LECren/Ealtion: 04 2024 Operator’s manual Liebherr Assistance Systems Mining excavators Document identification ORIGINAL MANUAL Order number: 12252691 Edition: 04/2021 Valid for: Mining excavators Author: LEC - Technical documentation department Product identification Manufacturer: —_Liebhert-Mining Equipment Colmar SAS Type: Mining excavators Type no.: - Address Liebherr-Mining Equipment Colmar SAS 49 tue Frédéric Hartmann CS 50038, F-68025 Colmar Cedex en copyright © Liebherr-Mining Equipment Colmar SAS 2021Operator’s manual Machine data Please fil in the following data when you receive your machine, This will also be of use to you when ordering replacement parts. Vehicle ident. number: WLHZ Construction year: First start-up date: rood copyright © Liebher-Mining Equipment Colmar SAS 2021 Mining excavators / 12262691 LECenfEaition: 04 12021Operator's manual Preface ‘This Operator's manual is intended for the operator who uses a machine that has Liebherr Assistance Systems. The Operator's manual belongs to the machine for the full lifetime of the machine. Make sure that a copy is always available in a location of the cab with easy access. IF this copy is lost, damaged or illegible, replace this copy immediately. Before starting or doing the maintenance of a machine that has assistance systems, all persons who start, operate or do the maintenance of a machine that has assis {ance systems must read the Operator’s manual carefully and understand it fully. This is applicable before the first start of the machine but also during the full lifetime of the machine. ‘The Operator’s manual helps familiarization with the Liebherr Assistance Systems and helps prevent incorrect operation of these systems. ‘The Operator's manual contains operating instructions and important data about the Liebherr Assistance Systems. ‘Some sections of this manual do not apply to all machines. It is possible that some. illustrations in this manual show details, devices or configurations which are different from the assistance systems or your machine. The values given in the illustrations are only illustrative. Liebherr machines and assistance systems are subject to continuous development and improvement. This may have resulted in modifications to your machine and your assistance systems which are not yet referred to in this manual. Should you need further explanations or information, please contact the Customer Service. Liability and warranty Liebherr will not recognize any warranty claim which is attributable to incorrect oper- ation, incorrect or unsatisfactory maintenance, use of unapproved operating materi- als or spare parts or failure to obey the safety instructions. If unapproved spare parts are used for maintenance or repair, Liebherr will cancel any obligation owed by Liebherr or its service partner such as warranty commitments, or service contracts, without prior notice. Modifications, conditions, copyright Liebherr reserves the right to make modifications without prior notice in the course of technical developments. The information and illustrations contained in these instructions shall not be copied and distributed, nor be used for the purposes of compatition. All rights are expressly reserved in accordance with copyright laws, ‘The warranty and liability conditions of the general business terms and conditions of Liebherr will not be enlarged upon through the above information. copyright© Liebher-Mining Equipment Colmar SAS 2021Operator's manual copyright© Liebher- Mining Equipment Colmar SAS 2021Table of contents 1 Safety instructions... 14 12 13 14 15 18 2 Human-machine interface 24 2.2 2.3 24 3 Operational Excellence .. 34 32 33 34 ‘Meaning of the symbols in this manual. Intended application. 1.2.1 Laws, rules, guidelines and safety instructions . 1.22 Intended use. Personnel requirements... 1.3.1 Personal protective equipment... 1.3.2. Personnel qualifications 1.3.3 _ Safety instructions at the place of use. Safety instructions for operation Safety instructions for maintenance... rns 1.5.1 Safety instructions for the maintenance of the electrical system: nee 1h 1.52 _ Safety instructions for spare parts. Modifications, add-ons and conversions... ELEERSS SASS Display fr Liebherr Assistance Systems 24 Aocess management. 22 2.24 Access levels, : 22 2.2.2 _ Session management. 23 Overview of Liebherr Assistance Systems wrt User Settings... a Soars 7 25 24.1 Open the User Settings . see 26 2.42 Main page: - : 26 243 Theme... 26 244 Language 27 2.4.5 Units system 27 2.46 Start page. ‘Truck Loading Assistant 3.44 Cycle time... 3.1.2. Open the Truck Loading Assistant 3.1.3. Select a truck. 3.1.4 Do the first cycle time. 3.4.5 Do the next cycle times until the N-1 cycle time.. 3.1.6 Add or remove a bucket payload manually 3.1.7 Do the last cycle time N. 3.1.8 Validate the truck exit 3.1.9 Recall the truck... 3.1.10 Trucks List Management. Performance Monitoring Assistant... 3.2.1 Open the Performance Monitoring Assistant. 3.2.2 Production overview. 3.2.3 Loading Key Performance Indicators (KPI)... 3.24 Time distribution. 3.2.5 Excavator efficiency Operational Conformance Assistant 3.3.1 Open the Operational Conformance Assistant 3.32 Definitions. 3.3.3. Operational Conformance overview... 3.3.4 Operational Conformance detailed view 3.3.5 Operational Conformance logbook. Application Severity Assistant Mining excavators / 12252601 ‘copyright © Lisbher- Mining Equipment Colmar SAS 2021Operator's manual 3.4.1 Open the Application Severity Assistant serene 3T 34.2 Defintions....m . one ee 3.27 3.4.3 Severity indicators overview 5 : eaesrananasn 228 3.4.4 Detailed view of a working condition 3-29 Additional functions .. 4a 44. Machine Monitoring.......00ssmnnses 44 41.4. Open the Machine Monitoring Fi eae aeegee a 4.4.2 Main page nn . oot 4.1.3. How to read the data... 42 4.1.4 Howto read the data connected fo a malfuNctiON ..nnmnnnnnnn Srferens 43 4.2 Machine Information rns oh 4.2.4 Open the Machine Information ....nssunnuernnnnn 44 422 Identification . vnmnmnnnnninnnnnnnnnnannnnnnn, 45 423 HOUR svennrsmnnne 46 424 Versions... 42.5 Licenses 4.3 Advanced additional functions... 43.1 Data Export 43.2. Parameters Center 44 Advanced monitoring interface 4.4.1, Menus and functions of the display 44.2 Dashboard.. 44.3 Error pop-up 4.4.4 Notification center. 4.4.5 _ Indicator and error warning symbols Malfunctions. a Bt 5.1 Error codes a 5.2 Fault - Cause - Remedy... 54 52.1 Display 51 5.3 Fuses and relays.ennn 53 5.3.1 For 9150 machines. 53 5.32 For 9200 machines 5-3 53.3 For 9400 machines. 54 5.3.4 For 996B machines 55 5.3.5 For 9600 machines. 55 5.3.8 For 9800 machines. 56 copyright © Liebherr-Mining Equipment Colmar SAS 2021 Mining excavators / 12252691 jon: 04 12024 Lecieneg 1.1 » be 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, e.g. 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. Meaning of the symbols in this manual Work processes and actions that could cause danger are accompanied by safety i 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 ita high risk of death or serious injury if the appropriate preventative measures are not taken. Caution! ‘Warning relating to dangers that could result in physical injury and/or damage to the machine if the appropriate preventative measures are not taken. Note! This symbol identifies user tips and operating and maintenance procedures whose use will guarantee a high degree of user-friendliness and longevity to the machine ‘or which will considerably simplify working procedures. — This symbol identifies a listing + This symbol identifies a sub-listing O This symbol signifies the following: “The precondition must be fulfilled” ‘The machine operator or the maintenance personnel must first fulfil the precondi- tion described, ie. the machine must be brought into a particular work position in order to be able to camry 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’ Mining excavators / 12252691 copyright © Liebher-Mining Equipment Colmar SAS 2021 4-4 LEBHERRSafety instructions intended appiation 1.2 1.2.1 124 1.3 1.3.1 Operator's manual Ifthe machine operator or maintenance personnel have carried out the activities deseribed in an action, the result ofthis action will be described here. Following these notes does not relieve you of responsibility for following ad- itional 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. Intended application Laws, rules, guidelines and safety instructions Following these notes does not invalidate the requirement to comply with ad- ditional rules and guidelines! Additionally, it is necessary to comply with = Safety rules applicable in the place of use = Statutory "rules of the road” — Directives issued by employer's professional liability insurers, Intended use The Liebherr Assistance Systems give information, advices and warnings. They pro- Vide: — Information to support different aspects of the operation, = Advices and warnings to reduce errors and misuses. = Feedback to identify the areas that need improvement. Information, advices and warnings are visual. The Liebherr Assistance Systems do not intervene directly in the machine control and operation. Any other use or use beyond what is defined here shall be regarded as not according tothe intended use. The manufacturer is not liable for damage attributable to use not in accordance with the designated use. The user bears sole responsibility. This also applies to unauthorized modifications to the devices. Personnel requirements Personal protective equipment Wear safe working clothes when you are working on the assistance systems compo- nents, For certain work, it is mandatory to wear safety glasses, safety boots, a protective copyright © Liebher-Mining Equipment Colmar SAS 2021 Mining excavators / 12252691 LECren/Eciton: 04/2024LEcfenfEdiion: 04 /2021 Operator's manual 1.3.2 1.3.3 Safety instructions Personnel requirements helmet, working gloves, a high-visibilly tabard, ear defenders and additional protec- tive equipment. Avoid wearing rings, wristwatches, ties, scarves, open jackets and loose-fiting cloth- ing, Risk of injury, e.g. by getting snagged or pulled in Personnel qualifications Only expressly authorised and trained people are allowed to operate, maintain or re- pair the assistance systems. The statutory minimum age shall be complied with. Training of the personnel should include theoretical information about technology and safety as well as practical training on these systems. Itis essential to make sure that the operating personnel have read and understood the operator’s manual and any other additional instructions for special equipment which may be provided. Personnel who are undergoing training or instruction or are taking part in a general apprenticeship are only allowed to work on or with the assistance systems if perma- rently supervised by an experienced person. ‘The owner must check regularly that the personnel are working safely, with aware- ness of the potential dangers and in accordance with the operator's manual. ‘The responsibility of the personnel for operation or setup, maintenance and repair must be clearly defined. Make sure that a sufficiently equipped workshop is available to carry out the works, and that the responsible staff have the necessary qualifications. Certain work is al- lowed to be performed by the machine owner (or the machine owner's personnel), other work is only allowed to be performed by specialist personnel who have the cor- responding training. Only personnel with special knowledge and experience are allowed to work on elec- trical system. Safety instructions at the place of use Find out from the safety officer what special safety instructions are applicable at the place of use, and follow them. Do not work in any way which represents a safety risk. Refuse to obey instructions from third parties which contravene safety instructions. This also applies with regard to the rules of the road. Keep unauthorised people away from the machine during maintenance or repair. Cordon off a large area around maintenance zone if necessary. Inform the operating personnel before starting special and maintenance work. Ap- Point a supervisor. Unless specified otherwise in the operator's manual, all maintenance work on the machine must be performed on level, firm ground with the attachment lowered and the Diesel engine stopped. When working above head height, use safe ladders and working platforms intended for this purpose. Do not climb on parts of machine if they are not intended for this purpose. Wear safety harnesses when working at height. Keep all handles, steps, railings, pedestals, gantries and ladders free from dirt, snow and ice. Do not work on the machine unless it has been parked securely and is protected Mining excavators / 12262601 copyright © Liebherr-Mining Equipment Colmar SAS 2021 LIEBHERR usSafety instructions. Operator’s manual Safety instructions for operation against rolling and driving away. 1.4 Safety instructions for operation ‘The assistance systems cannot replace your vigilance. Thus, regardless of their presence on the machine = You are always responsible for the correct operation and for all the movements of the machine. — Always adapt the working methods to the operating environment, to the condi- tions of the job site and to the weather conditions. During the operation, the assistance systems can tell you about, for example, a ma- chine misuse, an extreme working conditions or a non optimal truck loading. Then, you remain responsible for the related subsequent action, for example: — Continue the operation. — Check if all the necessary conditions for correct operation are stil available — Inform the relevant responsible. — Stop the machine 1.5 Safety instructions for maintenance In all cases, if it is necessary to remove safety devices, the safety devices must be installed back and checked immediately at the end of the work. 1.5.1 Safety instructions for the maintenance of the electrical sys- tem = Check the electrical system regularty. 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 hi + switch the machine off immediately in the event of malfunctions in the power supply. = Work on the machine's electrical equipment may only be carried out by skilled electrical personnel or by trained personnel under the supervision of an electri- cian in accordance with electrical regulations. = When working on live parts, ensure that a second person is available to operate the emergency-off or the main switch and overvoltage release. Cordon off the working area with a red and white safety chain and a warning sign. Only use in- sulated tools. = When working on neutral and high tension subassemblies, after releasing the voltage, briefly disconnect the supply cable at earth and electronic devices such ‘as capacitors using an earthing rod. — First test the released parts to make sure that they are off circuit, earth them and then disconnect them briefly. Insulate adjacent live parts. — Disconnect the battery before working on the electrical system or carrying out any copyright © Lebherr-Mining Equipment Colmar SAS 2021 1-4 LIEBHERR Mining excavators / 12252691LEClen/Ecition: 04/2021 Operator's manual 1.5.2 1.6 Safety instructions Modifications, add-ons and conversions electric arc welding on the machine, First disconnect the negative, then the positive pole. When reconnecting, proceed in the reverse order. — Obey the applicable regulations and standards when you use or work with devic- €s that come into contact with electrical voltage. = Do not open the power supply housing of the electrical devices. — Disconnect the electrical devices from the power supply before you open them, — Discharge the static electricity from your body before you touch the electronic ‘components. — Make sure that there is no potential equalization through the electrical device (for ‘example, by ground loops). = Make sure that the electrical devices and the electronic components are suffi- ciently cool to touch. Safety instructions for spare parts ‘Spare parts must correspond to the technical requirements defined by the manufac- turer. This is always ensured when genuine spare parts are used. Spare parts that do not correspond to the technical requirements of manufacturer can impair the safe- ty and function of machine. When replacing parts, re-secure unscrewed bolt connections with the correct torque. Modifications, add-ons and conversions Do not undertake any modifications, add-ons and conversions on the machine with- ut the approval of the manufacturer, if such modifications, add-ons and conversions could impair safety. Third-party parts and add-on parts, or parts which do not have a general approval from Liebherr for installation, are not allowed to be fitted to or in the machine without the written approval of Liebherr. The necessary technical documents must be provid- ed to Liebherr for this purpose. Mining excavators / 12252601 copyright© Liebher-Mining Equipment Colmar SAS 2021 1-5 LIEBHERRSafety instructions Operator's manual ‘Moaicatons, add-ons and conversions ‘copyright © Lisbherr-Mining Equipment Colmar SAS 2021 Mining excavators / 12252681LEClenVEatton: 04/2021 21 A Human-machine interface Display for Liebherr Assistance Systems ‘The assistance systems display has a touchscreen, which is installed in the machine cab. 2 3 Fig. 2-1 Display 1 Touchscreen 4 USB port 2 Notused 5 Brightness switches 3° Status indicators 6 Display switch Touchscreen Incorrect use of the touchscreen! Risk of damage. > Donot touch or clean the touchscreen surface with sharp, hard or rough objects, > Do not clean the touchscreen surface with clothes or sponges. > Tap the buttons shown on the touchscreen 4 to get access to a menu or to use @ function, Mining excavators | 12252601 copyright© Lisbher-Mining Equipment Colmar SAS 2021 2-4 LEBHERRHuman-machine interface Operator's manual ‘Recess management Control elements The control elements 3, 5, and 6 are installed on the front face of the display. Si > Operate the two brightness switches 5 to adjust the intensity of the screen light. hes > Push the switch 6 to tun off the screen, Status indicators ‘The status indicators 3 come on or flash as follows: Indicator | Indicator color | Description symbol Green = Comes on when the display is ready to oper- ate. — Flashes when the display is in standby mode. Red — Gomes on when an error or a faull occur on the display. — Flashes when the temperature of the display is too high. } For details, refer to the related section in chapter *Malfunctions” of this manual. Yellow = Gomes on yellow when there is an input. ned = Comes on red when the display works. Blue = Comes on blue when the display is on. OO Tab. 2-1 Status indicators 2.2 Access management 2.2.1 Access levels Systems, and for the related additional functions, that are available with "Operator" This Operator's manual gives the operating instructions for the Liebherr Assistance access level. This manual also gives the instructions for the functions that are available with "Cus- tomer" access level. copyright © Lisbherr-Mining Equipment Colmar SAS 2024 2-2 LIEBHERR Mining excavators 12252691 LECien/Eiton: 04/2021LEClen/Edition: 04/2021 Operator's manual 2.2.2 Human-machine interface ‘Access management “Operator” access level is available in all cases. Then, "Customer" access level in- herits the authorizations of the previous level and has its specified authorizations. Thus, if the access level of your user account is not sufficient to see an information or to use a command, you cannot see it. > Refer to the following overview for the different acoess levels and the related au- thorizations. > For more information on the different user accounts and on the related authoriza~ tions, refer to the Service manual or contact Liebherr customer ser Session management A session is the period of operation between a user logs in to the system and logs ut of it. Thus, the sessions are used as references for the analysis-periods of the recorded data. > Start the electrical system of the machine. © An"Operator” session starts automatically (automatic login) & This symbol is shown. % You can operate the machine. > Stop the electrical system of the machine. ' The active session stops automatically You can also stop a session and start a new one when the electrical system of the machine is on (for example: for an operator shit) > Tap the “Logout” button on the title bar. > Tap the "Confirmation* button. % The active session stops. % Anew Operator session starts. ‘The "Confirmation" button goes off if: = You do not tap it in less than § seconds = You tap out of it. When a session starts, the session management system checks the access level of, the user account. Then, it controls the information and the actions that are authorized to access and to perform. When the access level of the user account is not sufficient to do an action, you cannot see it. Thus, for higher access level, it is necessary to connect a dongle. Ifyou have a dongle: > Connect the dongle to the USB port of the assistance system display. For some dongles, it can be necessary to enter a password. In this case, a special pane let you enter your password. Mining excavators / 12252601 ‘copyright © Lisbher-Mining Equipment Colmar SAS 2021 2-3 JEBHERRHuman-machine interface ‘Overview of Liebherr Assistance Systems Operator's manual 2.3 Overview of Liebherr Assistance Systems The overview that follows gives the different functions with related necessary access. levels, vo3a a7 R | Vea Vt0a voy 12 e) V4, ASE a < ie B| [oo] |@: (@| | ta-----4] | v 402 |< | dono Fig. 2-2 Access levels A. "Operator" access level B "Customer" access level Human-machine interface 11 Monitoring display (A, 8) 4° Other menus link (A, B) 12 User Settings 124 Theme (A, B) 12.2 Language (A, B) 12.3. Units system (B) 12.4. Start page (B) Operational Excellence Overview of Liebherr Assistance Systems Bit g | | copyright © Lebherr-Mining Equipment Colmar SAS 2021, Mining excavators / 12252601 Leclen'Edtion: 04 /2021LEClerVEdion: 04/2021 Operator's manual 2.4 Human-machine interface 2 Truck Loading Assistant (A, B) 24 Thucks List Management (A, B) 3. Performance Monitoring Assistant 3.1. Production overview (A, B) 3.2 Loading Key Performance Indicators (KPI) (A, B) 3.3 Time distribution (A, B) 3.4 Excavator efficiency (A, B) 5 Operational Conformance Assistant 5.1 Logbook (A, B) 5.2 Detailed view (A, B) 5.2.4 Time (A, B) 5.2.1 List (A, B) 6 Application Severity Assistant 6.x Working conditions (A, B) Additional functions 7 Machine Monitoring 7.x Machine systems (A, B) 8 Machine Information 8.1 Identification (A, B) 8.2 Hours (A, B) 8.3. Versions (A, B) 8.4 Licenses (A, B) Advanced additional functions 9 Data Export 9.4 PDF report (A, B) 10 Parameters Center 10.1, Pages for “Operator” access level (A, B) 10.2 Pages for "Customer" access level (B) 14. System Update 11.4 USB Update (A, B) 11.2. Remote Update (A, B) 14 Bucketload Calibration (B) User Settings > Refer to the sections and instructions of this manual that are applicable to your machine. User Settings ‘The User Settings lets you configure the display layout and the system. Mining excavators / 12252601 copyright© Lisbher- Mining Equipment Colmar SAS 2021Human-machine interface Operator's manual User Setings 2.4.1 Open the User Settings > Tap the “Other menu” button to get access to the different available menus. If necessary, swipe over the different menus, Bi > Then, tap the "User Settings” button to open the related main page. 2.4.2 Main page The main page gives access to different functions. If the access level of your user account is not sufficient to see an information or to use a command, you cannot see it a ss | = Fig. 2-3 Main page 1 Theme 3. Start page 2 Units system 4 Language When you configure a setting: — This setting is recorded for the next start. ~ This setting stays the same for all other users. 2.4.3. Theme * This function lets you select the theme of the display layout. row Then: copyright © Liebherr-Mining Equipment Colmar SAS 2024 2-6 me eae Mining excavators 12252691 LEcren/Eation: 04 / 2021LEClen/Eattion: 04/2024 Operator's manual 2.4.4 2.4.5 24.6 Human-machine interfacs User Settings > Tap the "Day" button to use the usual colors of the display layout. > Tap the "Night" button to use the dark colors of the display layout. } Tap the “Auto” button to set the colors of the display layout automatically Language This function lets you set the language in which the different titles and pages are writ- ten. > Select the button of the language you want to use, At the first start, the language is set on English language. Units system This function lets you set the units system for: — The Truck Loading Assistant = The Performance Monitoring Assistant. The available units systems that you can select are: = The International System of Units (SI) — The United States Customary System (USCS or USC). > Select the button of the units system that you want to use. ‘At the first star, the units system is set on the Intemational System of Units (SI). Start page This function lets you set the start page of the system. > Select the button of the start page you want to use. Mining excavators / 12282801 ‘copyright© Liebher-Mining Equipment Colmer SAS 2021 2-7 JEBHERR .Human-machine interface User Setings Operator's manual At the first star, the start page is set on the monitoring display. copyright © Liebher- Mining Equipment Colmar SAS 2021 Mining excavators / 12252601 Leclen/Edtion: 04/2021