges on the control panel when
starting

Electrical system: Check for warning and fault messages on display (monitor-
ing, grease, air conditioning, ...). If necessary refer to chapter 4 in the Operating
Manual to identify and rectify faults and errors.

copyright by
5 - 130 R 9250 / 10069862
MJFCIFSS
 Operating manual Maintenance
Control and maintenance chart

WORK TO BE PERFORMED AT 1000, 3000, 5000 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Air pressure system: Do a visual check of cut in and cut out pressure of air pres-
sure regulator

Cabin: Check if the safety lever is working properly

Cabin: Check the horn

Cabin: Check for green flash light on control module if fire fighting system is in-
stalled
LEC/en/Edition: 02 / 2015

copyright by
R 9250 / 10069862 5 - 131
MJFCIFSS
Maintenance Operating manual
Control and maintenance chart

WORK TO BE PERFORMED DAILY

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

General comments:

LEC/en/Edition: 02 / 2015

Tab. 5-15 1000 hours maintenance schedule - R9250

copyright by
5 - 132 R 9250 / 10069862
MJFCIFSS
 Operating manual Maintenance
Control and maintenance chart

5.18.7 2000 Hours Maintenance Schedule - R9250

Serial Number: Completed by :
Fleet Number:
SMU HOURS:
Travel Hours: Date and Signature :

WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

GENERAL HYDRAULIC SYSTEM

Do a visual check of all hoses, pipes and fittings for any external damage or leak-
age

Do a detailed check for good condition of pipes, hoses, clamps and fittings for
damage and leakage

Do a visual check of the hydraulic components for leaks and/or damages

Do a visual check of the hydraulic cylinder rods for leaks and good condition

GENERAL FASTENING

General hydraulic: Do a visual check for missing, broken or loosen mounting

screws of all hoses, pipes, fittings and clamps, tighten if necessary

Track components: Do a visual check for missing, broken or loosen mounting

screws of the sprockets, rollers, idlers, track guides, track pads, protection covers
and final drives, tighten if necessary

Track components: Do a detailed check for missing, broken or loosen mounting

screws of the rollers, pins locking and track guides, tighten the screws

Track components: Do a detailed check for missing, broken or loosen mounting

screws of the idler axis locking keys, tighten the screws

Track components: Do a detailed check for missing, broken or loosen mounting

screws of the track pads, tighten the screws

Travel gear: Do a detailed check for missing, broken or loosen mounting screws
of the gears, sprocket wheels and hydraulic motors, tighten the screws

Undercarriage: Do a detailed check for missing, broken or loosen mounting

screws of the side frames, tighten the screws

Undercarriage: Do a visual check for missing, broken or loosen mounting

screws of all parts, tighten if necessary

Attachment: Do a visual check for missing, broken or loosen mounting screws

of the pin covers fastening and greases connections, tighten if necessary
LEC/en/Edition: 02 / 2015

Uppercarriage: Do a visual check for missing, broken or loosen mounting

screws of the counterweight, tanks, Powerpack, control valve console, cab, cat-
walks, grease box, ladder, tighten if necessary

Uppercarriage: Do a detailed check for missing, broken or loosen mounting

screws of the counterweight, tanks, Powerpack, control valve console, cab, cat-
walks, grease box, ladder, tighten the screws

Swing gear: Do a visual check for missing, broken or loosen mounting bolts of
the swing gear and hydraulic motors, tighten if necessary

copyright by
R 9250 / 10069862 5 - 133
MJFCIFSS
Maintenance Operating manual
Control and maintenance chart

WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Swing gear: Do a detailed check for missing, broken or loosen mounting bolts of
the swing gear and hydraulic motors, tighten the bolts

Swing ring: Do a detailed check for missing, broken or loosen mounting screws
and protective nuts of swing ring, tighten the bolts

Diesel engine: Do a visual check for missing, broken or loosen mounting screws
of the thermic protection on exhaust manifold fastening, tighten if necessary

Diesel engine: Do a visual check for missing, broken or loosen mounting bolts
of the starter motors, alternator and AC compressor, tighten if necessary

Diesel engine: Do a detailed check for missing, broken or loosen mounting

screws of the splitterbox, tighten the screws

Diesel engine: Do a detailed check for missing, broken or loosen mounting

screws of the engine, tighten the screws

Hydraulic: Do a detailed check for missing, broken or loosen mounting screws

of pumps, motors, clamps, ..., tighten the screws

TRACK COMPONENTS

Clean track chains (after the end of each shift)

Do a visual check of the tensioning cylinders, idler, carrier and track rollers for
leaks

Do a visual check of the track chains tension

Liebherr recommends to measure the track chains with TCM software

TRAVEL GEAR

Do a visual check of the gear for leaks, if there are leaks, check oil level

Sample and analyse gear oil, change oil if necessary

Change gear oil (if filled with COB-1 gear oil)

Change gear oil (if filled with COB-2, COB-3 or COB-4 gear oil)

Sample and analyse lifetime sealing interspace oil, change oil if necessary (op-
tional equipment)

Change lifetime sealing interspace oil (optional equipment)

Change brake oil

UNDERCARRIAGE
LEC/en/Edition: 02 / 2015

Do a visual check of all parts for damages and cracks

- If necessary fill out the "Structural Inspection" form in Service Manual - Chapter
4

ATTACHMENT

Do a visual check of the bucket teeth and wear kit for wear

Do a visual check of the grease supply at each lube point

copyright by
5 - 134 R 9250 / 10069862
MJFCIFSS
 Operating manual Maintenance
Control and maintenance chart

WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Do a visual check of cable harness and sensors for damage

Do a visual check of all parts for cracks

- If necessary fill out the "Structural Inspection" form in Service Manual - Chapter
4

Do a visual check of the fastening of pin covers

UPPERCARRIAGE

Do a visual check of the service trap for leaks or damage

Do a visual check of oil, grease or fuel for leaks

Do a detailed check of all structural parts for cracks

- If necessary fill out the "Structural Inspection" form in Service Manual - Chapter
4

Do a detailed check of the dust separator on air filter (cyclone) and hoses for
damage

Do a detailed check and lubricate the covers, doors hinges, locks as well as ser-
vice trap, access ladder cylinders bushings and swivel pins

Do a visual check if the fan guards are in place and secured

Do a functional test of the camera system and global view around machine (in-
cluding mirrors)

SWING GEAR

Do a visual check of the swing gears for leaks and oil level in expansion tanks

Sample and analyse gear oil, change oil if necessary

Change gear oil (if filled with COB-1 gear oil)

Change gear oil (if filled with COB-2, COB-3 or COB-4 gear oil)

SWING RING

Do a detailed check of the grease supply (outlet of new grease around the swing
ring)

Do a detailed check of the pinion gear teeth for damage

Do a detailed check of the swing ring axial play

CENTRALIZED LUBRICATION SYSTEM

LEC/en/Edition: 02 / 2015

Perform a complete daily maintenance given in the LINCOLN Operating Instruc-

tions Manual

Do a check of the grease tank level

Every 1000 hours, perform a complete 1000 hours Maintenance Echelon given
in the LINCOLN Operating Instructions

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R 9250 / 10069862 5 - 135
MJFCIFSS
Maintenance Operating manual
Control and maintenance chart

WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

DIESEL ENGINE AND SPLITTERBOX

Do a visual check in and around the engine compartment for leaks, contamina-
tion and damage

Check engine oil level

Sample and analyse engine oil

Change oil in Diesel engine

Replace engine oil filters

Check coolant level

Do a visual check of the engine and external pipework for leaks

Do a visual check of the exhaust gas system connections for leaks

Do a visual check of the thermic protection on the exhaust manifold fastening

Do a visual check of the oil supply / return pipework for leaks

Drain off water and sediment at fuel tank

Do a visual check of the water separator on fuel filters, drain if necessary

Replace all fuel filters

Do a visual check of the vacuum indicators for air filters clogging, clean or replace
if necessary and reset the indicator

Do a visual check of the air channels in precleaner, clean if necessary

Replace primary element of the air cleaner (if necessary or at least once a year)

Replace safety element of the air cleaner if indicated (if necessary or at least
once a year)

Do a sealing control of the air intake system

Check oil level in the splitterbox

Sample and analyse splitterbox oil

Change oil in splitterbox, if BOSCH splitterbox is installed

Change oil in splitterbox, if LIEBHERR splitterbox is installed

Do a visual check of the splitterbox breather for clogging, replace if necessary

Replace filter in splitterbox breather

LEC/en/Edition: 02 / 2015

Do a visual check of the splitterbox input shaft seal or engine main rear seal for
leaks

Do a detailed check of the engine and the splitterbox rubber buffers (replace if
necessary and at least every 10000 hours)

Do a visual check of the starter motors, alternator and AC compressor for cables,
and brackets

copyright by
5 - 136 R 9250 / 10069862
MJFCIFSS
 Operating manual Maintenance
Control and maintenance chart

WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Do a visual check of the air intake hose for condition and leaks

Do a visual check of the coolers for clogging and damage, clean or replace if nec-
essary

Do a visual Check of the radiator core and fan, clean if necessary

Do a visual check of the radiator cap for leaks, replace if necessary

Perform the complete "Daily" Maintenance Echelon given in the CUMMINS Op-
erating and Maintenance Manual

Every 250hours or 6 months, perform a complete Maintenance Echelon given in

the CUMMINS Operating and Maintenance Manual

See CUMMINS Operation and Maintenance Manual for other maintenance

(Eliminator, Centinel, Fleetguard, valves and injectors adjustment)

Every 10000 hours or 2 years, perform a complete Maintenance Echelon given

in the CUMMINS Operating and Maintenance Manual

HYDRAULIC SYSTEM

Drain water sediment from hydraulic tank

Check oil level in hydraulic tank

Sample and analyse hydraulic oil and change oil if necessary

Change hydraulic oil

Clean magnetic rods of the leak oil filter

Clean magnetic rods of all return filters

Replace filter element of the return filters

Replace filter element of the leak oil filter

Replace the hydraulic tank air filter

Replace control oil filter element

Replace swing pumps replenishing oil filter elements

Replace the control valves high pressure filters, replace filter elements after each
replacement or repair of a working pump and check the internal surface of the
filter housing

Do a visual check of the oil cooler protection filters, clean or replace if necessary
(optional equipment)
LEC/en/Edition: 02 / 2015

Do a detailed check of the oil coolers, clean if necessary

Do a visual check of the cooling fan blades, replace if necessary

Check and adjust primary and secondary pressure relief valves

Do a detailed check of mounting of components (pumps, motors, ...)

Every 4000 hours (or at least once a year), all hydraulic pumps must be checked
and adjusted by trained and qualified Liebherr personnel

copyright by
R 9250 / 10069862 5 - 137
MJFCIFSS
Maintenance Operating manual
Control and maintenance chart

WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Every 8000 hours, replace following high pressure (HP) hoses:

all HP hoses between work pumps and valve banks,
all HP hoses of the swing circuit:
all HP hoses between swing pumps and swing motors,
all pressure equalizing hoses between swing pump / swing motors circuits,
all HP pilot hoses of the swing pumps regulation,
all HP hoses between upper deck and attachment,
all HP hoses of the oil cooler fan drive circuit, including HP pilot hoses,
all HP hoses of the water cooler fan drive circuit, including HP pilot hoses.

ELECTRICAL SYSTEM

Press to open dust discharge valve on aeration devices for cabin and electrical
boxes

Replace main element on aeration devices for cabin and electrical boxes (at least
once a year)

Replace safety element on aeration devices for cabin and electrical boxes, after
3 services of main element

Do a visual check of the head and floodlights, clean if necessary

Do a visual check of electric harness, sensors for damage and/or rubbing zone

Do a detailed check of fuses and circuit breakers

Do a visual check of wiring system damage

Check battery electrolyte level (refill if necessary) and clean battery terminals

Do a test of all emergency stops (engine stop only)

Make sure that the display goes off after each test

AIR PRESSURE SYSTEM

Drain air tanks

Replace filter cartridge of air dryers

CABIN

Do a detailed check of the V-belt tension for air conditioner

Do a visual check of the cabin for oil/fluids leaks

Operate air conditioner every week for 10 minutes

LEC/en/Edition: 02 / 2015

Do a visual check of the condenser unit and evaporator filter

Do a visual check of the refrigerant level, if necessary refill circuit

Replace if necessary the air conditioner filter/dryer (at least once a year)

Yearly check condition of the refrigerant receiver, if necessary replace it

Perform maintenance for the second air-conditioning system (optional equip-

ment)

copyright by
5 - 138 R 9250 / 10069862
MJFCIFSS
 Operating manual Maintenance
Control and maintenance chart

WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Lubricate all doors seals with silicone or talc (before cold season)

Do a visual check of the AC for leaks or rubbing hoses or pipes

Do a visual check of the locks and hinges on doors and windows (lubricate if nec-
essary)

Do a detailed check of the cabin rubber mounts

Do a detailed check of the heater exchanger and filter for leaks

FIRE FIGHTING SYSTEM

Do a visual check of the fire fighting system condition (optional equipment, refer
to the fire fighting system documentation)
- If any issue contact fire fighting local dealer

Follow the inspection intervals recommended by the specific Health and Safety
rules existing in country and/or on mine site

START THE ENGINE TO CHECK THE FOLLOWING ACTIONS

General: Maintenance work must include the check of the correct functions of
hydraulic and electric systems before starting operation

Attachment: Check function of the working attachment lubrication system during

operation

Attachment: Check if the damping system on equipment is working correctly

Uppercarriage: Check position of the hydraulic shut-off valve

Uppercarriage: Check movement and locking of the access ladder

Uppercarriage: Check that the swing movement of the uppercarriage is locked

when the access ladder is lowered

Swing Gear: Check function and operation of the swing brake

Swing Ring: Check function of the swing ring bearing lubrication system during
operation

Swing Ring: Check function of the swing ring teeth lubrication system during op-
eration

Diesel engine: Check speed on RPM gauge

Diesel engine: Check running noises

Diesel engine: Check exhaust gas colour

LEC/en/Edition: 02 / 2015

Diesel engine: Check oil pressure and coolant temperature during operation

Diesel engine: Check if the prelub system is working properly

Electrical system: Clean and check LCD screen of the display for proper func-
tion when starting

Electrical system: Check indicator lights and gauges on the control panel when
starting

copyright by
R 9250 / 10069862 5 - 139
MJFCIFSS
Maintenance Operating manual
Control and maintenance chart

WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ...

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

Electrical system: Check for warning and fault messages on display (monitor-
ing, grease, air conditioning, ...). If necessary refer to chapter 4 in the Operating
Manual to identify and rectify faults and errors.

Air pressure system: Do a visual check of cut in and cut out pressure of air pres-
sure regulator

Cabin: Check if the safety lever is working properly

Cabin: Check the horn

Cabin: Check for green flash light on control module if fire fighting system is in-
stalled

LEC/en/Edition: 02 / 2015

copyright by
5 - 140 R 9250 / 10069862
MJFCIFSS
 Operating manual Maintenance
Control and maintenance chart

WORK TO BE PERFORMED DAILY

Initials
Check
Comments
Check for first and only interval or Check for repeat interval

General comments:
LEC/en/Edition: 02 / 2015

Tab. 5-16 2000 hours maintenance schedule - R9250

copyright by
R 9250 / 10069862 5 - 141
MJFCIFSS
Maintenance Operating manual
Centralized lubrication system

5.19 Centralized lubrication system

LEC/en/Edition: 02 / 2015

copyright by
5 - 142 R 9250 / 10069862
MJFCIFSS
Servicing Manual
Centralized Lubrication System for LIEBHERR Hydraulic Excavator
R 9250
Manual

1 Function of the lubrication system

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

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

System 1 Equipment lubrication- Slewing rim lubrication

Single-line system

Main components: Hydraulic pump "P1" 609-29333-1

Injectors LM-5, SL-1
Progressive metering devices SSV

System 2 Gear rim lubrication

Main components: Hydraulic pump "P2" 644-46265-1-L

Progressive metering devices SSV

1.2 Sequence of a lubrication cycle

1.2.1 Systems 1

Upon expiration of the pause time the pump begins operating and supplies the lubricant to the injectors 9 (LM-5, SL-1) 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 solenoid valve (Y79). The relieved lubricant
reaches the pump reservoir via a bypass.
The pistons in the injectors 9 (LM-5, SL-1) return to their initial position by spring force.
The pause time begins. The system is ready to carry out a new lubrication cycle.

1.2.2 System 2

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

nderungen vorbehalten

LINCOLN GmbH & Co. KG Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259 Tx 466088
Servicing Manual
Centralized Lubrication System for LIEBHERR Hydraulic Excavator
R 9250
Manual
1.3 Schema

SWING GEAR
PINION GREASING
SSV8

P1 Lubrication pump -attachment B69 Pressure switch / end of lube cycle for P1
P2 Lubrication pump -swing ring teeth B51 Limit switch on progressive distributor for P2
Y79 Solenoid valve / pressure release (attachment) 8 Progressive distributor SSV
U15 Lubricating system monitor 9 Grease injector banks LM-5, SL1
1 Grease tank (80L) B50-1 High level and Low level sensor for P1
B50-2 High level and Low level sensor for P2

nderungen vorbehalten

LINCOLN GmbH & Co. KG Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259 Tx 466088
Servicing Manual
Centralized Lubrication System for LIEBHERR Hydraulic Excavator
R 9250
Manual

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. 600 g/h for P1, 20 g/h for P2.

nderungen vorbehalten

LINCOLN GmbH & Co. KG Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259 Tx 466088
Servicing Manual
Centralized Lubrication System for LIEBHERR Hydraulic Excavator
R 9250
Manual

3 The lubrication system monitor

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 excavator is started the lubrication system is automatically

alive.
The lubrication pump then carries out a complete lubrication cycle, is
stopped only for the duration of the set pause time, etc....
The pause time is factory set at 2 hours.

During lubrication the diesel engine must be in operation because the

lubrication pump is driven via the compressed air of the excavator.
During a lubrication cycle, the pump function is represented by a
rotating girder on the field indicator.
The delivery of grease can be checked by ensuring that the control pin
of each injector moves back and forth.

The flashing of the pushbutton C indicates a malfunction in the

a b automatic lubrication system (lubrication cycle still not completed after
about one hour).

The fault is also indicated by means of an intermittent whistling sound at

the control unit. Possible causes of malfunction are:

Blockage or breakage of the main line

Fault at the pressure switch
Lack of lubricant in the grease reservoir
Fault in the power supply of the lubrication system
Fault in the compressed air system

An additional lubrication cycle can be triggered at any time by pressing

c d e the key c on the control unit U15 (at least 2 sec).

On malfunction of the command unit U15, an additional lubrication cycle

can be triggered by key S84-2 of the emergency unit command E52.

nderungen vorbehalten

LINCOLN GmbH & Co. KG Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259 Tx 466088
Servicing Manual
Centralized Lubrication System for LIEBHERR Hydraulic Excavator
R 9250
Manual

4 Inspection and maintenance

Do not perform any repairs while system is pressurized.

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

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

1. System as a whole

Daily: Visual check of the lubrication points for escaping lubricant

Visual check of the hose connections for leaks or wearing

Weekly: Visual check of the screwed pipe connections for leakage

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

2. Pump station

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

1000 hours: Clean filter element of grease filter

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

nderungen vorbehalten

LINCOLN GmbH & Co. KG Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259 Tx 466088
Servicing Manual
Centralized Lubrication System for LIEBHERR Hydraulic Excavator
R 9250
Manual

5 Exchanging / topping up grease reservoirs

CAUTION Lines are pressurized. Be careful when decoupling.

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

5.1 P1 and P2: Filling of the container

Filling of the container through service-plate

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

nderungen vorbehalten

LINCOLN GmbH & Co. KG Postfach 1263 D-69183 Walldorf Tel +49 (6227) 33-0 Fax +49 (6227) 33-259 Tx 466088
Servicing Manual
Centralized Lubrication System for LIEBHERR Hydraulic Excavator
R 9250
Manual

6 Malfunctions and their remedy

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

Malfunction: No pressure build-up in the system

Cause: Remedy:

Malfunctions of the pump See Troubleshooting: Pump

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

Air trapped in the main line De-aerate the line

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

Injectors leaky or worn See Troubleshooting: Injectors

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

Cause: Remedy:

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

Solenoid valve faulty Replace solenoid valve, check voltage supply

Grease too hard or not suitable for low temperatures Change lubricant

nderungen vorbehalten

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