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    LIEBHERR EXCAVATOR

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    LIEBHERR EXCAVATOR

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    22 views49 pages

    01 General Information R900 Litronic LIEBHERR

    Uploaded by

    ashraf elsayed
    LIEBHERR EXCAVATOR

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 49
    SUBGROUP INDEX 1.01, Chart / Coming into Effect of Modifications 1.10. Safety Information 1.20. Conversion Factors 1.20.01 Tightening Torques 1.20.06 150 Tolerances 1.30. Torque values for UNC / UNF screws 1.40. Repair welding 1.50. Lubricants Benennung/Description/Dénomination LIEBHERR DatumiEaion/Date 04.96 General Information Typ Mode! Type ‘Abifiom/a parti de BlarPage/Feuile 1. Foreword This manual has been prepared to provide you with technical information on the design and construction of the various components which made up the LIEBHERR excavator. It contains brief and precise descriptions, guidelines and drawings of adjustment procedures as well as hydraulic and electrical schematics, and graphically depicted diagrams and sectionals to help you with any repairs, which might become necessary on our hydraulic excavators, We deliberately avoided full drawings and details of each repair stage, a practice often adopted in workshop manuals of this kind, since only skilled mechanics already familiar with most repair work described in this manual, shouid perform repair work. This manual is also intended to provide you with information regarding certain adjustment values. Instructions on_ maintenance is excluded from this manual, since it are covered in the individual Operation and Maintenance Manual Be sure to observe all accident prevention guidelines and adhere to all safety information before and during any maintenance and / or repair procedure on the hydraulic excavator. To perform tests and repairs listed in this manual, a complete set of standard tools, as well as special tools and fixtures shown and listed, is necessary. Always observe utmost cleanliness and order. No special emphasis is put on replacing sealing components, since it is taken for granted that all removed seals, O-rings and gaskets are repiaced during the course of repair. Tighten any screw connections, if no other values are given, to the required tightening torque. Certain notes are used throughout this manual to emphasize important or critical instructions. [JER This mark used in our descriptions denotes an important note or reminder, which should be especially noted This exclamation mark used in our descriptions denotes an important note or a AA eminder of safety practices or directs attention to unsafe practices, which could pose danger for the mechanic and / or the machine. if proper precautions are not taken. This Service Manual has been issued by the Customer Service Department of LIEBHERR - FRANCE, 2, avenue J. REY 68000 COLMAR. This manual will be updated regularly, as a registered holder of a Service Manual you will automa: tically receive all revised and new pages according to the latest series status, Some Service Information bulletins may also need to be filed in this Service Manual This book may not be copied nor given to third persons without our approval! We reserve the right to make changes We trust that with this information contained in this manual and your cooperation we have taken another step toward continuing improvement of service on our LIEBHERR hydraulic excavators. LIEBHERR - FRANCE SA. Explanation In order to make it easy to find certain information or to remove and/or add pages in case of changes or improvements, the following system has been established: Page No. Subgroup Main group 7 10. 01 Hydraulic components Var. displacement double pump (PVD Page 01 The index for the main groups can be found on the index page. The subgroups can be found on the index page in front of the main group. In addition, the machines with serial numbers are listed on the index, which is valid for this subgroup. In case of minor changes we will issue revised pages and update the date. If an already existent sub group is completely revised, we will assign a new sub group number. Anderungsmarke Artder Anderung Anderungseinlauf ab 5.Nr. Modification mark Kind of modification Modified on machines from S.N. Repére de modif. Nature de la modification Modifie & partir de n* de Serie (a) Regler "GLD" ersetzt Regler "GLR" R922: Nr. 202, 210, 212 + 223, Horsepower limiter "GLD" replaces "GLR" 225 + 245, 272 > Régulateur "GLO" remplace regul. "GLR" | R932: Nr. 486, 498,511 541 651 R942: Nr. 333, 340, 347, 350, 354 360, 362 — 376, 449 -- (b) Bausatz “Power safety” serienmaBig eingebaut | R900, Nr. 192— “Power safety” serially mounted R902 Nr. 2150—> Fonetionnement de secours monté de série R912 Nr-2175-2 | R922: Nr. 380+ R932; Nr. 805— R982; Nr. 542 iS) Einfahrung der Platine A1 von LBC R900: Nr. 101+ Mounting of print plate At (maker LBC) R902; Nr 44t— Montage du circuit imprime Al de fabrication | R912: Nr.3472—+ LBC R922: Nr. 3558+ R932: Nr. 727-> | R942: Nr. 489+ (@) Hydraulikélstandsonde B14 R900: Nr. ~ Fabricat Honsberg ersetzt Fabrikat Bedia R902: Nr. 2001+ Hydraulic oil level transmitter 814 R92: Nr.2287 Model Honsberg replaces model Bedia R922: Nr. 103 Capteur de niveau / hulle hydraulique B14 R932; Nr. 550+ Le modéle Honsberg replace le modele Bedia__| R942: Nr. ~~ (e) Dieselmotor ausgerdstet mit Wasserfilter R902 Pea “Fleetguard” R912 3388 Diesel engin fitted with "Fleetquard" water filter | R 922: 3527 ‘Moteur Diesel equipe de filtre a eau “Fleetguard” | R932 3152, 3156, 3159 R942 3077 > (f) Umstellung auf das Fahrerhaus Fabrikat "SIAC" | R 902: 2105-+ Mounting of the new driver's cab "SIAC’ R912 2617, 2646.-- Machine avec nouvelle cabine de fabrication R922: 331, 352 “Siac” R932; Nr.673,727— R942: Nr. 485, 489-> a) Serienmassiger Einbau der Funktion R902: 3292+ “Druckzuschaltstufe Heben” R912: 3720-> Function "Pressure cut-in stage - lift boom" R922. 3642 serially mounted R932, 4001 Montage de serie de la fonction "commutation | R942: 4001.» de pression en montee fleche" ‘Benennung/Description/Denomination, Ws R900 R942 Bee Liemcewe Angaben iiber den = Fam Chart / Coming into Effect of Modifications | Depus LIEBHERR auf von Anderungen Datum Eaition 03.97 Entree en vigueur des modifications ae, 1.01.01 Anderungsmarke Modification mark Repére de modif. Art der Anderung Kind of modification Nature de la modification Anderungseinlauf Modified on machines Modifie a partir de (hy) Druckschalter B30 hinfallig. Eingangssignal "B30" an GLD ber Drucktaste $130 R902 Ne 3370. 3373, 3374, 3381, Pressure switch B30 suppressed. Input signal - "B30" to horsepower controller GLD given by | R912: Nr. 3660, 3993, 3700, 3708, push button $130 3715, 3716, 3750, 3761, 3762, Pressostat B30 supprimeé. Signal d’entrée "B30" 3764, 3769, 3771, 3772, 3784, pour regulateur GLO donne par poussoir 130 3786 > R922: Nr. 3636, 3650, 3653 3656+ R932: Nr. 3380, 3381, 3392, 3397, 3401 3406, 3411 —> R942: Nr. 4005, 4026, 4047 —-4052, 4055 > @ Bremsventile auf Fahrwerksmotoren mit Anfahrdrosselbohrungen versehen R900: Nr-3065 Brake valves on travel motors fitted with t R902: Nr3291—> bores for travel start . Clapets de freinage sur moteurs de translation | R912: Nr. 3638 avec orifices calibres R922: Nr. 3616-> R932: Nr3311-> R942: Nr.3213— (k) Rickschlagventil im Steuerkreis far die Motorverstellung entfallt (in den Fahrmotoren) Non return valve (in control line for travel motor displacement is suppressed (in travel motor) Suppression du clapet anti-retour (sur circutt de ‘commande de cylindree des moteurs) a interieur des moteurs de translation R900-R942 ~ 08,97» 1.01.01 Working with an excavator can be dangerous, it could result in injury or death if proper precautions are not taken! WE URGE YOU TO READ THIS MANUAL CAREFULLY! This safety information is provided to operators and maintenance mechanics to ensure the safe operation and maintenance of the excavator. Itis essential that you read and familiarize yourself with this information, which explains safety requirements and precautions and specific hazards of which you should be aware. This also applies to any personnel which might be working on, the machine only occasionally, such as during set up or maintenance. It is essential that you read and familiarize yourself with this information, which explains safety requirements and precautions and specific hazards of which you should be aware Careful adherence to these safety guidelines will permit safe operation and maintenance and potentially prevent personal injury to yourself and others, and possible damage to the excavator In addition to these instructions you must follow the safety regulations applicable to your work environment and job site and any federal, state and local safety requirements and federal highway regulations). {A model excavators must also fallaw focal. GENERAL SAFETY INFORMATION Consult our employer or supervisor for specific # Study the Operation and Maintenance Manual belore operating or working on the excavator. safety equipment requirements and salety Make sure that you have additional information regulations on the job site for special attachments of your machine, read it Always tilt up the safety lever before leaving the and understand it! operator's seat, © Allow only authorized personnel to operate Do not carry tools, replacement parts or other service or repair the excavator. Make sure to supplies while climbing on or off the excavator. observe any minimum applicable age Never use the steering column, control levers or requirement. joysticks as handhold * Allow only properly trained personnel to Never jump off the excavator, climb on and off ‘operate or work on the excavator, make sure to the excavator using only the steps, rails and clearly specify the person who is responsible for handles provided set up, maintenance and repairs When climbing on or off the excavator, use both '# Make sure the operator knows his responsibility hands for support and face the machine regarding the observance of traffic regulations If needed, use the front window as an escape and permit him to refuse any unsafe instructions hatch given my a third person " Ch et ' tn no other guidelines are given, perform © Any persons still in training should only operate maintenance ond repair uulizing the following or work on the machine under the supervision precautions and guidance of an experienced person Park excavator on firm and level ground. Rest @ Check and observe any person working or tne-attachment on the ground operating the excavator periodicaily and regularly, if they observe safety instructions and Place all control in neutral position and raise guidelines given in the Operation and the safety lever. Maintenance Manual Turn the engine off and remove the ignition © Wear proper work clothing when operating or key. LIEBHERR Edition working on the excavator. Rings, watches, bracelets and loose clothing such as ties, scarves, unbuttoned of unzipped shirts and jackels are dangerous and could cause injury! Wear proper safety equipment, such as safety glasses, safety shoes, hard hats, work gloves, rellector vests and ear protection. Benennung/Descr gtionDenom nation 07.93 Safety Informations Before working on the hydraulic circuit, move all joysticks and pedals with the ignition key in contact position to relieve the servo pressure and the remaining pressures in the different main circuits. In addition, relieve the pressure in the hydraulic tank as described in the Operation and Maintenance Manual Typ Médet Tee Page 1.10.01 Secure all loose parts on the excavator Never operate the excavator without a complete walk around inspection. Check if all warning decals are on the machine and if they are all legible Observe all danger and safety guidelines For certain special applications, the excavator must be equipped with specific safety equipment. Use the excavator only, if they are installed and functioning properly Never perform any changes, additions or modifications on the machine, which could influence the safety, without obtaining the permission from the manufacturer. This also applies to the installation and adjustment of safely devices and safety valves as well as to any welding on load carrying parts. Do not install any equipment or attachments made by other manufacturers or any which are not specifically authorized by LIEBHERR for installation without first obtaining the written permission from LIEBHERR LIEBHERR will issue any required technical documentation for approved installations CRUSHING AND BURN PREVENTION Never work underneath the excavator unless it is safely resting on the ground and / or is properly biocked and supported Never use damaged or insufficient wire ropes, slings or chains. Always wear gloves when handling wire ropes Never reach into bores during attachment installation or removal. Never align bores with your fingers or hands. Use proper alignment tools when installing, changing or servicing attachments Keep objects away from the radiator fan Rotating fans will swirl and throw out objects, which can become very dangerous and cause severe injury to yourself and others. Avoid contact with any components contai: ning coolant. At or near operating tempe. rature, the engine coolant is hot and under pressure and could cause severe burns. Check the coolant level only after the radiator cap is cool enough to touch. Remove the radiator cap slowly to relieve pressure Do net allow your skin to come into contact with hot oil or components containing hot oil At or near operating temperature, engine and hydraulic oil is hot and can be under pressure Always wear safety glasses and protective gloves when handling batteries. Keep sparks or open flames away! Never permit anyone to hand guide the bucket or grapple into position When working in the engine area, make sure the top covers and side doors are properly secured or closed with the appropriate supports. Never work underneath or on the excavator unless itis properly blocked and supported. FIRE AND EXPLOSION PREVENTION Always turn off the engine while refueling the excavator, Never smoke or allow an open flame in relueling areas or where batteries are being charged, or where batteries or flammable materials are stored Always start the engine as described in the ‘Operation and Maintenance Manual. Check the electrical system regularly and frequently. All defects, such as loose connections, burnt oul fuses and bulbs, burnt or damaged cables must be repaired immediately by an electrician or especially trained personnel Never store flammable fluids on the machine except in storage tanks intended for the excavator’ operation, Inspect all components, lines, tubes and hoses for oil and fuel leaks and / or damage. Replace or repair any damaged components immediately Any oil, which escapes from leaks, can easily cause a fire. Be certain that all clamps, guards and heat shields are installed. These components prevent vibration, rubbing, chafing and heat build-up. Install tie wraps to fasten hoses and wires, as required Cold start ether is extremely flammable. Use ether only in ventilated areas and as directed. Never use it near heat sources or open flames, do not permit anybody to smoke. Know the location of the excavator's fire extinguisher and be familiar with its opera- tion. Make sure you know your local fire regulations and fire reporting procedures 1.10.01 MACHINE START UP SAFETY Before excavator start up, perform a thorough walk around inspection Visually inspect the excavator, look for loose bolts, cracks, wear, any leaks and any evidence of vandalism, Never start or operate an unsafe excavator. Report all defects to your foreman or supervisor and make sure they are corrected immediately Make sure alt covers and doors are closed and ocked and all warning decals are on the machine Make sure all windows, as well as inside and outside mirrors are clean, and secure all doors and windows to prevent any unintentional movement Be certain that the area surrounding the excavator is free of other personnel, and that no ‘one is working on or under the excavator before starting the engine. Aller entering the cab, adjust the operator's seat and controls, the inside and outside mirror, the armrests and fasten and adjust the seat belt Be certain that all controls can be reached comfortably All noise protection devices on the machine must be functional during operation, ENGINE START UP AND OPERATING SAFETY atu LIEBHERR Before start up, check if all indicator lights and instruments are functioning properly, place al controls in neutral position and tlt the safety lever up, Before starting the engine, alert any nearby personnel that the excavator is being started by sounding the horn. Start the machine only when seated in the ‘operator's seat, and with the seat belt fastened {if nstalled) If you have no other instructions, start the engine as outlined in the Operation and Mainte- nance Manual Henennung Descrpton/Denamination n 07.93 Safety Informations Tilt the safety lever down and check alll indi cators, gauges, warning devices and controls for their proper indication Start and operate the engine only in a well ventilated area. If necessary, open doors and windows Warm up the engine and hydraulic system to operating temperatures. Low engine and hydraulic oil temperatures can cause the exca- vator to be unresponsive. Check that all attachment functions are operating properly. Move the excavator slowly into an open area and check ail travel functions for their proper ‘operation, check travel and swing brakes, the steering function as well as the turn signals and ights MACHINE OPERATING SAFETY Familiarize yourself with job site rules. Be infor med about traffic and hand signals and safety signs. Ask who is responsible for signaling. Check your surrounding for any obstacles in the working and movement range, check the load carrying capacity of the terrain, and secure the job site Lo shield it from any public highway traffic Always keep a sale distance from overhangs, walls, drop offs, and unstable ground. Be alert of changing weather conditions, bad or insufficient visibility and of changing ground conditions Be alert for utility lines, check the location of underground cables, gas and water lines, and work especially careful in that vicinity. If necessary andi or if required, call local autho- rities to mark the location. Keep sufficient distance to electrical lines. When working in the vicinity of high voltage electrical lines, keep proper distance to assure that the attachment does not come close to the lines DANGER! You must inform yourself about safe distances, act Type ah From Deus are Feat 1.10.02 In case you do touch a high voltage line by accident, proceed as follows: do not leave the machine, = move the machine, if possible, from the danger zone until you obtain sufficient distance, - warn any personnel in the vicinity not to come close to the excavator and not to touchit, ~ instruct or initiate that someone turns off the voltage 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, make sure that the attachments and equipment is secured properly to avoid accidents. When traveling on public roads or highways, make sure to observe trallic regulations, and make sure that the machine meets federal ang local public highway standards, Always turn on the lights if visibility is bad or if you are still working during dusk Never allow other personnel on the excavator Operate the excavator only while seated and with the seat bell fastened, if installed, Report any problems or needed repairs to your foreman or supervisor and make sure they are corrected immediately, Do not move the excavator until you are certain that no one is endangered by moving the excavator On machines without negative brakes check the brake system before starting to work, as outlined in the Operation and Maintenance Manual. Never leave the operator's seat while the machine is still moving Never leave the machine unattended, with the engine running, When moving the excavator, keep the upper- carriage in lengthwise direction and keep the load as close as possible to the ground Prevent any working movements, which could tip the machine over If the excavator begins to tip or slip on a grade, immediately lower the attachment and load to the ground and turn the excavator facing downhill Hf possible, always operate the excavator with the attachment positioned uphill or downhill, never sideways Always travel slowly on rough or slippery ground and on slopes Always travel downhill at permissible speed, so you don't loose control over the machine. The engine must run at nominal speed, use only the foot pedals to brake and slow down the machine Never shift during down hill travel, always shift toa lower gear before traveling downhill Never load over an occupied truck. Request that the driver leave the cab, even if a rock protection is installed, For demolition work, clearing, crane operation, etc. always use the appropriate protection device designed for this specific application If operating in visually obstructed terrain or whenever necessary, have another person guide you. Always have only one person signal you. Allow only experienced persons to attach loads or to guide operators. The guide must be visible by the operator and / or must be in voice contact with him, Depending on the attachment combination, it is possible for the bucket teeth to hit the cab, the cab protection or the boom cylinders. Be very careful when the bucket teeth get in this range to prevent any damage MACHINE PARKING SAFETY Park the excavator only on firm and level ground Ifit becomes necessary Lo park the machine on. 2 grade, properly block and secure it with wedges. Lock the uppercarriage with the lock pin. Lower the attachments to the ground and anchor the bucket lightly in the ground. Bring all operating levers in neutral position and engage the travel and swing brakes. Turn the engine off as outlined in the Operation and Maintenance Manual and raise the safety lever before you leave the operator's seat. Lock the machine, remove all keys and secure the excavator against vandalism and unautho- rized use. 1.10.02 MACHINE TRANSPORTING SAFETY LIEBHERR Datum ation Use only suitable transporting and lifting devices with sufficient capacity Park the machine on firm and level ground and block the chains or wheels If necessary, remove part of the attachments during transport When loading the machine on a flatbed trailer or railroad car, be sure that the loading ramp incline is less than 30” and covered with wooden planks to prevent skidding, Remove all mud, snow or ice from track components before moving up the ramp. Before loading, secure the uppercarriage with the undercarriage with the lock pin Align the machine with the fading ramp. Attach the manual contro! levers to the foot pedals for sensitive control Have another person guide and signal the operator. Have blocks or wedges ready to block the machine, if necessary, to prevent the machine from rolling backwards. Retract the attachment as far 2s possible and lower the attachment as close as possible to the loading surface and carefully drive up the ramp. and onto the flat bed trailer When the excavator is on the trailer, release the uppercarriage lock pin, turn the uppercarriage back and lower the attachment. If the backhoe attachment is attached, tilt the stick and bucket in and relock the upper- carriage Carefully secure the uppercarriage and other parts with chains, wedges and blocks to prevent slipping Release the hydraulic pressure, remove the ignition key, raise the safety lever, close and lock the cab and close and secure all other doors and leave the machine Carefully check out the transport route. Make sure that width, height and weight allowances are within the permitted limits sencrnungibescrition Denomination 07.93 Check that there is enough clearance under: neath ail bridges, underpasses, utility lines, and in tunnels. During the unloading procedure, proceed with the same care and caution as during the loading procedure Remove all chains and wedges. Start the engine as outlined in the Operation and Maintenance Manual. Carefully drive off the loading platform Keep the attachment as close a8 possible to the ground level. Have another person guide and signal you. MACHINE TOWING SAFETY Safety Informations Observe the correct procedure: check the index in your Operation and Maintenance manual and refer to the appropriate section : “Towing the Excavator" Only tow the excavator if absolutely necessary, for example to remove it for repairs from a dangerous job site Be sure all towing and pulling devices such as cables, hooks, and couplers are safe and adequate Make sure that the cable or the towing rod are strong enough and are routed around the center of the undercarriage or to the towing hook on the undercarriage, which is designated for this purpose. Be aware that any damage to the machine caused by towing is never covered by the manufacturer's warranty Never allow anyone to stand near the cable when pulling or towing the excavator. Keep the cable tight and free of kinks. Engage travel slowly, and do not jerk. With a slack cable, the sudden impact of the load being towed could snap and break During the towing procedure, keep within the required transport position, permissible speed and distance After the towing procedure is completed, return the machine to its previous state Proceed as outlined in the Operation and Maintenance Manual when putting the excavator back inservice ab beau Tat Peg Fete 1.10.03 MACHINE MAINTENANCE SAFETY The machine may not be made unsafe when, performing maintenance work. Never attempt maintenance procedures or repairs you do not understand Check the Operator's and Maintenance Manual for service and maintenance intervals, Make sure you use only appropriate tools for all maintenance work Refer to your Operator's and Maintenance Manual to see, who 's authorized to perform certain repairs. The operator should only perform the daily / weekly maintenance procedures The remaining work may only be performed by especially trained personnel Use only replacement parts corresponding to the technical requirements specified by the manufacturer. This is assured by using only original Liebherr replacement parts. Always wear proper work clothing when maintaining the excavator. Certain work may only be performed with a hard hat, safety shoes, safety glasses and gloves. During maintenance, do not allow unautho- rized personnel to enter the maintenance Secure the maintenance area, as necessary. Inform the operator before any special or maintenance work. Make sure he knows the person, who is in charge of the work. If not otherwise noted in the Operation and Maintenance Manual, always make sure the excavator is parked on firm an level ground and the engine is turned off During maintenance and service work, make sure you always retighten any loosened screw connections! If iL 1s necessary to disconnect or remove any safety devices during set up, maintenance or repair, make sure that after completion of repairs, the safety devices are reinstalled and checked for proper function Before any maintenance work and especially when working under the machine, make sure a “Do not operate’ tag is attached to the starter switch. Remove the ignition key Before any repairs or maintenance work, clean any oil, fuel and / or cleaning substances from any fittings and connections Don't use any harsh cleaners and use only lint free cloths. Use only nonflammabie cleaning fluids to clean the machine Any welding, torch or grinding work on the machine must be explicitly authorized. Before any using a welder, torch or grinder, clean off any dust and dirt and remove any flammable materials from the surrounding area. Make sure the areas sufficiently ventilated Danger of Fire and Explosion! Before cleaning the machine with water or steam (high pressure cleaning) or other cleaning fluids, make sure that all openings, which , for safety and/ or functioning reasons should not be exposed to water / steam/ cleaners, are covered and / or masked off Especially sensitive are electrical motors, control boxes and plug connectors. Make sure that the temperature sensors of the fire alarm and extinguishers system do not come in contact with the hot cleaning fluids, which could trigger the fire extinguishing system. Remove all coverings and masking material after completing the cleaning procedure. Then check all fuel lines, engine oil lines and hydraulic oil lines for leaks, loose connections, chafing and / or damage. Fix any problems immediately. Never employ aggressive cleaning agent or high pressure cleaning apparatus (water or steam) during the two first months following machine delivery or repainting Observe all product safety guidelines when handling oils, grease, and other chemical substances Make sure service fluids and replacement parts are disposed of properly and in an environ: mentally sound manner When using hot service fluids, be very careful (They can cause severe burns and injury!) Operate combustion motors and {uel operated heaters only in well ventilated areas. Before operating these unils, check ventilation. n addition, always follow applicable local regulations. Never try to lift heavy parts. Use appropriate lifting devices with sufficient load carrying capacity. When replacing or repairing parts or components,make sure they are mounted very carefully on lifting devices, to prevent any possible danger. Use only suitable and technically sound tifting devices, make sure that lifting tackle, wire cables, etc. has adequate load carrying capacity Never position yourself, walk or work underneath suspended loads. Never use damaged lifting devices, or devices which are not sufficient to carry the load Always wear gloves when handling wire cables 1.10.03 LIEBHERR eit Ask only experienced personnel to attach loads and guide and s.gnal the crane operator. The guide must be within the visibility range of the ‘operator and / or must be in direct voice contact with the operator. When working overhead, use appropriate and safe ladders, scaffo'ding or other working plat- forms designated for that purpose. Never step on parts or components on the machine when maintaining or repairing items overhead When working high above ground, make sure you are fitted with ropes and appropriate safety devices which will prevent a possible fail Always keep handles, steps, railings, platforms and ladders free of dirt, snow and ice! When working on the attachments, for example when replacing the bucket teeth, makes sure the attachment is supported properly Never use metal on metal support! Never work underneath the machine if it is raised or propped up with the attachment. The undercarriage must be supported with wooden blocks and supports. Always support the raised machine in such a way that any shifting to the weight change will not influence the stability. Do not support the machine with metal on metal support, Only qualified, especially trained personnel may work on travel gear, brake and steering systems. IF it becomes necessary that the machine must be repaired on a grade, block the chains with wedges and secure the uppercarriage to the undercarriage with the lock pin. Only qualified, especially trained personnel may work on the hydraulic system. Never check for leaks with your bare hands, always wear gloves. Fluid escaping from a small hole can have enough force to penetrate the skin. Never loosen or remove lines or fittings before the attachment has been lowered to the ground and the engine has been tured off, Then turn the ignition key to contact position, move all servo controls (joysticks and foot pedals) in both direction to release pressures. Then release the tank pressure as outlined in this Operation and Maintenance Manual Check all lines, hoses and screw connections regularly for leaks and externally visible damage. Fix any damage immediately BenennungyDescription/Deneminatior n 07.93 Safety Informations Oil sescaping from fittings etc. can cause serious Injury and fires, Before any repairs, always relieve pressures before opening up any system sections and pressure lines (hydraulic lines and air pressure lines) Always route and install hydraulic and air pressure lines properly. Do not interchange the connections, The length and quality of hoses must match specifications and requirements Change all hydraulic hoses in specified or appropriate time intervals, even though no damage or detects are visible Always disconnect the battery cable before working on the electrical system or before any arc welding on the machine. Always disconnect the negative (-) cable first and reconnect it last Check the electrical system regularly. Make sure that any problems, such as loose connections, burnt out fuses and bulbs, scorched or chafed cables are fixed immediately by an electrician or qualified personnel Use only Original fuses with the specified amperage. Never use a different size or stronger fuse than the original fuse. (On machines with electrical medium or high woitage systems: If there is any problem with the electrical energy supply, turn the machine off immediately. ~ Any work on the electrical system may only be performed by a qualified electrician or qualified personnel under the guidance and supervision of an electrician, according to electro - technical regulations If any work 1s required on any parts which carry current, use a second person to turn off the main battery switch, if necessary. Rope the work area off with a red and white safety rope or chain, and set up warning signs. Use only insulated tools. When working on medium and high voltage components, shut off the voltage and connect the supply cable to the ground and ground the components, such as the condensor, with a grounding rod Check all disconnected parts if they are truly free of current, ground them and close them olf quickly. Insulate any close-by, current carrying parts. Pressure Length Volume Torque Weigth Temperature: bar inches feet liter liter liter gallons cm m3 Kpm ‘im felbs flbs kg metrt metr.t Ibs Ibs Conversion factors x 145 = x 03937 - x 3937 = x 3937 = x 25.40 = x 3048 = x 2642 = x 2413 = x 1.057 = x 3.785 = x 06102 = x 13079 = x 723 = x 7375 = x 138 = x 1.358 = x 2.2046 = x 1102 = x 2208.6 = x 4536 = x o00asa . Degree C x 1.8 plus 32 = Degree Fahrenheit, Degree O degree Celsius = 32 degree Fahrenheit F minus 32 devided by 18 = Degree Celsius, Pst inches inches inches gallons pints quarts liter cubicinen cubic yard flbs fulbs Kom Nm. Ibs Shortt bs ka Metzic ton 100 degree Celsius = 212 degree F LIEBHERR DatumieaionDave 10.90 Senennung/Descvaton/Dénom ination Conversion factors lye. Type Abitromia parti ce BiatwrageFeulle 1.20.00 Torque values for nuts and bolts with standard (coarse) metric thread or fine metric thread This chart provides the standard torque values for nuts and bolts, This torque chart should be used unless a specific torque is givenin the manual The torque values and conversions are approximate (rounded up or down) and apply to nuts and bolts without additional treatment (not lubricated) NOTE: The torque value for treated (cadmium plated) or lubricated nuts and bolts is (approx) 20% less of the values shown in the charts (1 Nm x 0.7375 = ftibs) EXEMPLE : The torque shown in the chart is 50 Nm (37 ft-lbs) 50 Nm (37 Fibs) less 20% = 40 Nm (30 ft Ibs) Stondord metre thread Fine metre thread | Tightening | Tightening Tightening | Tightening ottsize | Grade | force | torque | Boitsize | Grade | ore | torque fain | Maint Fain | Mginnm 3500 ad ma iO a ér00 S e400 ei ms | S300 bs i | 10300 a 9000 vos m6 13300 88 - 13100 17,0 | m7 13300 #9 23a00 330 ~ “76500 25,0 88 18100 27 wa 220, 370 | ext 133 | deseo) a des00 | aso 13 | 300 ° 1 as) 23600 0 i M91 183 | 33600, 38 | of 8 ae | 26000 a a8 30500 7 wo 163 | 38800, 70 | toxt 3 aa a Bs | doo aro 33 $3500 36 +—~s5 | 28500 sa | M10 x 1,25 109 41500 | 79 133 | tee00 3 aa) 38500 a0 as | «3000 96 m2 163 | e600 || 180 Przxtas] 183 | Baooo 8 | 133 | eeo00 | t00 13 | Sano0 tes 88 40500 | 92 maxis | 188 e000 33 3 #009 133 88 ~ "53000 140,0 88 58000 150 wa 163 | 73000 | 2080 Panaxaas| 139 | Beano 20 133 | $3000 | 3860 33 | 180000 38 LIEBHERR we ‘Sub group index’ DaunFanonba Tightening torques 1.20.01 Standard metic thread Fine metic thread ; ; | Tightening | Tightening Tightening | Tightening Bottsize | Grade | force | “torque | Gottsize | Grade | tore | “torque faints | Bgl dim aint | Maint 33] 72000 | ris 3317000 | 230 me | 108 | 106000 | 3100 Jmmexts | 108 | sieo00 | Bao 123 | {24000 | 3700 123 | {38000 | 390 ea | 91000 | 300 ee | 106000 | 30 mia | 103 | 123000 | «430, | mmexas | 109 | ts2000 | ao 123 | Stoo. | sia 123 | 77000 | Seo 88 17000 430 88 134000 480 mao | 103 | t0000 | Gan | waoxts | 103 | 1000 | bao 123 | tsio00 | 50 123 | daanoo | 800 as 146000 | seo ea | 166000 | a0 22 198 | oso. | 30 | maaxts | 108 | d5e000 | 40 123 | aso | 870 123 | 275000 | so70 ea | vea000 | 740 es | 200000 | 830 mea | 103 | 233000 | sae | aweaxas | 183 | 3as000 128 20000 | 1240 | 129 333000 ~ 88 189000 maax2 | 103 | dy0000 123 | 313000 38 | 221000 | 1700 ae | 2se000 | mer | 138 | aiso0n | 1350 | warns | 103 | Sevo00 133 | 310000 | 1850, 123 | 230000 T 88 245000 M27x2 10.9 350000 123 | cdo —) 8 | 270000 | 3500 ea | 323000 mao | 103 | 3asooo | 2100, | mwoxas | 105 | abco00 123 | #0000 | 2500 23 | $3800 T &3 | 309000 maox2 | 103. | dapoo0 | 125 | S15000 88 335000 2000 \ 88 396000 133 168 | ago | 3800 J maaxas | 163. | Ses000 | 129 560000 3400 12.9 659000 a2 | 309000 waax2 | 103 | aaoo00 | 123 | S1S000 - 88 395000 2600 8B 475000 mas | 103 | e000 | 5700 | awexts | 108 | 677000 123_| eso000 | 4300 123 | 32000 es | «25000 | | wsexa | 108. | braa00 } 12.9 710000 | 88 475000 | 3400 BB 562000, mao | 103 | e700 favo, | magxns | 108 | soroco | 125 | 790000 | Se00 [tes | 837000 a2 | 510000 w3axa | 103. | jzo0e0 123 | 0000 Tightening torques for straight male stud coupling -LB=standard version SB = heavy duty version Straight male couplings = GE (R = inch, M™= metric) Connections with conical and Connections with cylindrical sealing edge eolastic seal ring | Tightening torque Tightening torque type | tendsice FE | oe | tmcadsice | NY Mork MorR LB _ Ge6-im | Mtoxi 2 20 [Gee tied | Mi0xt at 70 GE6-LR R18" 2 20 | GE6-LR-ed R18" cal 10 “eim |wrxis 3 29_| Gee Med |Mi2xi5 | ca? 20 GEB-IR Ria ca 4 29 [Geeited [Rie 2 | 20 GEid-uM | Mtaxts | aa 39 [GE0-iMed| miaxts | cad 29 GE10-LR R14 - a4 39 | GE10-tRed | R 1/4 ca.2 20 GE12-LM Vv [ae 59 | GE 12 iM-ed| 16x15 a3 29 GE12-LR R38" ca. 6 $9 | GE12 LR-ed | R 3/8" ca 4 39 GE15-IM | Mi18x1,5 a7 69 | GE 15-LM-ed | M 18x 1,5 ca.4 i “Geis-ia PRI eT 708 | GE1S-iR-ed [RUZ ae GE1S-IM | M22x15 | ca. “i108 GE1E Lw-ed [M22x13 | ca6 GE 18-LR R12" att 108 | GE 18-LR-ed | R 1/2" ca. 6 GE 22-LM M16x1,5 als | 128] GE 22-LM-ed | M 26x 1,5 a7 GE2-IR [Ra a6 157[ GE 27-tR-ed [RA <9 GE2-IM | M33x2 2 216 | GE%e UNved | 26x15 | ca 12 GE 28-1LR RI a. 27 265 | GE26-LR-ed | RI Ta 14 “GE35- IM xd [ea 36 353, | Ge35-Uvved| Ma?x1,5 | ca 20 Ge35-1R | RIWA

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