Omm Ex-9200 PDF

Operating manual Maintenance
Lubricants and operating fluids
Fig. 5-4 Grease control box E1043
H58 Swing ring grease

H59 Attachment grease
The warning lights H58 and H59 come on when the related grease level is too low.
5.3.4 Lubricant chart
Designation Medium Symbol Classification Viscosity Quantity*
Diesel engine Engine oil See the Operation and Maintenance 142 L
Manual for CUMMINS engine.
Hydraulic tank Hydraulic oil See section "Lubricating and oper- 3400 L in
ating material specifications". whole cir-
cuit
LEC/en/Edition: 01 / 2016
2200 l in
hydraulic
tank
Swing gear Transmission See section "Lubricating and oper- 2 x 32 L

oil ating material specifications".
copyright © Liebherr-Mining Equipment Colmar SAS 2016

R9200 / 11695477 5 - 13
Maintenance Operating manual
Designation Medium Symbol Classification Viscosity Quantity*
Travel gear Transmission See section "Lubricating and oper- 2 x 38 L

oil ating material specifications".
Lifetime travel gear (optional)
Lifetime sealing interspace Hydraulic oil Use same oil as used for hydraulik 2 x 3,4 L
(optional) tank.
Splitterbox Transmission API-GL-5 SAE 90 10 L

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

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

SIGMA S30 cc
Cold climate conditions:

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

AGIP ROTRA LSX
CASTROL SAF XO 75W90
Idler Wheel VARIAX - EP 80W90 2 x 3300 cc

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

panels or talc
Tab. 5-3 Lubricant chart
*The given quantities are only guidelines. Check fluid level after each change or refilling.
5.3.5 Operating material chart
Designation Medium Symbol Quantity*
Fuel tank See the Operation and Maintenance Manual for CUMMINS 4477 L
engine.

5 - 14 R9200 / 11695477
Designation Medium Symbol Quantity*
Engine coolant See the Operation and Maintenance Manual for CUMMINS 184 L
engine.
Windshield washer Commercially available windshield washer fluid or dena- 30 L

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

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

PLANETELF PAG SP 20
Refrigerant oil to add in the system after a compressor re- - 0,163 L

placement:
PLANETELF PAG SP 20
Refrigerant oil in the full system: - 0,363 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.
5.3.6 Service trap

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

The service trap is manually moved up and down from the ground level.
Fig. 5-5 Service trap handle

R9200 / 11695477 5 - 15
Use the handle 1 and the lever which is installed on the access ladder (one more
lever is installed into the cab elevation).
Caution!
The service trap must be moved down only if the uppercarriage and the undercar-
riage are aligned.
Caution!
For safety reasons, the machine can only be operated if the service trap is locked
in its top position. This means that the swing and travel movements remain locked.
If the service trap is not on its top position, the warning light H68 on the control board
comes on.
Fig. 5-6 Warning light H68: trap control lock
This safety measure can be bypassed as long as the button S122 on the control
board is activated.

5 - 16 R9200 / 11695477
Lubricating and operating material specifications
Fig. 5-7 Button S122: Disable trap control lock
5.4 Lubricating and operating material specifica-

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

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

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

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

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

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

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

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

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

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

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

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

5 - 20 R9200 / 11695477
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-
HER MINING EQUIPMENT COLMAR SAS.
Do not mix biodegradable hydraulic oils from different suppliers and never mix
with mineral oils.
Do not use vegetable oils as they do not possess the necessary thermal stability.
Depending on the temperature range, LIEBHERR recommends its poly-alpha-olefin
(PAO, HEPR) oils, that are biodegradable according to CEC-L-103-12 (21 days, >
60%, primary decomposition):
Liebherr Hydraulic Plus or Liebherr Hydraulic Plus Arctic
If these oils are not available locally or if further specifications are required, use one
of the following oils (before choosing an oil, contact our Customer Service):
Fully saturated synthetic ester-based oils, HEES
Depending on the temperature range, the viscosity grade of the HESS oil must con-
form to the above specifications hor hydraulic oils.
Caution!
LIEBHERR recommends to limit the use of HEES oils to areas where HEES oils are
mandatory by local regulations.
Lifetime of components made out of rubber material such as hoses, seals, compen-
sators might be reduced while using HEES oils!
When mixing ester-based biodegradable hydraulic oils with mineral oils, there is a
risk of agressive chemical reactions, which might damage the hydraulic equipment.

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

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

5 - 22 R9200 / 11695477
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. 5-11 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).
Fig. 5-12 Taking an oil sample

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

R9200 / 11695477 5 - 23
Caution!
Gears flushing is necessary when switching from mineral oil to synthetic oil.
Use new oil to flush the gear when switching from mineral oil to synthetic oil.
Flushing with cleaning fluid or Diesel fuel is not permitted.
Use gear oil meeting following viscosity classes and specifications (depending on the
ambient temperature):
Fig. 5-13 Swing gear and travel gear oils
* COB-1: Gear oil according to DIN 51517, part 3, CLP-HC(1)

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

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

ENCE PERFORMANCE
Tab. 5-6

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

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

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

Use gear oil with viscosity classification SAE 90 or SAE 80W90 and meeting speci-
fications API-GL-5 and MIL-L-2105 B, C or D.

R9200 / 11695477 5 - 25
Fig. 5-14 Gear oils for use as splitterbox oil
5.4.7 Lubricating grease and other lubricants
Lubricating grease
Use grease which agrees with the specifications that follow (depending on the ambi-
ent temperature).
Lubricating grease for the swing ring, attachment bushings and swing gear bearing / general lubricating
points:
– KP2K or KPF2K according to DIN 51502
– ISO-L-XBCEB2 according to ISO 6743-9
TEST / REQUIREMENT STANDARD / REFERENCE REQUIRED LEVEL / PERFOR-
MANCE
Consistency ISO 2137 / ASTM D 217 NLGI grade 2
Grade according to DIN 51818
Soap / Thickener - Greases made of calcium simple
soap are not permitted
Base oil viscosity at 40°C ISO 3104 / ASTM D 445 > 400 mm²/s
Dropping point ISO 2176 / ASTM D 566 > 160°C
Four ball wear test DIN 51350 / ASTM D 2596 > 2300 N
Lubricating solids, maximum particle size: -
– Maximum grain size for Graphite 25 microns
– Maximum grain size for MoS2 15 microns
– Maximum grain size for other solids ad- 15 microns
ditives
Lubricating solids, maximum content: -
– Maximum for Graphite 8%
– Maximum for MoS2 5%
– Maximum for other solids additives 5%
Tab. 5-9

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

– KPF2K according to DIN 51502
– ISO-L-XBCEB2 according to ISO 6743-9
TEST / REQUIREMENT STANDARD / REFERENCE REQUIRED LEVEL / PERFOR-
MANCE
Consistency ISO 2137 / ASTM D 217 NLGI grade 2
Grade according to DIN 51818
Soap / Thickener - Greases made of calcium simple
soap are not permitted
Base oil viscosity at 40°C ISO 3104 / ASTM D 445 > 400 mm²/s
Dropping point ISO 2176 / ASTM D 566 > 160°C
Four ball wear test DIN 51350 / ASTM D 2596 > 5500 N
Water resistance DIN 51807-1 1 - 90 or better
Water washout ASTM D 1264 79°C - 5% loss or better
Lubricating solids, maximum particle size: -
– Maximum grain size for Graphite 25 microns
– Maximum grain size for MoS2 15 microns
– Maximum grain size for other solids ad- 15 microns
ditives
Lubricating solids, maximum content: -
– Maximum for Graphite 8%
– Maximum for MoS2 5%
– Maximum for other solids additives 5%
Tab. 5-10
Cold climate conditions

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

Contact spray for slip rings Cramolin
Lubricant for pistons, piston Gleitmo 800
nuts and piston bearing in-
stallations on the hydraulic
cylinders

R9200 / 11695477 5 - 27
Lubricant Description / manufacturer

Special anti-corrosive materi- Castrol-Tarp
al for installation areas of
sealing elements on hydraulic
cylinders
Anti-corrosion grease for Liebherr special grease CTK
open piston rods (cylinders
that do not move often or
transportation)
5.4.8 Lubricants specifications for -40°C
Engine oil
Refer to the Operation and Maintenance Manual for the CUMMINS Diesel engine.
First filling
Use BP Vanellus Ultima 5W30 from -40°C to +30°C (if the excavator is equipped with
a preheating the temperature range can start at -50°C instead of -40°C).
Hydraulic oil
Refer to the section "Lubricating and operating material specifications" of this
manual.
Gear oil
SAE 75W90 API GL5 with pourpoint < -54°C:
– BP gear oil Syntrax Universal Plus 75W90
– AVIA gear oil Synthogear FE 75W90 EP from -50°C to +40°C
Grease: general lubepoint

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

– low temperature grease: Liebherr Universalfett Artic
– grease Petro-Canada Vulcan Synthetic Arctic from -55°C to -20°C

5 - 28 R9200 / 11695477
Condition monitoring with oil analysis
5.5 Condition monitoring with oil analysis
5.5.1 General information

Oil analysis helps to monitor the main components condition by observing oil chem-
ical and physical properties which can show either the oil contamination by foreign
or wear particles, or the degradation of its properties.
Component oil analysis in accordance with the recommended procedures, intervals
and specifications and the records of a component oil analysis are strongly recom-
mended because this will support any warranty claim raised upon LIEBHERR.
By comparing the oil properties and contaminants to reference levels and even more
by observing their trends over a period of operation, it is possible to optimize the com-
ponent lifetime, possibly to prevent further damage (preventive exchange) and po-
tentially to reduce rebuild and maintenance costs.
An oil analysis will give an indication of the component condition. But the measured
values and their trend over a period of operation need always to be interpreted in re-
lation to the machine operating conditions and to events such as services, top-up,
component change-out, etc.
The interpretation of the analysis results need also to be compared to samples of the
new oil. Therefore, new oil needs to be analysed twice a year and when changing to
another oil supplier.
This procedure is applicable for these components:
– splitterbox(es)
– swing gears
– travel gears (not on pontoon machines)
– hydraulic oil
– Diesel engine(s) (not on electrical machines)
These parameters must be monitored:
– iron level
– copper level
– silicon level
– water content
– viscosity change
– additives change (e.g. Ca, Mg, B, Zn, P, Ba or S)
5.5.2 Oil sampling
Sampling intervals
– For each component, get an oil sample according to the Control and maintenance
chart.
– When changing oil, get an oil sample of the used oil immediately before draining
it.
– For new oil, get an oil sample twice a year and when changing to another oil sup-
plier.

R9200 / 11695477 5 - 29
Sampling instructions
General sampling instructions:

Wear personal protective equipment.
Get the sample:
– during operation or immediately after stop
– at normal operating temperature
– not just after an oil change
– not just after a top-up
Clean the area around the sampling point before you get the sample.
Use an appropriate sampling kit.
Keep the sampling material away from humidity and dust. Take these precautions
to choose a storage area.
Make sure the sampling material is perfectly clean (without dust, water, fuel...).
If different sampling procedures are applicable for a component, always use the
same sampling point and the same sampling procedure for this component to
make sure that the analysis records stay relevant.
Fill the sampling bottle with oil to 80% level. Do not fill the sampling bottle to the
top.
Close the sampling bottle tightly to ensure the integrity of the sample.
Identify the sample with a label.
Carefully fill in a sample information sheet. In any case, it is mandatory to give this
information with the sample:
– machine type and serial number
– machine hours
– sampled component name:
• splitterbox (front/rear)
• swing gear (front/rear and left/right)
• travel gear (left/right)
• hydraulic oil
• Diesel engine (front/rear)
– sampled components hours
– sampled oil hours
– top-up oil quantity since last sample
– sampled oil type
Send the sample in oil-proof adapted material.
Check for the required sample delivery time and for sample export licence (if the
laboratory is located out of the country, make sure that the export of the sample
is authorized from your location to the laboratory).
Do not wait before sending the sample to the laboratory.

Record and save sampling operations and results.

5 - 30 R9200 / 11695477
If you get the oil sample with a sampling pump:
Fig. 5-15 Sampling pump
Use a sampling pump if you get the sample directly in the tank or on the compo-
nent (machine stopped).
Always use a new sampling hose.
Cut the sampling hose to the correct length (e.g. dipstick length plus 20 mm).
First, let sufficient oil flow to flush the sampling hose.
If you get the oil sample in the tank, take the sample in the middle of the tank.
If you get the oil sample through a sampling valve:

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

R9200 / 11695477 5 - 31
Ident Nr. Description Quantity Illustration
8145660 Sampling kit for mineral and synthetic oils: 1

10029626 – sample bottle 4
– envelope addressed to OELCHECK GmbH
7018368 6
– sample information sheet
7018369 12
7026817 Sampling kit for biodegradable oils: 1
– sample bottle
7026088 6
– envelope addressed to OELCHECK GmbH
– sample information sheet
8145666 Sampling hand pump: 1

– hand pump
– sampling hose
7019068 Sampling valve 1
7023359 ADR spill kit (International Carriage of Dangerous 1

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

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

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

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

To get a sample of the hydraulic oil:

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

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

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

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

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

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

5 - 36 R9200 / 11695477
Swing gear

level value
ers...).
Swing gear 250 hours).
(at 40°C and 100°C)
(*) Difference compared to new oil value.
Travel gear

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

R9200 / 11695477 5 - 37
Hydraulic oil

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

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

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

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

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

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

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

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

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

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

As a help way, the oil can also be drained through the oil drain plug. It is located at
the bottom of the oil pan of the Diesel engine. LEC/en/Edition: 01 / 2016

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

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

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

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

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

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

R9200 / 11695477 5 - 43

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Operating manual Maintenance

Lubricants and operating fluids

Fig. 5-4 Grease control box E1043

H58 Swing ring grease

5.3.4 Lubricant chart

Designation Medium Symbol Classification Viscosity Quantity*

Swing gear Transmission See section "Lubricating and oper- 2 x 32 L

copyright © Liebherr-Mining Equipment Colmar SAS 2016

Designation Medium Symbol Classification Viscosity Quantity*

Travel gear Transmission See section "Lubricating and oper- 2 x 38 L

Splitterbox Transmission API-GL-5 SAE 90 10 L

Swing ring teeth Lubricating See section "Lubricating and oper- 15 L

Track roller AGIP DIESEL ISO 100 16 x 2700

Cold climate conditions:

Carrier roller AGIP BLASIA 220 ISO 220 4 x 3350 cc

Cold climate conditions:

Idler Wheel VARIAX - EP 80W90 2 x 3300 cc

Cold climate conditions:

Hinges, joints, locks Engine oil - - - -

Rubber seal on doors and trim Silicon spray - - - -

Tab. 5-3 Lubricant chart

5.3.5 Operating material chart

Designation Medium Symbol Quantity*

copyright © Liebherr-Mining Equipment Colmar SAS 2016

Designation Medium Symbol Quantity*

Windshield washer Commercially available windshield washer fluid or dena- 30 L

Air conditioning system Refrigerating agent: - 2,2 kg

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

Refrigerant oil to add in the system after a compressor re- - 0,163 L

Refrigerant oil in the full system: - 0,363 L

Tab. 5-4 Operating material chart

5.3.6 Service trap

Lower and lift the service trap

Fig. 5-5 Service trap handle

copyright © Liebherr-Mining Equipment Colmar SAS 2016

Fig. 5-6 Warning light H68: trap control lock

copyright © Liebherr-Mining Equipment Colmar SAS 2016

Fig. 5-7 Button S122: Disable trap control lock

5.4 Lubricating and operating material specifica-

5.4.1 Lubricating oil for the Diesel engine

copyright © Liebherr-Mining Equipment Colmar SAS 2016

5.4.4 Hydraulic oil specifications for LIEBHERR Mining excava-

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

LIEBHERR oils for hydraulic system

Fig. 5-8 LIEBHERR oils for hydraulic system

A Ambient air temperature

copyright © Liebherr-Mining Equipment Colmar SAS 2016

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

Fig. 5-9 Engine oils for hydraulic system

A Ambient air temperature

– Single viscosity oils: API - CD / ACEA - E1

copyright © Liebherr-Mining Equipment Colmar SAS 2016

Fans speed regulation settings

Engine oil fans speed regulation setting

SAE30 (ISO VG100) "STANDARD"

SAE 10W (ISO VG46) "EXTRA-COLD" or "COLD"