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Operator's Manual R9200 - 410

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Operator's Manual R9200 - 410

Zevallos Romulo (LPE) ([email protected])

2023-02-03

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Copyright © Liebherr-Mining Equipment SAS
 Printed by: Zevallos Romulo (LPE) ([email protected])
Operator's Manual R9200 - 410

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Operator's Manual R9200 - 410

1. Preface
2. Product description
2.1. Assembly - overview
2.1.1. Machine and construction equipment
2.1.2. Uppercarriage
2.1.3. Undercarriage
2.2. Vibration emission
2.3. EC Declaration of Conformity
2.4. Technical data
2.4.1. Working technical data
2.4.2. Technical description
3. Safety instructions
3.1. Meaning of the symbols in this manual
3.2. Use in accordance with the regulations
3.3. Safety Instructions
3.4. Servicing the machine safely
3.5. Signs on the machine
3.5.1. Introduction
3.5.2. Arrangement and explanations of signs

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4. Control and operation

4.1. Operating and control elements
4.1.1. Overview of the control cab
4.1.2. Arrangement of joysticks
4.1.3. Keyboard
4.1.4. Cab control board
4.1.5. Monitoring display
4.1.6. Menus and functions of the display
4.2. The access and the outfit of the cab
4.2.1. Enter or leave the cab
4.2.2. Safety lever
4.2.3. Operator’s seat
4.2.4. Auxiliary seat
4.2.5. Sunshade
4.2.6. Emergency exit
4.2.7. Internal lighting
4.2.8. Fire extinguisher
4.2.9. Windscreen
4.2.10. Field of view
4.2.11. Lighting
4.2.12. Heating and air-conditioning system
4.3. Setting the machine into operation
4.3.1. Start and stop the machine
4.3.2. Starting aids: preheating of the Diesel engine coolant with the 30 kW heater
(optional equipment)
4.3.3. Starting aids: preheating of the Diesel engine coolant with the 35 kW heater
(optional equipment)
4.3.4. Starting aids: auxiliary preheating procedures (optional equipment)
4.3.5. Warm-up procedure for Diesel engine and hydraulic circuit
4.3.6. Jump start procedure
4.3.7. Emergency and safety operations
4.3.8. Travel movements
4.4. Working with the machine
4.4.1. Uppercarriage swing movements
4.4.2. Working position
4.4.3. Joystick functions when setting up the machine
4.5. General working methods
4.5.1. Minimum impact working methods for your machine
4.5.2. Preparatory activities
4.5.3. Positioning of the machine
4.5.4. Working with the backhoe bucket
4.5.5. Working with the Shovel bucket
4.6. Transport
4.6.1. Travelling procedures for mining machine
4.6.2. Excavator lifting and lashing operations

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5. Malfunctions
5.1. Error code charts
5.1.1. Heating and air-conditioning system
5.2. Faults and remedies
5.2.1. Diesel engine and fuel system
5.2.2. Hydraulic system
5.2.3. Transmission
5.2.4. Electrical system
5.2.5. Heating/air-conditioning system
5.2.6. Work equipment
5.3. Fuses and relays
5.3.1. Power electrical box E1003
5.3.2. Cab connection box E1005

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6. Maintenance

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6.1. Servicing the machine safely

6.2. Access points for the maintenance
6.2.1. Access points overview
6.3. Maintenance anchor points
6.3.1. Approved anchor points
6.3.2. Use the anchor points
6.4. Lubricants and operating fluids
6.4.1. General information on changing lubricants and operating fluids
6.4.2. Lubrication chart
6.4.3. Lubricant chart
6.4.4. Operating material chart
6.4.5. Service trap
6.5. Lubricating and operating material specifica­tions
6.5.1. Lubricating oil for the Diesel engine
6.5.2. Fuel
6.5.3. Coolant
6.5.4. Hydraulic oil
6.5.5. Swing gear oils
6.5.6. Travel gear oils
6.5.7. Splitterbox oil
6.5.8. Lubricating grease
6.5.9. Other lubricants
6.6. Condition monitoring with oil analysis
6.6.1. General information
6.6.2. Oil sampling
6.6.3. Sample processing
6.7. Diesel engine
6.7.1. Check the engine oil level
6.7.2. Change the engine oil
6.7.3. Replace the oil filter elements
6.7.4. Mounting screws
6.7.5. Elastic bedding
6.7.6. Belts
6.8. Splitterbox
6.8.1. Splitterbox mounting screws
6.8.2. Elastic bedding
6.8.3. Breather filter
6.9. Coupling
6.9.1. Check the coupling rubber rollers
6.10. Cooling system
6.10.1. Check and clean the cooling system
6.10.2. Check the coolant level
6.10.3. Coolant antifreeze and anti-corrosion fluid
6.10.4. Change the coolant
6.10.5. Replace the coolant filters

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6.11. Fuel system

6.11.1. Refuel
6.11.2. Drain the fuel tank
6.11.3. Clean the fuel tank
6.11.4. Fuel filtering system
6.11.5. Replace the dust filter for the vent valve
6.12. Dry air filter
6.12.1. Replace the primary filter element
6.12.2. Replace the safety element
6.12.3. Clean the precleaner
6.12.4. Clean the housing of the air filter elements
6.12.5. Check the air intake system, hoses, elbow tubes, clamps
6.13. Hydraulic system
6.13.1. Preparatory activities
6.13.2. Check the oil level in the hydraulic tank
6.13.3. Release the pressure from the hydraulic system
6.13.4. Drain and fill the hydraulic tank
6.13.5. Hydraulic oil coolers
6.13.6. Leak oil filter and return filter
6.13.7. Servo oil and replenishing filters
6.13.8. High pressure filters in working circuit
6.13.9. Servo oil circuit
6.13.10. Remove the pumps intake hoses
6.13.11. Bleed the hydraulic pumps
6.13.12. Bleed the hydraulic cylinders
6.13.13. Bleed the valve blocks
6.13.14. Oil cooler protection filters (optional)
6.13.15. Servicing the hydraulic cylinder
6.13.16. Replacement of the hydraulic hoses
6.13.17. Progressive criss-cross tightening procedure
6.14. Oil changes on components
6.14.1. General information
6.14.2. Swing gear – Oil change
6.14.3. Travel gear and Lifetime travel gear (optional) – Oil change
6.14.4. Swing gears and travel gears flushing
6.14.5. Splitterbox – Oil change
6.15. Track components
6.15.1. Check the track components mounting
6.15.2. Check the track tension
6.15.3. Increase the track tension
6.15.4. Decrease the track tension
6.15.5. Clean the travel gear

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6.16. Electrical system

6.16.1. Notes on the electrical system
6.16.2. Batteries switches and ECM connectors
6.16.3. Battery care
6.16.4. Electrical components location
6.16.5. Cab pressurization
6.17. Heating and air-conditioning system
6.17.1. Possible configurations
6.17.2. Heating system
6.17.3. Air-conditioning system
6.17.4. Additional maintenance work
6.17.5. Additional cab heater (optional equipment)
6.18. Greasing the machine
6.18.1. Lubrication of attachment bearing points
6.18.2. Lubricate the service trap
6.19. Check mounting bolts for tightness
6.19.1. Counterweight mounting bolts
6.19.2. Mounting bolts of the swing ring
6.19.3. Mounting bolts of the fuel tank
6.19.4. Mounting bolts of the hydraulic tank
6.19.5. Mounting bolts of the engine cooler box
6.19.6. Mounting bolts of the oil cooler box
6.19.7. Mounting bolts of the pumps box
6.19.8. Mounting bolts of swing gear and swing motor
6.19.9. Mounting bolts of the cab elevation
6.19.10. Mounting bolts of the cab
6.19.11. Mounting bolts of the service trap
6.19.12. Mounting bolts of hydraulic pumps
6.19.13. Mounting bolts of side frames
6.20. Drive unit brakes and swing gear brakes
6.21. Starting aids (optional equipment)
6.21.1. Fuel system of the coolant heater
6.21.2. Coolant circuit of the starting aids
6.22. General maintenance points
6.22.1. Replacing working parts
6.22.2. Welding work on the machine
6.23. Control and maintenance chart
6.23.1. General information
6.23.2. How to use the maintenance chart
6.23.3. Daily Maintenance Schedule - R9200
6.23.4. 250 Hours Maintenance Schedule - R9200
6.23.5. 500 Hours Maintenance Schedule - R9200
6.23.6. 1000 Hours Maintenance Schedule - R9200
6.23.7. 2000 Hours Maintenance Schedule - R9200

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7. Appendix
7.1. Fluids and lubricants specification
7.2. Visual check of the hydraulic hoses
7.2.1. Preface
7.2.2. General information
7.2.3. Components functions
7.2.4. Recommendations for hose assembly maintenance
7.3. Cleaning procedure for hydraulic circuits
7.3.1. Preface
7.3.2. General information about hydraulic oil contamination
7.3.3. General cleaning procedure
7.3.4. Working pumps circuit
7.3.5. Swing circuit
7.3.6. Cooling pumps circuit
7.3.7. Travel motors circuit
7.3.8. Backhoe cylinders lines
7.3.9. Shovel cylinders lines
7.3.10. Clean the hydraulic tank
7.3.11. Restart the machine
7.3.12. Monitor the restarted machine
7.4. Centralized lubrication system

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1 | Preface
These operating instructions have been written for the machine operator and for the maintenance personnel of the machine.

They contain:

• The technical data.

• The safety requirements.

• The operating instructions.

• The maintenance instructions.

The operating instructions are to be read and used carefully by all persons who carry out work with or on the machine before
putting the machine into ser­vice for the first time and later, at regular intervals.

Work with or on the machine includes, for example:

• Operation including setting up and equipping, rectifying malfunctions during the course of work, resolving production dropouts, care,
disposal of operating and process materials.

• Maintenance, including maintenance, inspection and repair work.

• Transportation or loading the machine.

The operating instructions allow the machine operator to familiarize himself with the machine more easily and prevent malfunctions
occurring due to improper operation.

The observance of the operating and maintenance instructions by maintenance per­sonnel:

• Increases reliability in use.

• Extends the service life of your machine.

• Reduces repair costs and downtime.

The operating instructions belong with the machine for the entire lifetime of the machine. Place a copy in an easily reached position on
the cab storage shelf. This copy must be replaced immediately if lost, damaged or unreadable.

The operating and maintenance instructions must be completed by information on current national regulations for accident prevention
and protection. In addition to the operating instructions and legally binding regulations on accident prevention which apply in the user
country and at point of use, authorized specialist rules for safe and correct working procedures are also to be observed.

These operating and maintenance instructions contain all the information required for operating and maintaining your machine.

• Some illustrations in these operating instructions may depict details and working devices which differ to your machine.

• In some illustrations, protective devices and covers have been removed in the in­terests of better presentation.

• Improvements, which are always being incorporated into our machines, may result in changes to your machine which are not yet
indicated in these operating in­structions.

However, should you require any further explanations or information, LIEBHERR's technical documentation, sales school and customer
service departments are avail­able for your convenience.

You will appreciate that Liebherr warranty claims made on the basis of improper operation, unsatisfactory maintenance, use of
unauthorized operating materials or non-adherence to safety regulations cannot be recognized.

Liebherr will annul any and all obligations incurred by Liebherr and / or its dealerships, such as guarantee commitments, service
contracts etc. without prior notice in the event that replacement parts other than original Liebherr parts or parts purchased from Liebherr
are used for maintenance or repair work.

Modifications, conditions, copyright

We reserve the right to make modifications without prior notice in the course of tech­nical developments.

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The information and illustrations contained in these operating instructions may neither be copied and distributed, nor used for the
purposes of competition. All rights are expressly reserved in accordance with copyright laws.

The warranty and liability conditions of Liebherr general business conditions will not be enlarged upon through the above information.

From: Operator's manual R 9200 - 410

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2 | Product description

From: Operator's manual R 9200 - 410

2.1 | Assembly - overview

This section comprises an overview of the machine and descriptions of the compo­nents shown.

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From: Operator's manual R 9200 - 410 > Product description

2.1.1 | Machine and construction equipment

Figure 1. Machine and construction equipment - backhoe attachment

100 Uppercarriage 320 Stick cylinder

200 Undercarriage 330 Stick
300 Boom cylinder 340 Bucket tilt cylinder
310 Boom 350 Backhoe bucket

Figure 2. Machine and construction equipment - shovel attachment

100 Uppercarriage 320 Crowd cylinder

200 Undercarriage 330 Crowd
300 Boom cylinder 340 Shovel tilt cylinder
310 Boom 350 Shovel bucket

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From: Operator's manual R 9200 - 410 > Product description > Assembly - overview

2.1.2 | Uppercarriage

Figure 1. Uppercarriage

20 Swing gear installation 80 Covering

25 Swing ring installation 85 Lower covering
40 Service trap 90 Cab
50 Engine installation 95 Catwalk and handrail
60 Hydraulic tank installation 110 Fuel tank
65 Oil cooler installation 115 Counterweight installation
70 Control valve installation 120 Access ladder
75 Rotating deck 125 Emergency ladder
77 Cab elevation

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From: Operator's manual R 9200 - 410 > Product description > Assembly - overview

2.1.3 | Undercarriage

Figure 1. Undercarriage

208 Idler wheel 1000 Rotary connection

400 Track chain 4500 Travel gear with sprocket wheel
From: Operator's manual R 9200 - 410 > Product description > Assembly - overview

2.2 | Vibration emission

Designation Unit Value Measurement uncertainty

Hand-arm vibrations m/s² ≤ 2,5 The measurement
Whole-body vibrations m/s² ≤ 0,5 uncertainty is defined in
standard EN 12096:1997

Vibration emissions

Operator’s seat
• The operator’s seat built into the machine by the manufacturer conforms to ISO 7096:2000, EM 6.

Hand-arm vibrations
• If the machine is operated as intended, the weighted (frequency-weighted) effective value of the hand-arm vibrations in accordance
with ISO 5349-1:2001 is less than 2.5 m/s².

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Whole-body vibrations
• The value conforms to the specifications of the technical report ISO/TR 25398:2006.

• As the specified values are individual effective values for specific typical application areas, only a limited assessment of the load
imposed on the operator by whole-body vibrations is possible.

• In order to accurately assess the daily exposure of an operator over an 8-hour shift, use the Liebherr brochure concerning whole-body
vibrations as well as the software developed especially for this purpose.

• Both these resources are available from the Liebherr dealers and are included on the documentation CD (Liebherr-Parts) delivered
with every new machine.

From: Operator's manual R 9200 - 410 > Product description

2.3 | EC Declaration of Conformity

Figure 1. Sample EC Declaration of Conformity

From: Operator's manual R 9200 - 410 > Product description

2.4 | Technical data

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From: Operator's manual R 9200 - 410 > Product description

2.4.1 | Working technical data

Table 1. Working technical data

Backhoe Shovel

Permitted working angle (12,5 m3)* 5° - 9% 5,5° -

10%
Permitted travelling angle 25° - 46% 25° -
46%
Working ambient temperature range -12°C to +55°C -12°C to
Arctic packages in +55°C
option*** Arctic
packages
in
option***
Noise emission**: 71 dB(A) 71 dB(A)
1,13 dB(A) 1,13
• LpA (inside cab)
dB(A)
• Measurement uncertainty

* The permitted working angle has been determined for a hydraulic excavator in standard configuration (with bucket volume as given in
the table above) with a mate­rial density of 1,8 t/m3.

Changing the excavator configuration or the material density has an impact on the permitted working angle. In this case, LEC
recommends contacting Customer Ser­vice in order to determine specific working conditions and the permitted working an­gle in particular.

The machine stability has been defined relative to a firm horizontal surface and taking into account a safety factor. Operating the
excavator with a different configuration (e.g. on soft or uneven ground, on a slope or when subject to side loads) will reduce this safety
factor and may affect the machine stability. This shall be considered by the operator. When working on slopes, it is not permitted to
overload the bucket and to work with a material density different from that intended for the bucket provided by LEC.

In order to use the excavator in material handling operations, LEC recommends also contacting the Customer Service.

** The sound pressure level (LpA) is determined according to ISO 6396. The measurement uncertainty is determined according to ISO
4871.

*** If installed, the optional arctic packages change the working ambient temperature range of the machine. In this case, a special
information label in the cab indicates the applicable temperature range.

From: Operator's manual R 9200 - 410 > Product description > Technical data

2.4.2 | Technical description

This should be taken from the accompanying technical description.

From: Operator's manual R 9200 - 410 > Product description > Technical data

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3 | Safety instructions
Working with the machine holds dangers to which you as the owner, machine operator or maintenance expert could be exposed. If you
regularly read and note the safety 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 maintenance work. The following information comprises safety regulations which, if
fol­lowed 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 pro­fessional associations.

For EU countries, guideline 2009 / 104 / EC contains the minimum required safety information applicable to the owner.

From: Operator's manual R 9200 - 410

3.1 | Meaning of the symbols in this manual

Work processes and actions that could cause danger are accompanied by safety informations in these operating instructions. These
safety informations describe vari­ous dangers which are emphasized by the terms Danger, Caution and Note.

These terms are identified by symbols in the operating instructions and have the fol­lowing meaning:

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

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

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

• This symbol identifies a listing.

◦ This symbol identifies a sub-listing.

▢ This symbol signifies the following: “The precondition must be fulfilled”.

The machine operator or the maintenance personnel must first fulfil the precondition described, i.e. the machine must be brought into a
particular work position in order to be able to carry out the actions subsequently described.

• ▶ This symbol identifies an action.

The machine operator or the maintenance personnel should be active at this lo­cation and carry out the action described.

• ▷ This symbol means “Carry out an activity".

If the machine operator or maintenance personnel have carried out the activities described in an action, the result of this action will be
described here.

Following these notes does not relieve you of responsibility for following ad­ditional rules and guidelines!

Additional points that should be noted are:

• The safety regulations which apply on site

• Statutory road traffic regulations

• The guidelines provided by professional associations.

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From: Operator's manual R 9200 - 410 > Safety instructions

3.2 | Use in accordance with the regulations

• The hydraulic excavator is a machine with work equipment (e.g. hoe type bucket, grab, bucket attachment) designed to detach, lift,
transport and shake off earth, stones and other materials, while the transportation of the load itself usually takes place without moving
the machine. Moving the machine when it is carrying a load must be carried out while observing the appropriate safety measures (see
section "Notes for safe working").

• Machines used for hoisting are subject to specific conditions and must be fitted with special safety devices (for further information, see
section “Hoisting work” or contact Liebherr customer service).

• Demolition machines can have attachments and special tools that are specially made to demolish, cut, loosen, separate or break into
parts buildings or structures, collect, transport and sort demolition waste. Thus, machines used for demolition application are subject to
specific conditions and must be fitted with special safety devices (for further information, contact Liebherr customer service).

• Machines used underground (deep mining and tunnel construction) must be equipped with exhaust gas reducing equipment (e.g.
diesel particle filter). Always comply with the statutory regulations applicable at the location of operation.

• Special tasks require special attachments and possibly also special safety devices. This equipment may only be attached to the
machine and used with the ex­plicit consent of and according to the instructions of the manufacturer of the basic machine.

• Any other use, in particular transporting persons or working in explosive atmospheres or contaminated environments is not deemed to
be in accordance with regulations. The manufacturer is not liable for any damage resulting from this action. The user is solely
responsible for the risk incurred.

• Observing the operating instructions and the inspection / maintenance instructions is also deemed to be appropriate use in
accordance with regulations.

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From: Operator's manual R 9200 - 410 > Safety instructions

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3.3 | Safety Instructions

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General safety instructions

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• Please familiarize yourself with the operating instructions before starting up the machine.

• Ensure that you have obtained, read and understood any additional instructions relating to special accessories for the machine.

• Only specifically authorized persons may operate, maintain or repair the machine. The legal minimum age is to be adhered to.

• Only employ trained or appropriately instructed personnel. Clearly establish which personnel are responsible for operating, setting up,
maintaining and repairing the machine. Give personnel the power to refuse to carry out unsafe instructions. This also applies in
relation to traffic regulations.

• Only permit apprentices and personnel who are in training or who have only general training to operate on the machine under the
constant supervision of an ex­perienced member of staff.

• As far as possible, monitor personnel to ensure that they are adhering to safe working practices, are aware of risks and are observing
the operating instructions.

• Always wear safe work clothes when you are working on or with the machine. Avoid wearing rings, wrist watches, ties, scarves, open
jackets, baggy clothing etc... There is a risk of injury from, for example, getting caught up or being drawn in.

• Wear individual protective equipment (protective goggles, safety helmets, safety shoes and gloves, reflective vests and ear protection
etc....).

• Ensure that you obtain information on any special safety regulations for the job site from the site foreman.

• Always tilt up the safety lever before leaving the operator’s seat.

• When getting in and out, do not hold on to the steering column, control panel or joystick. Doing this could cause unintentional
movement, which could result in an accident.

• Never jump from the machine; use the steps, ladders, gangplanks and supporting straps provided for this purpose.

• Face the machine when getting in or out and always use three-point support, i.e. two hands and one foot or two feet and one hand
must always be in contact with the access system at the same time.

• Familiarize yourself with the location of the emergency exit.

• In the absence of any other instructions, proceed as follows for all maintenance and repair work:

◦ park the machine on firm, level ground

◦ align the uppercarriage with the undercarriage so that the sprockets locate at the back-end

◦ anchor the bucket in the ground.

◦ place all operating levers into neutral and tilt the safety lever up.

◦ switch off the engine and remove the start key.

• Before touching any parts of the hydraulic circuits, you must also operate all pilot control devices (joystick and pedals) in all directions
with the start key in contact position and with the security lever lowered, in order to reduce the actuating and dynamic pressures in the
work circuits. You must then reduce the internal tank pressure as described in these operating instructions.

• Secure all loose parts on the machine.

• Never operate a machine before carrying out a careful inspection tour and checking whether any warning signs are missing or
illegible.

• Respect all danger and safety instructions.

• For special applications the machine must be equipped with specific safety equip­ments. Work only if they are mounted and functional.

• Do not carry out any modifications, alterations or conversions to the machine which may affect safety without the express permission
of the manufacturer. This also applies for the installation of safety devices and valves and for welding work on load-bearing parts.

• Do not make modifications, alterations and repair to any operator protective structure (for example: the structure of the cab, Falling
Object Protective Structures (FOPS), Front Guard Protective Structures (FGPS), Roll-Over Protective Structure (ROPS), Tip-Over
Protection Structure (TOPS)) without the written approval of Liebherr.

• If an operator protective structure is damaged, contact the Customer Service, which will tell you if it can be repaired or if it must be
replaced.

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• If the repair of the operator protective structure is approved by Liebherr, you must obey the repair instructions and guidelines provided
by Liebherr. If the repair of the operator protective structure is not possible, it must be replaced.

• Not original equipment and component parts or such kind, which has generally not been validated by Liebherr for installation or
extension, has not to be installed or added onto the excavator without previous written agreement of Liebherr. Wherefore the
necessary technical documentations has to be at Liebherr’s dis­posal.

Avoidance of crushing and burns

• Do not work beneath the attachment if it is not safely positioned on the ground or supported.

• Do not use any damaged or insufficient load-bearing take-up materials, such as ropes or chains.

• Wear adapted work gloves when working with wire cables.

• When working on the attachment, never use your fingers to locate bores; use the correct punch for the procedure.

• Ensure that no objects enter the fans when the engine is on. The fan will eject or destroy these objects and will itself be damaged.

• Near operating temperature, the parts of the engine cooling system, of the exhaust system and of the hydraulic system can reach very
high temperatures. Avoid coming into contact with coolant carrying parts, with parts from the exhaust system and with hot oil or oil-
bearing parts. There is a risk of sustaining burns.

• Only check the coolant when the sealing cap of the expansion container has cooled to a point where it is possible to touch it. Then
turn the cap carefully to let off the overpressure.

• Wear protective goggles and gloves when working on the battery. Avoid sparks and naked flames.

• Never permit the bucket to be guided by hand by auxiliary personnel.

• When reaching into the engine compartment, always secure the side doors against unintentional closing by positioning the supports if
provided for this pur­pose.

• Never lay under the machine if it is raised with work attachment and has not been correctly and securely supported with appropriate
supports.

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Avoidance of fire and explosions

• Switch off the engine when refuelling.

• Do not smoke or use a naked flame when refilling tanks and working near or charging the batteries.

• Always start the engine in accordance with the operating instructions.

• Check the electrical system regularly.

• Have all faults, such as loose connections, blown fuses and lamps and clogged or abraded cables rectified by authorized personnel.

• Do not transport any combustible liquids anywhere on the machine other than in the tanks provided for this purpose.

• Check all lines, hoses and screwed joints regularly for leakage and damage.

• Rectify leakages immediately and replace damaged components.

• Oil spraying out of leaking areas can easily cause a fire.

• Ensure that all holds and shields are correctly installed to guard against vibration, abrasion and heat accumulation.

• Do not use cold start materials (ether) in the vicinity of heat sources, naked flames or in inadequately ventilated areas.

• Do not use any starting aids containing flammable material to start diesel engines with preheating or flame glow systems. There is a
risk of EXPLOSION.

• Familiarize yourself with the location and operation of fire extinguishers on the machine and with local fire warning and fire abatement
options.

• It is possible to install an extinguisher into the driver’s cab.

• All doors, covers and boxes locks have to be unlocked before operation in order to facilitate firefighting in case of fire. Only electrical
boxes from and over 50V must remain locked during operation.

Bringing the machine safely into service

• Carry out a careful inspection tour around the machine each time before starting it.

• Ensure that no one, except an authorized person, is in the work and movement area of the machine.

• Check the machine for loose bolts, cracks, wear, leakage and damage.

• Never attempt to operate a damaged machine.

• Ensure that any damage is immediately rectified.

• Ensure that all hoods and covers are closed, but that locks are unlocked, to facil­itate the fight against fire in case of.

• Ensure that all warning signs are present.

• Keep windows and interior and exterior mirrors clean. Secure doors and windows against unintended movement.

• Ensure that no one is working on or under the machine and warn personnel in the vicinity of the machine that it is about to start by
sounding the horn.

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Safely getting up
• Proceed with the same precautions to climb up or down onto the machine, as to install yourself at the operator’s seat.

• When getting up or down, position the machine on even, horizontal ground. The upper structure should be positioned with the
undercarriage in such a way that the steps and ladders are aligned with each other.

• Ensure that steps, ladders and hand-rails (grips) are in good condition. In particular, you should ensure that they are free of dirt, oil, ice
and snow. NOTE: To ensure that the doors open properly in all weather conditions, the door seals must be dusted with talc or silicon at
least every two months or more often if required. The door hinges and locks should be greased regularly.

• Face the machine when getting in or out and always use three-point support, i.e. two hands and one foot or two feet and one hand
must always be in contact with the access system at the same time.

• If you are able to reach the door handle with your free hand, open the doors before you climb any higher. External influences, such as
wind, can make it more difficult to open doors. Because of this, always use your hand for control when opening doors. Ensure that the
door is latched open to prevent it slamming open and shut.

• In case of bad weather conditions, be particularly vigilant to realise the climbing and descent from the cab with the best safety
conditions, and do or give the instructions to the execution of prior preparations to be accomplished, as enunciated above, in order to
displace yourself safely.

• Be particularly vigilant with those prerequisites conditions.

• For cab with a side door:

◦ Now continue to climb up, still using the three-point support and sit down in the operator’s seat as soon as you enter the cab.

◦ Fasten the safety belt (if available), unlock the door, using the planned lever, and close it immediately using the door handle, before
tilting down the safety lever, and start the machine.

◦ If you wish to work with the door open, it is necessary to fasten your safety belt. If unavailable, let it be installed before working with
the door open.

• For cab with a rear door:

◦ Now continue to climb up, still using the three-point support and close the door as soon as you enter the cab.

◦ Sit down in the operator’s seat and fasten the safety belt (if available) before tilt­ing down the safety lever, and start the machine.

Adjusting the operator’s standing position

• Before starting the machine, adjust the seat, mirrors, armrests and operator’s controls in such a way that you are able to work
comfortably and safely.

• Acoustic insulation devices on the machine must be set to the insulation position throughout operation.

Protection from vibration - seat adjusting

• Keep the seat in good condition and adjust it as follows:

◦ The seat and its damping action should be adjusted depending on the weight and height of the operator.

◦ Check the seat’s damping action and adjustment mechanisms regularly and ensure that these seat characteristics remain as per
the seat manufacturer’s in­structions.

Utilisation in confined spaces

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

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Starting the machine safely

• Before starting, check all control lamps and instruments for correct function, place all operator’s controls in Neutral and tilt the safety
lever up.

• Before starting, sound the horn briefly to alert people in the vicinity of the machine.

• Only start the machine from the driver’s seat.

• In the absence of any other instructions, start the engine in accordance with the regulations given in the operating instructions.

• Tilt the safety lever down and then test all display and checking devices.

• In enclosed spaces, only allow the engine to run when there is adequate ventilation. If necessary, open doors and windows to ensure
sufficient fresh air supplies.

• Bring the engine and hydraulic oil to operating temperature. Low oil temperatures make the control unit react sluggishly.

• Check that the attachment is operating correctly.

• Move the machine carefully to an open area and then check the function of the travel and swing gear brakes, the steering and the
signalling and lighting devices. Lighting devices must always be clean.

Stopping the machine safely

• Only stop the machine on level, firm ground.

• If the machine has to be stopped on an incline, chocks should be used to secure it from rolling away.

• Before stopping the machine, each time it is possible, align the uppercarriage with the undercarriage so that the sprockets locate at
the back-end. This is the only one position which enables a secured access to every maintenance locations on the uppercarriage.

• Use the stop bolts to secure the uppercarriage facing the undercarriage, if avail­able.

• Lower the attachment and anchor the grab lightly in the ground.

• Position every control lever into neutral position and apply the travel and swing brakes.

• Stop the engine in accordance with the operating instructions and tilt the safety lever up before leaving the cab.

• Lock the machine, included hoods and compartments, remove every keys and secure the machine against unpermitted use and
vandalism.

Safely getting down

• Proceed with the same precautions to climb up or down onto the machine, as to install yourself.

• Stop the machine on level, horizontal ground. The upper structure should be positioned with the undercarriage in such a way that the
steps and ladders are aligned with each other.

• Open and lock the door. Be sure of it’s locking. Take care of weather conditions ! Unfasten the safety belt.

• Position yourself with your face toward the machine when getting out and use three-point support, i.e. two hands and one foot or two
feet and one hand must always be in contact with the access system at the same time. Climb down until you can close the doors
safely. Always use your hand for control when closing the doors. Lock the door.

• Now climb down to the ground.

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Working safely with the machine

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• Before you start working, acquaint yourself with the special features of the job site and any special precautions and warning signals.
Examples of particular work environments would be on-site or traffic obstructions, the load-carrying capacity of the ground and any
requirements to make the job site safe from public use.

• Always maintain a safe distance from overhangs, edges, slopes and unsafe ground.

• Be particularly careful in conditions of reduced visibility and changeable ground conditions.

• Familiarize yourself with the location of power and gas lines on the job site and take particular care when working near them. If
necessary, inform the responsible authorities.

• When working in areas with underground lines (gas, electricity), adhere to the laws, regulations and rules applicable at the place of
use.

• Maintain a safe distance from electrical aerial lines. Do not allow the attachment to come near cables when working near electrical
aerial lines. Risk of fatality! In­form yourself about required safety distances.

• The following actions must be carried out in the event of any transfer of electricity:

◦ do not move the machine or its attachment,

◦ do not leave the driver’s cab,

◦ warn any personnel in the vicinity not to come close to the excavator and not to touch it,

◦ instruct or initiate that someone turns off the voltage,

◦ move the machine, if possible, from the danger zone to a sufficient distance,

◦ do not leave the machine until you are absolutely sure that voltage in the line, which had been touched or damaged, has been
turned off!

• Before moving the machine, always ensure that any attachments are safely se­cured.

• When driving onto public roads, paths and squares, observe current traffic regulations and if necessary, ensure that the machine has
been made safe as per reg­ulations beforehand.

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

• Do not permit any passengers in the machine.

• Only work when seated properly and with the safety belt securely fastened (if available).

• Report all function faults and ensure that all necessary repairs are carried out im­mediately.

• Assure yourself that no one is endangered when you start the machine moving.

• Before you start working, test the brake system in accordance with the regulations given in the operating instructions.

• Never leave the driver’s seat while the machine is moving.

• Never leave the machine unattended while the engine is running.

• The machine must be positioned, moved and operated in such a way that it is stable and that there is no danger of overturning. Only
known loads may be moved with the attachment; this applies particularly when using the grab.

• Position the upper structure in the longitudinal direction when moving and hold the load as close to the ground as
possible.EXCEPTION: excavators used for loading and unloading, see the part Safe use when loading and unloading (particularly
when loading and unloading wood).

• Adjust your driving speed to suit site conditions.

• Avoid any working movements which may tip the machine. Should the machine start to tip or slide sideways, however, turn the upper
structure to face downhill and lower the attachment at the same time.

• As far as possible, work downhill or uphill and not side on to the slope.

• Drive safely on stony, slippery or inclined ground.

• Always travel in the direction of the slope and not perpendicular to the slope, with the uppercarriage aligned with the undercarriage.

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• Only drive downhill at the permitted speed or you could lose control of the ma­chine.

• Always shift down to a lower running step before a slope. When doing this, the diesel engine must run at maximal speed and the
speed may only be reduced us­ing the foot pedals.

• Load an occupied truck only if all safety requirements are fulfilled, notably in order to protect the truck operator.

• For demolition work, digging and crane operations etc., always use protective de­vices specifically designed for the purpose.

• For terrain which is difficult to gain an overview of and whenever necessary, ask for the assistance of a spotter. Only permit one
person to give you signals.

• Authorize only experienced people to attach load and to give indications to the machine operator. This people must be in the
operator’s sight or in radio contact with him.

• Depending on the attachment combination, there is a risk of collision between the work tool and the machine (uppercarriage and
undercarriage). The greatest de­gree of care must be taken to avoid damage.

• Depending on the attachment combination, there is a risk of collision between the work tool and the cab, the cab protection or the
boom cylinders. The greatest de­gree of care must be taken to avoid damage when the hoe teeth come within this area.

• Depending on the attachment combination, there is a risk of collision between the work tool and the attachment parts. The greatest
degree of care must be taken to avoid damage.

• Depending on the attachment combination, there is a risk of collision between the lift ring of the attachment and the cab or the cab
protection. Before operating, ensure that there is no risk of collision, especially on excavator with cab elevation. If necessary remove
the lift ring.

• In case of a thunderstorm:

◦ lower the attachment to the ground and if possible anchor the digging tool into the soil.

◦ leave the cab and move away from the machine before the storm breaks out. Otherwise, you must stop the excavator, turn off the
radio and keep inside the closed cab until the end of the storm.

• Auxiliary control units can have various functions. Always check their functions when starting up the machine.

• Stop the swinging motion of the uppercarriage when lowering the attachment into a ditch without striking the attachment on the ditch
walls.

• Inspect the machine for damage if the attachment has been swung into a wall or any other obstacles.

• Applications in which the attachment is to be used to strike the material being extracted are not permitted, even when working in a
longitudinal direction.

• Repeated strikes against an object leads to damage to the steel structures and machine components.

• Please refer to your Liebherr dealer if special teeth for heavy-duty or special ap­plications are required.

• Do not attach too large bucket or bucket with side cutters or that are during operations with rocky material. This would prolong the
work cycles and may lead to damage to the bucket as well as further machine components.

• With the 2x45° offset articulation, the offset position may only be employed if the working tool or the attachment does not touch the
material.

• Operation of the offset articulation to drill into the material is not permitted.

• Do not lift the machine during operation. Should this happen, lower the machine slowly back to the ground.

• Do not let the machine fall heavily on the ground and do not hold it back with the hydraulics. This would damage the machine.

• During operation with the attachment it is forbidden to raise the machine with the dozing blade (e.g. carving at the ceiling when
tunnelling).

• Do not dig under the undercarriage. Take all necessary measures to prevent ground collapse under the machine.

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• The operation of Liebherr Mining machines in the following Mining applications is not approved or condoned by Liebherr:

◦ Batter pulling (also known as Scaling), without exception.

◦ Double benching (also known as Split benching or Double flitching) when the material is un-blasted and non-fragmented material
which requires the boom down (rod side) pressure to exceed 50 bar.The use of these Mining methods will result in increased
fatigue levels to steel structures and components of the respective Liebherr Mining Machine and therefore will significantly reduce
the expected lifetime of structures and/or com­ponents.

Working safely with the machine used for demolition appli­cation

• Machines used for demolition application are subject to specific conditions and must be fitted with special safety devices (for further
information, contact Liebherr customer service).

• If the machine can be used for demolition application, you must also obey the ad­ditional safety instructions that follow.

Before the operation of the machine

• Make sure that no persons are in the hazard area of the machine.

• Make sure that the working conditions are in the specified limits.

• Make sure that the special safety devices necessary for the task operate correct­ly.

• Always obey the applicable local regulations.

Incorrect use of the machine used for demolition application

• Demolition works must be carried out only by trained specialist personnel.

• Do not operate the machine if the counterweight is not suitable for the attachment or special tool you use.

• Do not operate the machine if applicable and approved operator protective structures (e.g. FOPS, front protective grid) are not
installed.

• Do not move suddenly and jerkily.Do not stop it suddenly.Always move the attachment or special tool slowly and with constant speed
movements.

• Because of the possible effects on the machine stability, reduce the height and the speed of the movement.

• Do not lift the machine with the attachment or special tool.

• Make sure that there is no rubble on the attachment or special tool.

• Operate the machine in the position that follows:

◦ Align the uppercarriage with the undercarriage so that the sprockets locate at the back-end.

◦ Work over the idler.

• Keep a sufficient distance between the machine and the object to demolish.

• Do not use the inertia of the attachment or special tool as an additional force.

• Never leave the machine unattended while the attachment or special tool is not safely positioned on the ground.

• Lay down the attachment or special tool on the ground to park the machine.

• Obey the symbols shown on the display and the acoustic warning signals.

• Prevent unwanted lateral forces on the attachment or special tool when the up­percarriage turns.

• Do not drive at a right angle to the slope.

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Incorrect use of the attachment or special tool used for demolition ap­plication
• Make sure that you use an attachment or special tool exclusively designed for the task.

• Only use attachment or special tool approved by Liebherr.

• Only operate the attachment or the special tool with closed windshield and with a front protective grid.

• Only operate the attachment or the special tool with closed door.

• Do not clean the ground with the special tool.

• Make sure that the special tool works in its specified limits. For more information, also refer to the Operator’s Manual of the tool
manufacturer.

Safe use of a hydraulic hammer or a hydraulic ripper

• According to the severity of the application, the use of a hydraulic hammer or a hydraulic ripper can result in vibrations, shocks or
stresses which are higher than in normal use. It may reduce the expected lifetime of structures and/or compo­nents.

• The hydraulic hammer or the hydraulic ripper must be selected with particular care. When using a hydraulic hammer or a hydraulic
ripper not permitted by Lieb­herr, warranty for steel structures and machine components will be ceased.

• Before beginning breaking tasks, position the machine on firm and level ground.

• Use a hydraulic hammer or a hydraulic ripper designed exclusively for breaking stone, concrete and other breakable materials.

• Only operate the hydraulic hammer or the hydraulic ripper in the longitudinal direction of the machine and with the windshield closed
or with a front protective grid.

• Ensure during hammer or ripper operation that no cylinder is entirely extended or retracted and that the stick is not in the vertical
position.

• In order to avoid damages to the machine, try not to break stone or concrete while performing retraction and extension motions of the
hydraulic hammer.

• Do not apply the hydraulic hammer uninterrupted for more than 15 seconds at a time to the same place. Change the breaking point.
Too long uninterrupted oper­ation of the hydraulic hammer leads to an unnecessary overheating of the hydrau­lic oil.

• Do not use the drop force of the hydraulic hammer or of the hydraulic ripper to break stone or other materials. Do not move obstacles
with the hydraulic hammer. Misuse of this nature would damage both the hammer and the machine.

• Do not use the hydraulic hammer or the hydraulic ripper to lift objects.

• Before beginning breaking tasks, the pressure of the dampening accumulator of the hydraulic ripper must be adjusted depending on
the nature of the ground and the excavator model.

Safe use of a ripper

• Rippers are generally used in applications where the use of a bucket is not efficient to break out rocks. Thus, these applications are
more severe than in normal use.

• According to the severity of the application, the use of a ripper can result in vibrations, shocks or stresses which are higher than in
normal use. It may reduce the expected lifetime of structures and/or components.

• Special hydraulic devices can be necessary. Contact the Liebherr customer ser­vice.

• The ripper must be selected with particular care. When using a ripper not permitted by Liebherr, warranty for steel structures and
machine components will be ceased.

• Before beginning breaking tasks, position the machine on firm and level ground.

• Do not use the ripper to lift objects.

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Safe use when loading and unloading (particularly when loading and unloading wood)
• According to use, it can be necessary when working with a grab to move with the attachment raised and the load lifted up; this applies,
for example, when loading and unloading wood.

• Here, the centre of gravity of the machine will be displaced upwards in the vertical direction. The driving characteristics of the machine
will thus be influenced persistently, e.g. through reduction of the dynamic stability.The following instructions are therefore to be
observed at all times:

◦ Adjust vehicle handling to suit the altered machine characteristics and environ­mental conditions.

◦ Reduce your speed to prevent the need for sudden braking and steering ma­noeuvres.

◦ Avoid sudden speed changes, such as braking, accelerating and changing di­rection.

◦ Only rotate the uppercarriage when the undercarriage is stationary.

◦ Only rotate the uppercarriage after you have picked up the load.

◦ Only move the machine when you have picked up and lifted the load and rotat­ed the upper structure to the driving position.

◦ There is a danger of possible swinging movement and dropping of the load when the attachment is raised.

◦ A protective grid (FOPS) in accordance with ISO 10262 must be attached to the cab.

◦ A protective roof (FOPS) in accordance with ISO 10262 must be attached if there is a risk of objects falling from above.

◦ Only the maximum permissible load may be taken up using the grab.

• NOTE: The weight of absorbent materials, such as logs, is dependent on length, diameter and specific weight. The influencing
variables present in a natural prod­uct, such as moisture, must be noted.

• Working procedures when using machines with grabs require the machine oper­ator to receive special instruction and training.

• Use as part of the work process is only permitted when the machine operator has sufficient training and practical experience.

Safe use of machines with tower elevation

• Due to the tower elevation, the centre of gravity of the machine will be displaced upwards in the vertical direction. The driving and work
characteristics of the ma­chine will thus be influenced persistently, e.g. through reduction of the dynamic stability.

• Due to the heightened centre of gravity, the machine must be aligned horizontally before use. In horizontal alignment, the centre of
gravity of the uppercarriage is over the centre of the undercarriage, which reduces the risk of tilting.

• The machine can still sway and tilt despite being aligned!The following instructions are therefore to be observed at all times:

When moving the machine:

• Rotate the uppercarriage parallel to the undercarriage (transport position).

• Draw the attachment as close as possible to the machine.

• Only at this point may the support feet be retracted and the machine moved.

• Moving with loads is not permitted.

• Check the terrain to be covered to ensure that the ground is solid and even. Potholes and uneven surfaces jeopardize the stability of
the machine.

• Adjust vehicle handling to suit the altered machine characteristics (high centre of gravity) and environmental conditions.

• Reduce your speed to prevent the need for sudden braking and steering ma­noeuvres.

• Avoid sudden speed changes, such as braking, accelerating and changing di­rection.

• Ascending gradients and obstacles may only be approached in the longitudinal direction in order to prevent unacceptable banking of
the machine.

• Special care should be taken when driving through narrow passages - drive slowly!

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When loading and unloading:

• The machine must be supported and aligned horizontally before moving (swing) the uppercarriage out of the transport position.

• It is imperative that you check the contact surface of the support (load carrying capacity of the substrate). A support subsiding would
have disastrous conse­quences!

• Carry out all movements with increased care.

• To slew the load, move the attachment as close as possible to the machine (Caution! swinging grab) and hold the load close to the
undercarriage and above the substrate.

• Avoid braking or accelerating the attachment or uppercarriage abruptly.

• Do not lift any loads which are heavier than those given in the load chart.

Protection from vibration

• Vibrational loads on mobile building machinery are mainly the result of the type and method of use. The following parameters in
particular are decisive influences:

◦ Terrain conditions: Uneven areas and potholes;

◦ Operational techniques: Speed, steering, brakes, controlling the machine’s control elements when driving and working.

• To a large extent, the machine operator determines the vibrational loads since he selects the speed, gearbox ratio, working method
and route himself.This means that there is a wide range of different vibrational loads for the same machine type.

Whole-body vibrational load for the machine operator can be reduced if the following recommendations are observed:

• Select suitable machines, attachment parts and auxiliary devices for each part of the job.

• Use a machine that has a suitable seat (i.e. for earth-moving machinery such as hydraulic excavators, this should be a seat which
corresponds with EN ISO 7096).

• Keep the seat in good condition and adjust it as follows:

◦ The seat and its damping action should be adjusted depending on the weight and height of the operator.

◦ Check the seat’s damping action and adjustment mechanisms regularly and ensure that these seat characteristics remain as per
the seat manufacturer’s in­structions.

• Check the maintenance status of the machine, particularly with respect to: tyre pressure, brakes, steering, mechanical connections
etc.

• Do not steer, brake, accelerate, shift gears, move or load the machine’s attach­ment jerkily.

• To reduce vibrational load, adjust the machine speed to suit the route as follows:

◦ Reduce speed when driving on difficult terrain;

◦ Drive around obstacles and avoid driving on very difficult terrain.

• Keep the terrain on which the machine is working and driving in good condition:

◦ Remove large stones and obstacles;

◦ Fill in ruts and holes;

◦ Have machines ready to prepare and maintain suitable ground conditions and calculate in sufficient time to carry out any work
required.

• Drive longer distances (e.g. on public roads) at an appropriate (medium) speed.

• Use special auxiliary systems (if available) which reduce vibration for machines that are driven frequently.If such auxiliary systems are
not available, regulate speed to avoid "oscillating" the machine.

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Attaching and removing attachment parts safely

• Equipment or attachments made by other manufacturers or those which do not have general approval from Liebherr for installation or
attachment may not be in­stalled or attached to the machine without Liebherr’s prior written consent.

• Liebherr must be provided with the appropriate technical documentation neces­sary for this purpose.

• Obey the instructions of the manufacturer of the approved working tool and of re­lated approved devices.

• Before carrying out any major repair work on the attachment, position the ma­chine on level, firm ground.

• Do not work beneath the equipment if it is not safely positioned on the ground or supported with appropriate supports.

• Before loosening lines or unscrewing bolts, you must store the equipment, switch off the engine and press the start key to the contact
position and both joysticks and the push-buttons to “Turn grapple” in order to reduce the pressure in the hy­draulic system.

• Do not attempt to lift heavy parts. Use devices which are suitable for this purpose and which have sufficient load carrying capacity.

• Do not use cable which is damaged or does not have sufficient load carrying capacity. Wear work gloves when working with wire
cables.

• When working on the attachment: switch off the engine and keep the safety lever tilted up. Never use your fingers to locate bores; use
the correct punch for the pro­cedure.

• During repair work: ensure that the hydraulic lines are secured correctly and that all bolts and connections are tight.

• When you have removed and chocked an attachment part, close open areas of the hydraulic circuit to stop dirt entering. Only allow
authorized persons in the vi­cinity of the machine or the lifting device used.

Removing and installing attachment pins safely

• If possible, always use a hydraulic bolt press to press out the attachment’s bolts.

• If you have to remove a bolt using a sledge-hammer, a driving punch and a bore hole conductor held by another person must be used.

• To drive in a bolt, screw the drive screws provided in the toolbox if provided into the bolt's threaded hole and only hammer these
screws.

• When installing bolts locked by means of castle nuts and cotter pins, first drive the bolt to the stop, then screw the castle nut by hand
until contact and then only pull it far enough to push in the cotter pin.

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Transporting the machine safely

• Due to transport restrictions, use only suitable means of transport and lifting de­vices with sufficient load-carrying capacity.

• Park the machine on a flat surface and wedge the crawler or wheels securely.

• If required, detach a part of the machine’s working attachment during transporta­tion.

• The ramp used to drive the machine up onto the flatbed trailer should not exceed an inclination of the angle value indicated in the
"Technical data" section of this manual (machine must be able to walk up unaided) and should have a wooden cover to prevent sliding
back.

• The undercarriage should be swept clean, i.e. before driving up the ramp, clean any snow, ice and mud from the crawler / wheels of
the machine.

• Align the machine precisely with the loading ramp.

• Attach the hand levers for fine-tune driving (crawler excavator) onto the travel pedals.

• Ensure that a spotter gives the machine operator the required signal.

• Prepare the placing block to ensure against rolling back when the machine is driv­ing up onto the flatbed.

• Tilt the attachment up and drive up the loading ramp. While doing this, always hold the attachment securely over the loading area,
drive very carefully up the ramp and onto the transportation vehicle.

• Rotate the uppercarriage carefully to the rear and lower the attachment. Due to restrictions during transport on hoe attachment, tilt the
arm in and dismantle the bucket during transportation.

• After loading the machine onto the flatbed trailer, the upper structure must be secured facing the undercarriage using the stop bolts
(only A devices).

• Secure the undercarriage and the remaining individual parts using chains and blocks to prevent slipping.

• Before you leave the machine, reduce pressure on all pressure lines, remove the ignition key and tilt up the safety lever.

• Lock all cab and panel doors.

• Before transportation, find out all details about the route to be travelled, particularly as they relate to width, height and weight
restrictions.

• Pay particular attention when driving under electrical lines and bridges and through tunnels.

• When unloading the machine, take the same amount of care as was taken when it was loaded. Remove all chains and blocks. Start
the engine as per the operating instructions. Drive carefully off the trailer’s loading area and down the ramp. Hold the working
attachment as securely as possible over the ground while doing this. Have a spotter guide you.

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From: Operator's manual R 9200 - 410 > Safety instructions

3.4 | Servicing the machine safely

General safety instructions

• Maintenance and repair work may only be carried out by specially trained person­nel.

• Observe statutory timetables or intervals given in the operating instructions for repeat tests / inspections. It is imperative that a suitably
equipped workshop is avail­able in order to carry out maintenance work.

• The inspection and maintenance schedule given at the end of these operating instructions defines precisely who is required /
permitted to carry out what work.Jobs listed as daily / weekly work may be carried out by the machine's driver or maintenance
personnel when they have received appropriate instruction.The remaining work may only be carried out by specialist personnel with
appro­priate training.

• Replacement parts must correspond to the technical requirements determined by the manufacturer. Original replacement parts are
always guaranteed to meet these criteria.

• Always wear safe work clothes when carrying out maintenance work. Avoid the wearing of rings, wrist watches, ties, scarves, open
jackets, baggy clothing etc... There is a risk of injury from, for example, getting caught up or being drawn in.Protective goggles, safety
helmets, safety shoes and gloves, reflective vests and ear protection etc. are required for specific jobs.

• Do not remain in direct proximity of the diesel engine while the diesel engine is running.Persons with pacemakers should not approach
within 20 cm of the running diesel engine.Do not touch voltage-carrying parts on the electrical connection of the individual solenoid
injection pumps (Unit Pumps UP) while the diesel engine is running.

• Do not permit unauthorised persons to approach the machine during mainte­nance work.

• Cordon off a wide maintenance area if required.

• Inform operational personnel before starting to carry out any special work and repair work. Designate persons in charge of
supervision.

• In the absence of any other information in the operating instructions, carry out all maintenance work on the machine on level, firm
ground with the working equip­ment set aside and the engine switched off.

• For some machines, the only one position which enables a secured access to every maintenance locations on the uppercarriage, is
when the uppercarriage is aligned with the undercarriage so that the sprockets locate at the back-end.The ladder situated on the
undercarriage only corresponds with the uppercar­riage’s access when the excavator is in this configuration.

• Pull out the ignition key and shut off the main battery switch.

• Always tighten any loose screw connections during maintenance and repair work.

• The mounting bolts of the main components, of the hydraulic hoses and of the counterweight must be replaced after every removal.

• If safety devices have to be dismantled during set-up, maintenance and repair work, they must be immediately reinstalled and
checked at the end of the work.

• When carrying out repair work, particularly when working under the machine, hang a “Do not start” warning sign in a clearly visible
position on the control panel. Pull out the start key and shut off the main battery switch.

• Operate combustion motors and fuel operated heaters only in well ventilated ar­eas. Before operating these units, check ventilation.

• In addition, always follow applicable local regulations.

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Cleaning
• Clean oil, fuel or care products off the machine before starting maintenance or repair work and pay particular attention to connections
and screw fittings.Do not use aggressive cleaning products and use lint-free cleaning cloths.

• Do not use aggressive cleaning products or steam jet devices to clean the machine for the first two months after initial set-up of the
machine (or after repaint­ing).

• Do not use combustible liquids to clean the machine.

• Before cleaning the machine with water or steam jets (high pressure cleaner) or other cleaning materials:

◦ lubricate all bearing points, bolt connections and the rim bearing to prevent wa­ter or steam entering the bearing points.

◦ cover or glue shut all openings into which for safety or functional reasons water or steam may not be permitted to enter.Electric
motors, electrical components, control boxes, plug connections and air filters are particularly at risk.

• Ensure that the fire warning systems and fire extinguishers of the engine compartment’s temperature sensor do not come into contact
with hot cleaning products during cleaning work.The fire extinguisher could start.

• If you use a high pressure cleaner with steam or hot water to clean the machine, observe following recommendations:

◦ the distance between the nozzle and the surface to be cleaned must be no low­er than 20 inches

◦ the water temperature should not exceed 60°c (140°F)

◦ limit the water pressure to 80 bar maximum (1160 PSI)

◦ if you employ cleaning fluid, only use neutral cleaning agents such as custom­ary car shampoos diluted to 2 or 3 percent maximum

• After cleaning:

◦ remove all covers completely.

◦ check all fuel, engine oil and hydraulic lines for leakage, loosened connections, chafing and damage.

◦ rectify any defects found immediately.

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

Corrosion protection
• The corrosion protection of the machine must be inspected and renewed at regular intervals. For further information, refer to the
Maintenance manual for corro­sion protection.

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Field of view
• Mirrors and cameras, which were possibly removed for the transport, must be inevitably reinstalled and correctly adjusted before the
initial set-up of the machine.

• Regularly check that the interior and exterior mirrors as well as the cameras are correctly adjusted.

• Control the surroundings, and particularly the nearness area of the machine, dur­ing operation or when travelling.

• Mirrors are installed on the machine:

◦ on the left to check the left side of the machine.

◦ on the front to check the front side of the machine.

◦ on the right to check the right side of the machine.

◦ above the counterweight to check the rear side of the machine.

• On some machines, some mirrors may be replaced with cameras.

• At each extension, construction or change on the machine, the sight conditions must be maintained. These conditions must otherwise
be checked according to ISO 5006.

• Mirrors and cameras must always be clean.

• Damaged mirrors and cameras must be immediately replaced.

• The site has to be organised so that the dangers due to a restricted field of view are minimized, particularly for machines with an
operating weight which is supe­rior to 40 tons.

Crack testing
• Even when the machine is operated carefully, there is a possibility of individual cases of overloading occurring, which could lead to
cracks or loose connections. The machine should therefore be checked regularly for cracks, loose connections or other visible
damage to maintain operational safety.

• In order to be able to check for cracks, it is essential that the machine is kept clean and cleaned regularly.

• The tests should be carried out in accordance with the monitoring and mainte­nance plan:

◦ every 250 operating hours by the machine owner’s maintenance personnel.

◦ every 500 operating hours by authorised specialist personnel.

• It is advisable to carry out these tests: supported, on firm, horizontal substrate, with the equipment in longitudinal and cross direction
for variable loads. Current accident prevention regulations must be adhered to.

• Especially check the supporting components, in particular:

◦ framed construction undercarriage with axle and gearbox storage, support outriger, lower slewing ring support with tower and
slewing ring.

◦ framed construction uppercarriage with bearing for boom and hoist cylinder, upper slewing ring support, cab suspension, mounting
for slewing gear and coun­ter weight.

◦ framed construction components of attachments, e.g. boom, stick, quick change adapter, digging tool and grapple.

◦ hydraulic cylinders, axles, steering, pins and pin connections, ascents, ladders and mounting elements.

• The crack test should be carried out visually. If a crack is suspected, the dye penetration test should be carried out as a crack test on
areas which do not have good visibility, such as the ring bearing support, in order to increase testing safety.

• Any damage found must be rectified immediately. Welding work on load-bearing parts of the earth-moving machinery, loading devices
and transport devices may only be carried out by trained specialist personnel and only in accordance with the accepted rules of
welding engineering. In case of doubt, contact the LIEBHERR customer support service to discuss suitable remedies.

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Welding, drilling, firing and grinding work

• Any welding on structural parts (as undercarriage, uppercarriage, equipment parts,…) may only be done by the manufacturer, or
authorized official dealer. If this rule is neglected, the warranty is voided.

• Only carry out welding, drilling, firing and grinding work on the machine with express authorization. Clean dust and combustible
materials off the machine and its surrounding areas before welding, drilling, firing or grinding.Ensure adequate ventilation. Risk of fire
or explosion.

• Before welding repairs on other parts, always disconnect the battery. Always re­move the negative terminal first and reconnect it last.

• Nevertheless if welding repair should be done on components which may contain inflammable gases (welded counterweight, hydraulic
tank, fuel tank, …), these components must be previously and sufficiently ventilated with pressurized air to avoid all fire or explosion
hazard

• Before welding, connect the ground cable as close as possible to the welding point, so the welding current will not run through parts
like the swing ring, rotary connection, gears, bushings, bearings, hinges, joints, hydraulic hoses, sockets, rubber parts or seals.

Process materials
• When working with oils, greases and other chemical substances, observe the ap­propriate current safety regulations for the product.

• Ensure that process materials and replacement parts are disposed of in a safe and environmentally acceptable manner.

• Take care when handling hot process materials (Risk of burning and scalding).

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Repair work
• Do not attempt to lift heavy parts. Use devices which are suitable for this purpose and which have sufficient load capacity. When
replacing single parts and larger subassemblies, carefully secure them on lifting devices so that they do not present a risk. Only use
suitable and correctly functioning lifting devices and load take-up devices with adequate load capacity.Do not stand or work under
swinging loads.

• Do not use lifting devices which are damaged or do not have sufficient load carrying capacity.Wear work gloves when working with
wire cables.

• Authorize only experienced people to attach load and to give indications to the crane operator. This people must be in the operator’s
sight or in radio contact with him.

• When working above body height, use safe climbing devices and working platforms which are appropriate for the job.Do not use
machine parts as climbing devices if they are not designed for this purpose.When working at height, wear a harness to prevent
falling.For further information, see section "Maintenance anchor points" or contact Lieb­herr customer service.

• Ensure that all grips, steps, rails, platforms and ladders are free of dirt, snow and ice.

• Pneumatic cylinders do not have to be used as handles. Open doors and covers carefully, so that pneumatic cylinders do not hit their
stops, because this could cause mechanical damages.

• Make sure the equipment on which you will operate is securely supported before working (e.g. replacing teeth). Prevent metal
touching metal when doing this.

• For safety reasons, never open and remove a track chain unless having previously totally released the pretension of the chain
tensioning unit.

• Never lay under the machine if it is raised with work equipment and has not been securely supported with appropriate supports.

• Always jack the machine up in such a way that any weight displacement does not jeopardize stability and prevent metal touching
metal while doing this.

• Work on the suspension, brake and steering systems may only be carried out by trained specialist personnel.

• If the machine has to be repaired on a slope, secure the crawler with chocks and connect the upper structure to the chassis using stop
bolts.

• Only personnel with special training and experience may work on hydraulic equip­ment.

• When searching for leakage, wear protective gloves. A fine jet of liquid under pressure can penetrate the skin.

• Do not unscrew any lines or connections before you have set aside the equipment, switched off the engine and depressurized the
hydraulic system. After switching off the engine, with the start key in contact position and with the safety lever down into its lowest
position, you must operate all pilot control devices (joystick and pedals) in all directions in order to reduce the actuating and dynamic
pressures in the work circuits. You must then reduce the internal tank pressure as described in these operating instructions.

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Electrical system
• Check the electrical system regularly.Have all faults, such as loose connections, blown fuses and lamps and clogged or abraded
cables rectified by personnel.

• Only use original fuses with approved current strength.

• For machines with electrical neutral and high tension leads:

◦ switch the machine off immediately in the event of malfunctions in the power supply.

• Work on the machine’s electrical equipment may only be carried out by skilled electrical personnel or by trained personnel under the
supervision of an electri­cian 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 in­sulated tools.

• When working on neutral and high tension subassemblies, after releasing the voltage, briefly disconnect the supply cable at earth and
electronic devices such as capacitors using an earthing rod.

• First test the released parts to make sure that they are off circuit, earth them and then disconnect them briefly. Insulate adjacent live
parts.

• Disconnect the battery before working on the electrical system or carrying out any electric arc welding on the machine.First disconnect
the negative, then the positive pole. When reconnecting, proceed in the reverse order.

Hydraulic accumulator
• All work on the hydraulic accumulators must be carried out by trained specialist personnel.

• Inexpert assembly and handling of hydraulic accumulators can cause serious ac­cidents.

• Do not operate damaged hydraulic accumulators.

• Before working on a hydraulic accumulator, you must reduce the pressure in the hydraulic system (hydraulic system including
hydraulic tank), as described in these operating instructions.

• Do not carry out welding or soldering or do any mechanical work on the hydraulic accumulator.The hydraulic accumulator can be
damaged by heat penetration and can be made to rupture by mechanical working. RISK OF EXPLOSION!

• Only charge the hydraulic accumulator with nitrogen. There is a RISK OF EXPLO­SION if oxygen or air is used.

• The accumulator body can become hot during operation; there is a risk of burning.

• New hydraulic accumulators must be charged with the pressure required for the purpose of use before installation.

• The operating data (minimum and maximum pressure) are marked permanently on hydraulic accumulators. Ensure that this marking
remains visible.

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Hydraulic lines and hoses

• It is forbidden to carry out repair work on hydraulic lines and hoses!

• All lines, hoses and bolt connections must be checked regularly for externally visible damage and any possible damage must be
immediately checked for leakage.

• Never check for leaks with your bare hands, use a sheet of paper or something else.

• Any damaged parts must be removed immediately! Spurting oil can lead to injury and burns.

• Even with correct storage and permitted load, lines and hoses are subject to the natural aging process. This restricts their duration of
use.

◦ Incorrect storage, mechanical damage and unauthorized load are the most common causes of failure.

◦ In relation to duration of use, current norms, regulations and guidelines pertaining to lines and hoses at place of use must be
adhered to.

◦ Use at the limit range of permissible load can shorten duration of use (e.g. high temperatures, frequent movement cycles, extremely
high pulse frequencies, multiple shift usage).

• Lines and hoses should be replaced if the following are found during inspection:

◦ Damage to the outer sheath as far as the liner (e.g. chafing, cuts and cracks);

◦ Brittleness of the outer sheath (fracture formation in hose material);

◦ Deformations which do not correspond to the natural form of the line or hose, whether in a unpressurized or pressurized state or on
bends e.g. sheath sepa­ration, blistering;

◦ Unsealed areas;

◦ Non-adherence to requirements during installation;

◦ Damage or deformations to the hose fittings which reduce the tightness of the fittings or the hose / fitting connection;

◦ Hoses working themselves out of the fittings;

◦ Corrosion of the fittings which reduces function and tightness;

• When replacing lines and hoses, use only original replacement parts.

• Install and mount lines and hoses correctly. Do not mix up the connections.

• The following is to be noted when replacing lines and hoses:

◦ Always ensure that the lines and hoses are installed free of torsion. For high-pressure hoses, the screws from the half-clamps or full
flange must always be attached to both hose ends and should only be tightened afterwards.

◦ When tightening the flange on high-pressure lines and hoses with bent fittings, the side with the bent fitting must always be
tightened first and then the side with the straight fitting tightened afterwards.

◦ Any mounting clamps which are located in the centre of the hose may only be attached and tightened subsequently.

◦ Check daily to ensure that all clamps, covers and protective devices are properly fastened. Doing this will prevent vibration and
damage during operation.

◦ Install the lines and hoses in such a way that they cannot chafe on other lines, hoses or parts.

◦ A minimum distance from other parts of approx. half the exterior diameter of the hose is recommended. The distance should not,
however, be less than 10 to 15 mm.

◦ When replacing the lines or hoses on moving parts (e.g. from the boom to the stick), check before initial start-up that there are no
chafing areas in the entire area of movement.

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Disposal

Disposal of the machine

• Make sure that the individual elements of the machine are disposed of correctly after the service life in accordance with all applicable
national, regional or local regulations for waste disposal and environmental protection.

• Remove fuel, lubricants and operating fluids from all components before disposal.

Disposal of gas tanks and pressurized tanks

• Release the pressure fully from the pressurized tanks before disposal.

• Remove all fluids or gas from the tanks before disposal.

• Obey the instructions of the tank manufacturer for disposal.

Disposal of fuel, lubricants, operating fluids and consumables

• Collect and store fuel, lubricants and operating fluids in applicable containers be­fore disposal.

• Have fuel, lubricants and operating fluids disposed of in an applicable recycling point.

• Have refrigerant disposed of only by a trained air-conditioning and refrigeration technician.

• Obey the instructions of the fuel, lubricants and operating fluids manufacturer for disposal.

• Have metal parts disposed of in an applicable recycling point.

• Have plastic parts disposed of in an applicable recycling point.

• Have rubber parts disposed of in an applicable recycling point.

• Have electronic components disposed of in an applicable recycling point.

From: Operator's manual R 9200 - 410 > Safety instructions

3.5 | Signs on the machine

From: Operator's manual R 9200 - 410 > Safety instructions

3.5.1 | Introduction

The excavator comprises several types of signs:

• the safety plates provide warnings relating to dangers of accidents which could result in serious injury or death.

• the information plates indicate specific points relating to the operation, mainte­nance and characteristics of the machine.

• the nameplates are attached to components for which the machine serial num­ber must be provided when ordering spare parts.

DANGER!
Non-observance of safety plates can result in serious injury or death.

• ▶ Check warning plates regularly to ensure that they are complete and clearly leg­ible.
• ▶ Replace missing or illegible safety and information plates immediately. You will find the ordering numbers of these
plates in the spare parts book of the excava­tor.

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From: Operator's manual R 9200 - 410 > Safety instructions > Signs on the machine

3.5.2 | Arrangement and explanations of signs

Figure 1. Arrangement of signs on the machine

2 Typeplate LEC "CE" / "EAC" 30 Pumps installation label

3 Typeplate LEC 31 Label of the valve bank configura­tion (in the pumps box)

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4 Typeplate LAM 36 Emergency exit label

5 Typeplate LBR "CE" / "EAC" 40 Warning label
6 Typeplate LBR 44 Warning label
10 Restricted area label 48 Warning label
11 Maximum charge label 54 Door-closing label
12 Emergency stop label 56 Warning label
20 Danger signal 70 Emergency ladder label
21 Label safety belt 99 Warning according to Proposition 65 (for the U.S. market)
22 Label safety lever 100 Warning according to Proposition 65 (for the U.S. market)
23 Warning label - hydraulic valve 104 Label for the air conditioning sys­tem (*location depending on the machines)
25 Warning label 105 Arctic package label (optional equipment)
26 Controls adhesive label 600 Oil cooler box
27 Warning label 650 Engine cooler box
28 Ladder label 850 Valve bank

Plate 2: Typeplate LEC (Liebherr-Mining Equipment Colmar SAS) "CE" / "EAC"

This typeplate gives the following information:

• product identification number

• type
• construction month and year
• nominal engine power
• maximum speed
• operating mass*

Plate 3: Typeplate LEC (Liebherr-Mining Equipment Colmar SAS)

This typeplate gives the following information:

• product identification number

• type
• construction year
• nominal engine power
• maximum speed
• operating mass*

Plate 4: Typeplate LAM (Liebherr America)

This typeplate gives the following information:

• type
• product identification number

Plate 5: Typeplate LBR (Liebherr Brazil) "CE" / "EAC"

This typeplate gives the following information:

• product identification number

• type
• construction month and year
• nominal engine power
• maximum speed
• operating mass*

Plate 6: Typeplate LBR (Liebherr Brazil)

This typeplate gives the following information:

• product identification number

• type
• construction year
• nominal engine power
• maximum speed
• operating mass*

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* Estimated mass of the machine in its standard version (without optional equipment) according to its
configuration: Diesel, electric, backhoe, shovel or pontoon.
Plate 10: Restricted area label
Indicates access restriction to the related area.

Plate 11: Maximum charge label

Indicates the maximum allowable charge on the access ladder.

Plate 12: Emergency stop label

Indicates an emergency stop.

Plate 20: Danger signal label

Indicates to stay out of the surrounding operating area in order to avoid severe injury.

Plate 21: Safety belt label

Indicates to always seat belt while operating the excavator.

Plate 22: Safety lever label

Indicates precaution to be taken before leaving the driver seat.

Plate 23: Hydraulic tank shut-off valves label

Indicates precaution to be taken before starting the excavator.

Plate 25: Operating manual label

Indicates that the informations in the Operating manual must be carefully noted.

Plate 26: Information about control symbols

Schematic representation of the correlation between the main controls in the cab and the induced
actions for the operation of the excavator.

Plate 27: First use

Indicates that the informations in the Operating manual must be carefully noted be­fore the first use.

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Plate 28: Manual unlock label

Indicates the manual unlock of the ladder.

Plate 30: Information about the hydraulic pumps assembly

Schematic representation of the pumps installation. This label is installed in the pumps box.

Plate 31: Information about the valve bank configuration

Schematic representation of the components that are installed on the valve bank.

Plate 36: Emergency exit label

Indicates the emergency window.

Plate 40: Burn hazard label

Indicates risks due to hot surfaces and gives associated safety instructions.

Plate 44: Oil injection hazard label

Indicates risks due to oil discharge and gives associated safety instructions.

Plate 48: Explosion hazard label

Indicates explosion risk and gives associated safety instructions.

Plate 54: Door-closing label

Indicates that the concerned door must stay closed during operation.

Plate 56: Rotation blade hazard label

Indicates risks due to rotating blades and gives associated safety instructions.

Plate 70: Emergency ladder label

Indicates the emergency ladder.

Plate 99: Warning according to Proposition 65 (for the U.S. market)

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Plate 100: Warning according to Proposition 65 (for the U.S. market)

Plate 101: Lashing point label

Indicates the location of lashing points on the excavator.

Plate 102: Lifting point label

Indicates the location of lifting points on the excavator.

Plate 103: Anchor point label

Indicates the location of anchor points on the excavator.

Plate 104: Label for the air conditioning system

This label is installed on the air conditioning compressor. It gives the following information about the
material contained in the system:

• type
• designation
• quantity
• Global Warming Potential

Plate 105: Arctic package label (optional equipment)

Gives the applicable working ambient temperature range if the machine has an op­tional arctic package.

From: Operator's manual R 9200 - 410 > Safety instructions > Signs on the machine

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4 | Control and operation

From: Operator's manual R 9200 - 410

4.1 | Operating and control elements

From: Operator's manual R 9200 - 410 > Control and operation

4.1.1 | Overview of the control cab

Figure 1. Control cab

1 Control board U21 Left joystick

E1005 Cab connection box U22 Right joystick
P5 Hour meter U23 Right travel pedal
S100_1 Emergency stop U24 Left travel pedal
S7 Safety lever Display

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Figure 2. Standing position from operator’s point of view

S100_1 Emergency stop U21 Left joystick

S7 Safety lever U22 Right joystick
U23 Right travel pedal
U24 Left travel pedal

Figure 3. Switches configuration on the joysticks

S5L Horn switch S6L Switch for semi-automatic flap closing (for shovel
attachment only)
S5M Not used S6M Not used
S5R Switch for Liebherr Assistance Systems (optional equipment)1) S6R Switch for boom down with pres­sure
S55 Rocker switch up: Liebherr Assis­tance Systems (optional equip­‐ S57 Rocker switch for semi-automatic swing brake (optional
ment)1) equipment)
S55 Rocker switch down, depending on the machines:

• Not used
• Deactivation of the attachment damp­ing system2)
• Bucket Filling Assistant (for backhoe attachment only) (optional
equip­ment)

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1) If installed, refer to the Operator's manual for the Liebherr Assistance Systems.

2) For more information, refer to the Service manual.

From: Operator's manual R 9200 - 410 > Control and operation > Operating and control elements

4.1.2 | Arrangement of joysticks

Figure 1. Joysticks right (U22) and left (U21)

The left joystick (U21) controls the stick and swing movements.

• Direction of movement a and b: Stick is drawn in or out.

• Direction of movement c and d: Uppercarriage turns left or right.

The right joystick (U22) controls the boom and bucket movements.

• Direction of movement e and f: Bucket will be tilted up or down.

• Direction of movement g and h: Boom will be raised or lowered.

From: Operator's manual R 9200 - 410 > Control and operation > Operating and control elements

4.1.3 | Keyboard

Figure 1. Keyboard

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A168 – Powerpack keypad

Decrease the engine speed

• ▶ Push the "Decrease engine speed" button.

◦ ▷ The engine speed decreases to the previous lower step.
• ▶ Push and hold the "Decrease engine speed" button.
◦ ▷ The engine speed decreases continuously.
◦ ▷ The LED in the button flashes until you get the minimum speed.
◦ ▷ The LED in the button is on while the minimum speed is selected.

Increase the engine speed

• ▶ Push and release the "Increase engine speed" button.

◦ ▷ The engine speed increases until the next higher step.
• ▶ Push and hold the "Increase engine speed" button.
◦ ▷ The engine speed increases continuously.
◦ ▷ The LED in the button flashes until you get the maximum speed.
◦ ▷ The LED in the button is on while the maximum speed is selected.

Start / Stop

• ▶ Make sure that the electrical system is switched to on.

• ▶ Push and hold the "Start/Stop" engine button on the keyboard.
◦ ▷ The engine start procedure begins and the first LED in the button comes on.
◦ ▷ First LED in the button goes off when you release the button.
• ▶ Push the "Start/Stop" engine button on the keyboard again.
◦ ▷ The engine turns at minimum speed during a specified interval.
◦ ▷ The right LED in the button and the related symbol on the display flash.
◦ ▷ Then the engine stops. The right LED and the display symbol are on.
◦ ▷ The right LED goes off.
• ▶ Turn the ignition key S1 to position "0" to switch to off the machine.
• ▶ Remove the ignition key S1.

Eco / Power modes

Use this button to switch quickly between "Eco" mode and "Power" mode.

• ▶ Push "Eco / Power modes" button.

◦ ▷ Diesel engine speed is set to "Eco" mode.
◦ ▷ The LED above "Eco" in the button comes on.
• ▶ Push "Eco / Power modes" button again.
◦ ▷ Diesel engine speed is set to "Power" mode (maximum speed).
◦ ▷ The LED above "Power" in the button comes on.

Each time you push this button, the Diesel engine speed switches from one mode to the other.
You can also set the "Power" mode when you set the Diesel engine speed to the last step with "Increase engine speed"
button.

In this case, LPE - Engine Control that follows is not available.

Liebherr Power Efficiency (LPE) Engine Control

Depending on the machines, the Liebherr Power Efficiency (LPE) Engine Control (LPE - Engine Control) adapts the
Diesel engine speed automatically in relation to the machine movements.
In this case, "Eco / Power modes" which are given above are not available. Thus, "Mode" button replaces "Eco / Power
modes" button.

• ▶ Push "Mode" button.

◦ ▷ LPE - Engine Control adapts Diesel engine speed.
◦ ▷ The related LED in the button comes on.
• ▶ Push "Mode" button again.
◦ ▷ The Diesel engine speed is set to idle.
◦ ▷ The related LED in the button goes off.

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Travel brake
The travel brake is applied by default when you start the machine, undercarriage is locked and first LED in the button is
on.

• ▶ Push the button.

◦ ▷ The travel brake is released.
◦ ▷ The undercarriage is unlocked.
◦ ▷ First LED in the button goes off.
• ▶ Push the button again.
◦ ▷ The travel brake is applied.
◦ ▷ The undercarriage is locked.
◦ ▷ The first LED in the button comes on.

The travel brake is applied if the safety lever is up or the access ladder is down or the service trap is down.
Swing brake
The swing brake is applied by default when you start the machine, uppercarriage is locked, and first LED in the button
is on.

• ▶ Push the button.

◦ ▷ The swing brake is released.
◦ ▷ The uppercarriage is unlocked.
◦ ▷ The first LED in the button goes off.
• ▶ Push the button again.
◦ ▷ The swing brake is applied.
◦ ▷ The uppercarriage is locked.
◦ ▷ The first LED in the button comes on.

The swing brake is applied if the safety lever is up or the access ladder is down or the service trap is down.

A169 – Standard functions keypad 1

Windshield wiper

• ▶ Push the button.

◦ ▷ Intermittent mode is activated.
◦ ▷ First LED in the button comes on.

You can set the interval in the submenu "Wiper" of the monitoring display.

• ▶ Push the button again.

◦ ▷ Continuous mode is activated.
◦ ▷ First LED in the button goes off.
◦ ▷ Second LED in the button comes on.
• ▶ Push the button a third time.
◦ ▷ Windshield wiper is switched off.
◦ ▷ Second LED in the button goes off.

Windshield washer

• ▶ Push and hold button.

◦ ▷ Washing water is sprayed onto the windshield through the outlet nozzles.
◦ ▷ Windshield wiper runs continuously.
◦ ▷ First LED in the button comes on.
• ▶ Release button.
◦ ▷ First LED in the button goes off.
◦ ▷ Washing water is stopped.
◦ ▷ Windshield wiper finish its cycle.

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Front working lights / Attachment headlights

• ▶ Push the button.

◦ ▷ Front working lights on the uppercarriage are activated.
◦ ▷ First LED in the button comes on.
• ▶ Push the button again.
◦ ▷ Front working lights and attachment headlights are activated.
◦ ▷ First LED and second LED in the button are on.
• ▶ Push the button a third time.
◦ ▷ Front working lights are deactivated.
◦ ▷ First LED in the button goes off.
◦ ▷ Attachment headlights remain activated.
◦ ▷ Second LED in the button is still on.
• ▶ Push the button a fourth time.
◦ ▷ Attachment headlights are deactivated.
◦ ▷ Second LED in the button goes off.

Rear working lights

• ▶ Push the button.

◦ ▷ Rear top of cab working light is activated.
◦ ▷ First LED in the button comes on.
• ▶ Push the button again.
◦ ▷ Rear counterweight working lights are activated.
◦ ▷ First LED and second LED in the button are on.
• ▶ Push the button a third time.
◦ ▷ Rear top of cab working light is deactivated.
◦ ▷ First LED in the button goes off.
• ▶ Push the button a fourth time.
◦ ▷ Rear counterweight working lights are deactivated.
◦ ▷ Second LED in the button goes off.

A170 – Standard functions keypad 2

Overload warning device (optional)

If installed:

• ▶ Push the button.

◦ ▷ The overload warning device is activated.
◦ ▷ All the LED in the button come on.
• ▶ Do the deactivation procedure.
◦ ▷ The overload warning device is stopped.
◦ ▷ All the LED in the button go off.
• ▶ Refer to the related section for detailed description of the system.

If not installed:

• ▶ Push the button.

◦ ▷ This symbol is shown on the display.
◦ ▷ All the LED in the button are off.
• ▶ Push the button again.
◦ ▷ The symbol on the display goes off.

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Turn of the grapple / shear (optional)

• ▶ Push the button.

◦ ▷ The LED in the button comes on.
◦ ▷ You can turn the grapple / shear with the related operating and control ele­ments.
• ▶ Push the button again.
◦ ▷ The LED in the button goes off.
◦ ▷ The turn function of the grapple / shear is off.

High speed gear

• ▶ Push the button.

◦ ▷ Transfer from normal drive to fast drive is activated.
◦ ▷ First LED in the button comes on.
• ▶ Push the button again.
◦ ▷ Transfer from normal drive to fast drive is deactivated.
◦ ▷ First LED in the button goes off.

Auto Idle
Auto Idle function decreases automatically the Diesel engine speed, for example when the machine is on but you do not
operate it.

• ▶ Push "Auto Idle" button.

◦ ▷ Auto Idle function is on, but it is not activated.
◦ ▷ The LED on the button comes on.
• ▶ If you let the joysticks and pedals in neutral position during the specified Auto Idle interval:
◦ ▷ Auto Idle function is activated.
◦ ▷ The Diesel engine speed decreases automatically.
◦ ▷ The automatic speed adjustment and the Diesel engine speed are stored. The related symbol flashes on the
display.

You can set the Auto Idle interval in the submenu "Auto Idle control" of the monitoring display.

• ▶ If you push "Increase engine speed" button while Auto Idle function is activated:
◦ ▷ The Diesel engine speed does not change.
◦ ▷ The new step is stored.
• ▶ If you push "Decrease engine speed" button while Auto Idle function is activated:
◦ ▷ If the new step is higher than the Auto Idle speed, the Diesel engine speed does not change and the new step
is stored.
◦ ▷ If the new step is lower than the Auto Idle speed, Auto Idle function is deacti­vated.
• ▶ If you operate the joysticks or the pedals:
◦ ▷ Auto Idle function is deactivated.
◦ ▷ The Diesel engine speed is set to the stored value.
• ▶ Push "Auto Idle" button again.
◦ ▷ Auto Idle function is off.
◦ ▷ The LED on the button goes off.

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Auto Idle if LPE - Engine Control is installed

Auto Idle function decreases automatically the Diesel engine speed, for example when the machine is on but you do not
operate it.

• ▶ Push "Auto Idle" button.

◦ ▷ Auto Idle function is on, but it is not activated.
◦ ▷ The LED on the button comes on.
• ▶ If you let the joysticks and pedals in neutral position during the specified Auto Idle interval:
◦ ▷ Auto Idle function is activated.
◦ ▷ The Diesel engine speed decreases automatically.
◦ ▷ The automatic speed adjustment and the Diesel engine speed are stored. The related symbol flashes on the
display.

You can set the Auto Idle interval in the submenu "Auto Idle control" of the monitoring display.

• ▶ If you push "Increase engine speed" button or "Decrease engine speed" button while Auto Idle function is activated

or

• ▶ If you operate the joysticks or the pedals:

◦ ▷ Auto Idle function is deactivated.
• ▶ Push "Auto Idle" button again.
◦ ▷ Auto Idle function is off.
◦ ▷ The LED on the button goes off.

Bucket Filling Assistant (for backhoe attachment only) (optional equipment)

If installed, the Bucket Filling Assistant is automatically on when you start the ma­chine.

• ▷ The first LED in the button is on.

• ▶ Push the button.

◦ ▷ The functions of the Bucket Filling Assistant are off.
◦ ▷ The first LED in the button goes off.
• ▶ Push the button again.
◦ ▷ The functions of the Bucket Filling Assistant are on again.
◦ ▷ The first LED in the button comes on.

Automatic stick draw in (for shovel attachment only) (optional equipment)

• ▶ Push the button.

◦ ▷ The function is on, but it is not activated.
◦ ▷ The LED in the button comes on.
◦ ▷ If necessary during the work of the machine, the function is automatically ac­tivated and helps draw in the stick.
• ▶ Push the button again.
◦ ▷ The function is off.
◦ ▷ The LED in the button goes off.

A171 – Optional functions keypad

Special button for maintenance

Special button for maintenance

A171 Optional functions keypad

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1 Depending on the machines:

• Not used
• Special button for maintenance (de­activation of the attachment damping system and other functions) 1

1) For more information, refer to the Service manual.

Second air-conditioning system (optional equipment)

By default, the two air-conditioning units operate alternately. Thus, the first and sec­ond LED in the button come on.
But it is also possible to select only one air-conditioning unit.

• ▶ Push the button.

◦ ▷ Automatic air-conditioning mode is deactivated.
◦ ▷ First air-conditioning unit is operated.
◦ ▷ Second air-conditioning unit is deactivated.
◦ ▷ First LED in the button comes on.
◦ ▷ Second LED in the button goes off.
• ▶ Push the button again.
◦ ▷ First air-conditioning unit is deactivated.
◦ ▷ Second air-conditioning unit is operated.
◦ ▷ First LED in the button goes off.
◦ ▷ Second LED in the button comes on.
• ▶ Push the button a third time.
◦ ▷ Automatic air-conditioning mode is operated again.
◦ ▷ First and second LED in the button come on.

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From: Operator's manual R 9200 - 410 > Control and operation > Operating and control elements

4.1.4 | Cab control board

Figure 1. Control board

Standard functions: ECM engine monitoring system:

S1 Ignition key H60 ECM STOP indicator
S8 Internal cabin lighting H61 ECM WARNING indicator
S100_1 Emergency stop H62 ECM PROTECTION indicator
S122 Disable access ladder or trap control lock S82_1 Diagnostic increment
S126 External cabin lighting S82_2 Diagnostic decrement
S177 Winter position for the central­ized lubrication system (op­tional) S85 ECM monitoring ON/OFF
S233 Manual preheating of electri­cal boxes (if applicable) Safety operation engine:
S256 Rotary switch for control se­lection (if installed) S23 Diesel engine safety operation ON
H68 Trap control lock R6 Speed adjustment of the Die­sel engine
H92 Fire alarm (optional)

Air-conditioning: Greasing:
U103_1 Air-conditioning module A15 Greasing module
U103_2 Optional air-conditioning mod­ule (if installed)

Radio: Keyboard:
A2 Radio A168 PowerPack keypad
A169 Standard functions keypad 1
A170 Standard functions keypad 2
A171 Optional functions keypad

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Disable access ladder or trap control lock

• ▶ For further information about correct use of this function, refer to section "Entering or leaving the cab" or "Service Trap" of this
manual.

ECM (Electronic Control Module) engine monitoring system

If an indicator H60, H61 or H62 comes on during operation, test switches S82_1 and S82_2 will allow the engine maintenance mechanics
to ask system to indicate the re­corded default by giving a coded message via the control light.

• ▶ For further information, see Cummins Operation Manual.

Safety operation functions

• ▶ For further information about correct use of these functions, refer to section "Emergency operations" of this manual.

From: Operator's manual R 9200 - 410 > Control and operation > Operating and control elements

4.1.5 | Monitoring display

Figure 1. Monitoring display

1 Screen 3 Ambient luminosity sensor

2 Control buttons 4 Power indicator

Screen

NOTE!
The screen luminosity is automatically adjusted depending on the environmental lu­minosity detected by the sensor 3.

Control buttons
The control buttons F1, F2, F3, F4, F5, F6, F7 and F8 allow to switch between the different menus and to use the functions available on
the display.

Each button is aligned with the menu or function (represented on the bottom of the screen) it is associated with.

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From: Operator's manual R 9200 - 410 > Control and operation > Operating and control elements

4.1.6 | Menus and functions of the display

Main screen

The main screen comes on first when the machine is started. It shows different information and gives access to the
machine menus and functions.

• ▶ Push the "Main screen" button to go back to this menu from all others menus.

Figure 1. Main screen on cab display

The main screen is divided into four fields:

• the general information

• the dials and the error warning symbols

• the camera views

• the buzzer and the links to access the monitoring menus

General indicator field

Figure 2. General indicator field

1 General indicator field

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The upper field 1 shows time information and general indicator symbols. Each symbol has a specified location on the field. If two symbols
must flash on the same place, they flash alternatively.

• ▶ For symbols description, refer to the section "Indicator and error warning sym­bols".

Dials and error warning symbols field

Figure 3. Dials and error warning symbols field

2 Dials and error warning symbols field

The central field 2 shows measured values and error warning symbols.

Dials
The measured values that follow are represented with dial indicators:

Temperature of the Diesel engine coolant (°C) Battery voltage (V)

Fuel level (%) Hydraulic oil temperature (°C)

Diesel engine speed (min-1)

The related numerical value is also shown under the dial needle.

If a measured value is out of the possible range (e.g. in case of defective sensor):

• The related dial needle goes under the minimal value.

• The numerical value is shown in its field.

• ▶ In this case, contact LIEBHERR customer service.

If the signal transmitting communication is broken:

• The related dial needle goes under the minimal value.

• The messages below are shown:

◦ "NO SIGNAL!"

◦ "-50" for standard values (e.g. temperature, pressure)

◦ "-1" for strictly positive values (e.g. percentage, speed)

• ▶ In this case, contact LIEBHERR customer service.

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Error warning symbols

The error warning symbols can be shown anywhere in the central field 2. If all the symbol locations are on, the system show the most
important symbols.

If the same error occurs on different elements, the error symbol is on and the different related parameters flash alternatively.

• ▶ For errors description, refer to the section "Indicator and error warning symbols".

Camera views

Figure 4. Camera views

3 Camera views field

The main screen has two windows 3, which show the image from the monitoring cameras.

• ▶ Push the "Main screen" button to go back to the camera views from all others menus.

Buzzer and links field

Figure 5. Links field

4 Buzzer and links field

With the lower field 4, you can get access to different functions.

"Buzzer" function
The buzzer symbol is off (black color) until an error message occurs. When it occurs, the buzzer symbol becomes grey and the buzzer
sounds.

• ▶ When the buzzer sounds, push the "Buzzer" button to switch it to off.

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Links to the monitoring menus

The available monitoring menus from the main screen are:

• Menu "Diag"

• Menu "Check"

• Menu "Info"

• Menu "Settings".

Monitoring menus

Select a monitoring menu

Figure 6. Monitoring menus

Select a submenu
From each monitoring menu:

• ▶ Push the "Up" and "Down" buttons to select the necessary submenu.

• ▶ Push the "Accept" button to access to the selected submenu.

Return to the monitoring menu

From each submenu:

• ▶ Push the "Return" button to go back to the related monitoring menu.

Menu "Diag"

When an error occurs on the machine, the symbol of the menu "Diag" flashes red on the main screen. This symbol
continues to flash until there are errors not acknowl­edged or not rectified.

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Figure 7. Menu "Diag"

• ▶ Push the safety lever up to see the error messages.

A code number and a short description are shown for each error code.

• ▶ Push the "Up" and "Down" buttons to select an error message.

• ▶ Push the "Acknowledgement" button to acknowledge the error.

DANGER!
If the error shown on the display is not rectified immediately, this could cause injuries to persons or damages to the
machine.

• ▶ Rectify / have the error rectified immediately.

If you want to change the language of the messages:

• ▶ Refer to the menu "Settings".

Menu "Check"

This menu gives access to the submenus that follow:

Figure 8. Submenus of the menu "Check"

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Submenus:

Engine This submenu shows in real time different parameters values of the engine.

Inputs Attachment This submenu shows the status of digital and analogical inputs of the machine attachment.

Inputs / Outputs This submenu shows the status of digital and/or analogical:

• control inputs and/or movement inputs of the machine

• control general outputs of the machine

Steering This submenu shows the inputs status of:

• the primary electronic control of the ma­chine

• optional electronic controls

Submenu "Engine"

This submenu shows the information that follows:

Torque shown through a dial indicator and a numerical value Engine load rate

Engine speed shown through a dial indicator and a numerical value Intake manifolds pressure

Fuel rate shown through a dial indicator and a numerical value Engine coolant temperature

Status of mode "Safety start" (status light) Hydraulic oil temperature

Engine speed Barometric pressure

If a measured value goes out of the possible range:

• The related dial needle goes over the exceeded value.

If a measured value is missing:

• The related dial needle goes below the minimum value.

• The specified values below are shown:

◦ "-50" for temperature values

◦ "-1" for strictly positive values (e.g. percentage, pressure, current)

• ▶ In this case, contact LIEBHERR customer service.

Submenu "Inputs Attachment"

This submenu shows the information that follows:

• boom cylinder pressure

• boom angle
• rate of boom angular stroke

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• stick cylinder pressure

• stick angle
• rate of stick angular stroke

• bucket cylinder pressure

• bucket angle
• rate of bucket angular stroke

If a value connected to a position is out of the possible range:

• It is replaced by dots.

If a value is missing:

• "-1" is shown.

• ▶ In these cases, contact LIEBHERR customer service.

Submenu "Inputs / Outputs"

This submenu shows the information that follows:

Status lights Numerical values

Status of swing lock Splitterbox

temperature

Status of travel lock Splitterbox

pressure

Status of the air Swing speed

conditioning

Status of boom down Control pressure

with pressure

Status of the safety

lever

Status of the optional

semi-automatic swing
brake

If a value connected to a position is out of the possible range:

• It is replaced by dots.

If a value is missing:

• "-1" is shown.

• ▶ In these cases, contact LIEBHERR customer service.

Regulating solenoid valve of hydraulic oil Regulating solenoid valve of engine cooling
cooling

Flow control valves Regulating solenoid valve of power regulator of working

pumps

Working pump P# tempera­ture (if installed)

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Submenu "Steering"

This submenu shows the information that follows:

Solenoid valve of swing left (status light) Pedals left (L ) and right (R ) movements in forward and
rearward directions

Solenoid valve of swing right (status light) Pedal for special and/or optional controls (if installed)

Adjustment solenoid valve of swing left Joysticks left (L ) and right (R ) movements in all direc­tions

Adjustment solenoid valve of swing right Uppercarriage swing

Analog stick for special and/or optional controls

(if installed)

Menu "Info"

This menu gives access to the submenus that follow:

Figure 9. Submenus of the menu "Info"

Submenus:

Excavator This submenu shows the parameters of the machine (type, serial number, ...).

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Hours This submenu shows hour counters of:

• the machine working time

• the time during which the machine was on specified working mode
• the working time of special and/or op­tional tools (if installed)

Counter Engine This submenu shows different types of hour counters related to the engine life.

Counter User This submenu shows the different types of hour counters managed by the opera­tor.

Services This submenu shows the hour counters of the scheduled maintenance intervals of the engine and the
(optional) hydraulic system.

Submenu "Excavator"

This submenu shows the information that follows:

Version of software Type of engine

Type of machine Type of attachment

Serial number of the machine Type of cooling

Submenu "Hours"

This submenu shows the information that follows:

Working time of the engine Working time of working pumps

Working time of the machine Working time of the engine with its speed lower than
1000 RPM

Working time during which the machine was in swing Working time of the engine with its speed lower than
mode 1400 RPM

Working time during which the machine was in travel

mode

The hour counters related to the engine (working time and RPM) are set to zero if the engine is replaced. Thus, these values are related
to one specified engine.

The other values are related to the machine.

The following information is available when you can install optional special tools on the machine.

Working time of special tool (if installed) Working time of special rotary tool (if installed)

Submenu "Counter Engine"

This submenu shows the information that follows:

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Mode of working "Eco" Hours spent in the related mode of working

Mode of working "Power" Average engine power dur­ing the related period

Total of the two modes of working E and P Fuel consumption during the related period

Submenu "Counter User"

This submenu shows the same information as the submenu "Counter Engine", but it can be managed by the
operator.

• ▶ Push the "Reset" button to set to zero all the counters of this submenu.

Submenu "Services" (optional)

This optional submenu shows information about scheduled maintenance intervals. You can also confirm that you
have done the related maintenance task.

The available maintenance intervals of this submenu are scheduled into time ranges, that are set by a Liebherr service personnel.

When the machine gets a minimum range value:

• ▷ This symbol is shown on the main screen to tell you that a scheduled mainte­nance task is necessary.
• ▷ It flashes temporarily when you start the machine. Then, it stays on until the machine gets the maximum value of the
time range.

Thus, you can see working hours in this submenu:

• the last completed maintenance interval

• the remaining time before the next scheduled maintenance interval

Hours related to the engine

Hours related to the hydraulic system

When the necessary maintenance task is done:

• ▶ Push the "Up" and "Down" buttons to select the applicable symbol.

• ▷ The applicable symbol is shown by a white frame.

• ▶ Push the "Accept" button to confirm that the related maintenance task is done.
◦ ▷ The system records the time of this task.
◦ ▷ It calculates the next scheduled maintenance interval.

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Menu "Settings"

This menu gives access to the submenus that follow:

Figure 10. Submenus of the menu "Settings"

Submenus:

Time This submenu is used to set the time.

Auto idle control This submenu is used to set the auto idle interval of the auto idle function.

Wiper This submenu is used to set the wind­screen wiper interval.

Brightness This submenu is used to set the lumines­cence of the display.

Language This submenu is used to set the language in which the error codes are written.

Set a parameter
From each submenu of the menu "Settings":

• ▶ Push the safety lever up.

• ▶ Push the "Up" and "Down" buttons to select the parameter to set (time, value or language).

• ▶ Push the "Accept" button to record the new parameter.

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Submenu "Time"

You can also use this submenu to switch from summer to winter time (and back again).

• ▶ Push the "Daylight" button.

• ▷ This symbol is transparent when the time difference of an additional hour is de­activated.

• ▷ This symbol is green when it is activated.

Submenu "Brightness"

To use this submenu, you must before select the manual mode.

• ▶ Push the "AUTO" button.

Automatic mode

Manual mode

• ▷ Each time you push this button, the status light related to the selected mode comes on.

Indicator and error warning symbols

The symbols which are shown on the main screen give information about the conditions, the setting and the possible malfunctions of the
machine.

There are two types of symbols:

• The indicator symbols which are shown in the field 1.

• The error warning symbols which are divided into two groups:

◦ the engine error symbols shown in the field 5

◦ the other error symbols shown in the field 6

Figure 11. Indicators and error warnings on the main screen

1 General indicator symbols

5 Engine error symbols
6 Other errors symbols

• ▶ For symbols description, refer to the sections that follow.

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General indicator symbols (1)

The indicator symbols give information about the conditions and the setting of the machine. They are related to functions activated with
the keyboard.

Travel brake closed

This symbol is shown if the Travel brake button has been pressed on the control key­board.

Swing brake closed

This symbol is shown if the Swing brake button has been pressed on the control key­board.

Swing brake closed during uppercarriage swing movement

This symbol is shown if the Swing brake button has been pressed on the control key­board while the uppercarriage turns.

• ▷ A buzzer is activated in the cab.

Brakes manu
This symbol is shown if the Safety Brake Control has been allowed through emer­gency functions.

Power Control off

This symbol is shown if the Power Control Manu has been allowed via emergency functions.

Flow Control off

This symbol is shown if the Flow Control Manu has been allowed via emergency functions.

Fan Control off

This symbol is shown if the Fan Control off has been allowed via emergency func­tions.

Speed Control off

This symbol is shown if the Speed Control Manu has been allowed via emergency functions.

Preheating on
This symbol is shown while preheating is occurring.

Shovel movement blocked

This symbol is shown if the shovel movement is blocked (when grease level is low or when the track tensioning procedure
is in progress).
Pumps in Qmin
This symbol is shown when the working pumps flow rate is limited.

High Speed Gear

This symbol is shown if the High Speed Gear button has been pressed on the control keyboard.

Hydraulic oil temperature high

This symbol is shown if the hydraulic oil temperature is more than a specified oper­ating value.

• ▷ A buzzer is activated in the cab.

Hydraulic oil temperature low

This symbol is shown if the hydraulic oil temperature is below a specified operating value at the excavator start.

• ▷ The working pumps are automatically limited to 50%.

• ▷ The maximum limitation time of the working pumps is set to 15 minutes.

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Self-diagnostic of hydraulic pumps adjustment (if installed)

This symbol is shown during the self-diagnostic of the hydraulic pumps adjustment, which automatically operates at a
preset interval if the following preconditions are met:

• The Diesel engine operates at idle during a preset time.

• The hydraulic oil temperature is more than a preset value.
• The safety lever is in the down position.
• You do not operate movements with the machine.

During this self-diagnostic:

• ▷ You can hear hydraulic pumps noises.

• ▷ You can move the joysticks and the pedals at all times to operate the machine. In this case:

• The self-diagnostic stops immediately.

• It will automatically start when the preconditions are met again.

At the end of this self-diagnostic:

• ▷ If it is not necessary to adjust the hydraulic pumps, the symbol goes off and the function is off.
• ▷ If it is necessary to adjust the hydraulic pumps:

• If possible, the system adjusts them automatically.

• If the system cannot adjust them automatically, a dedicated error code is record­ed.
• ▶ Go to the monitoring menu "Diag". Refer to the related section of this manual.

Service necessary (optional)

This symbol is shown when a scheduled maintenance task is necessary.

• ▷ The symbol flashes temporarily when you start the machine.

• ▷ This symbol stays on until the specified time range is applicable.

• ▶ Go to the submenu "Services" of the monitoring menu "Info". Refer to the related section of this manual.

Engine error symbols (5)

The engine error symbols show malfunctions of the engine in the field 5.

These symbols have:

• an index which gives the affected element

• a symbol related to the error

• a background color (yellow or red) which gives the severity of the problem

Figure 12. Example of engine error symbol

Three symbols can be shown in the field 5. The most important symbol is shown in higher location. The less important symbol is shown
in lower location.

If the same error occurs on different indexed elements, the error symbol is on and the different index flash alternatively.

If all the error symbol locations are on, the system show the most important symbols.

Low engine oil pressure

This symbol is shown if the engine oil pressure falls below a specified operating val­ue.

• ▷ Perform engine power derate and motor stop procedure.

• ▶ Find and rectify the cause of the problem (see engine Operating and Maintenance Manual).

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Crankcase pressure high

This symbol is shown if the crankcase pressure exceeds a given operating value.

• ▷ Engine will undergo full derate.

• ▶ Find and rectify the cause of the problem (see engine Operating and Maintenance Manual).

Coolant pressure low

This symbol is shown if the coolant pressure drops below a given operating value.

• ▷ Engine will undergo power and speed derate and motor stop procedure.

• ▶ Find and rectify the cause of the problem (see engine Operating and Maintenance Manual).

Intake manifold overheating

This symbol is shown if the intake manifold temperature is more than a specified op­erating value.

• ▶ Find and rectify the cause of the problem (see engine Operating and Maintenance Manual).

Fuel overheating
This symbol is shown if the fuel temperature is more than a specified operating value.

• ▷ Perform engine speed derate.

• ▶ Find and rectify the cause of the problem (see engine Operating and Maintenance Manual).

Rail overpressure
This symbol is shown if the fuel rail pressure is more than a specified operating value.

• ▷ Perform engine power and/or speed derate.

• ▶ Find and rectify the cause of the problem (see engine Operating and Maintenance Manual).

Engine oil temperature high

This symbol is shown if the engine oil temperature exceeds a given operating value.

• ▷ Engine will undergo torque derate.

• ▶ Find and rectify the cause of the problem (see engine Operating and Maintenance Manual).

Engine shutdown necessary

This symbol is shown on the related dial indicator (field 2) if a engine shutdown is required.

Coolant overheating
This symbol is shown next to the coolant temperature dial indicator (field 2) if the coolant temperature is more than a
specified operating value.

• ▶ Find and rectify the cause of the problem (see engine Operating and Maintenance Manual).

High fuel pressure

This symbol is shown if the fuel pressure is above the safety limit.

Low fuel pressure

This symbol is shown if the fuel pressure is below the safety limit.

Engine electronic default (EDC)

This symbol is shown if an engine electronic default (EDC) is sensed.

Water in fuel
This symbol is shown if water has accumulated in the fuel filter.

• ▶ Drain water from the fuel filter.

Overspeed of Diesel engine

This symbol is shown if the RPM of the Diesel engine is above the safety limit.

Injection default
This symbol is shown if an injector default is sensed.

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Engine start at low coolant temperature

This symbol is shown as long as the engine coolant temperature is below a specified value.

• ▶ Avoid start the Diesel engine and operating the excavator under these conditions if the excavator does not have an
optional preheating system.
• ▶ If the excavator has an optional preheating system, operate the preheating sys­tem first until the symbol goes off.

Engine oil level

This symbol is shown if it is necessary to do a check of the engine oil level.

• ▶ Stop operation.
• ▶ Find and rectify the cause of the problem.

Engine oil differential pressure

This symbol is shown if there is a difference between the oil pressures before and after filtration.

• ▷ It is possible that the Diesel engine undergoes power derate.

• ▶ Find and rectify the cause of the problem (see engine Operating and Maintenance Manual).

Engine oil level in Centinel system (if installed)

This symbol is shown if it is necessary to do a check of the engine oil level in the Cen­tinel system (if installed).

• ▶ Stop operation.
• ▶ Find and rectify the cause of the problem.

Engine oil change necessary

This symbol is shown if it is necessary to change the engine oil.

• ▶ Stop operation.
• ▶ Find and rectify the cause of the problem.

Other error symbols (6)

The other error symbols show other malfunctions of the machine in the field 6.

These symbols have the same structure as above.

Three symbols can be shown in the field 6. The most important symbol is shown in higher location. The less important symbol is shown
in lower location.

If the same error occurs on different indexed elements, the error symbol is on and the different index flash alternatively.

If all the error symbol locations are on, the system show the most important symbols.

Splitterbox oil overheating

This symbol is shown if the splitterbox oil temperature is more than a specified oper­ating value.

• ▶ Stop operation and turn the engine to off.

• ▶ Find and rectify the cause of the problem.

Servo oil pressure low

This symbol is shown if the servo oil pressure decreases to less than a specified op­erating value.

• ▶ Stop operation and turn the engine to off.

• ▶ Find and rectify the cause of the problem.

Servo oil pressure high

This symbol is shown if the servo oil pressure is more than a specified operating val­ue.

• ▶ Stop operation and turn the engine to off.

• ▶ Find and rectify the cause of the problem.

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Coolant level low

This symbol is shown if the coolant level decreases to less than the minimum level.

• ▶ Stop operation and turn the engine to off.

• ▶ Find and rectify the cause of the problem.
• ▶ Add coolant to get the correct level.

Splitterbox oil pressure low

This symbol is shown if the splitterbox oil pressure decreases to less than the mini­mum level.

• ▶ Stop operation and turn the engine to off.

• ▶ Find and rectify the cause of the problem.

Battery level high

This symbol is shown if the battery level is more than a maximum level.

• ▶ Stop operation and turn the engine to off.

• ▶ Find and rectify the cause of the problem.

Battery level low

This symbol is shown if the battery level decreases to less than the minimum level.

• ▶ Stop operation and turn the engine to off.

• ▶ Find and rectify the cause of the problem.

Battery charging
When the excavator is operating, this symbol is shown if the V-belt alternators or the electrical charging system are
defective.

• ▶ Put the engine to low idle immediately.

• ▶ Allow the engine to idle for approximately 5 seconds.
• ▶ Switch to off the engine.
• ▶ Rectify the error.

Hydraulic oil overheating

This symbol is shown if the hydraulic oil temperature is more than a specified oper­ating value.

• ▶ Stop operation and let the engine run at high idle until the symbol disappear.

If necessary:

• ▶ Turn the engine to off.

• ▶ Find and rectify the cause of the problem.

Hydraulic oil level low

This symbol is shown if the hydraulic oil level decreases to less than the minimum level.

• ▷ Pumps are automatically set to minimum flow.

• ▶ Stop operation and turn the engine to off.

• ▶ Find and rectify the cause of the problem.
• ▶ Add hydraulic oil to get the correct level.

Pump temperature high (if installed)

This symbol is shown if the temperature of one of the working pumps or that of the swing pump is more than a given
operating value.

• ▶ Stop operation and stop the Diesel engine.

• ▶ Find and rectify the cause of the problem.

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Pump contamination (if installed)

This symbol is shown if metallic particles have been deposited on the contamination switch of one of the working pumps
or that of the swing pump.

• ▶ Stop operation and stop the Diesel engine.

• ▶ Find and rectify the cause of the problem.

Grease level low

This symbol is shown if the grease level falls below the minimal level.

• ▶ Stop operation and turn the engine to off.

• ▶ Find and rectify the cause of the problem.
• ▶ Add grease to get the correct level.

Greasing failure
This symbol is shown if a failure occurs on the lubrication system.

• ▶ Stop operation and turn the engine to off.

• ▶ Find and rectify the cause of the problem.

Greasing module not in operation

Only available with the greasing module A15, this symbol is shown if a failure occurs on the module.

Lifetime sealing interspace oil level high (optional)

This symbol is shown if the oil level in the Lifetime sealing interspace is more than the maximal level.

• ▶ Stop operation and turn the engine to off.

• ▶ Find and rectify the cause of the problem.

Lifetime sealing interspace oil level low (optional)

This symbol is shown if the oil level in the Lifetime sealing interspace is below the minimal level.

• ▶ Stop operation and turn the engine off.

• ▶ Find and rectify the cause of the problem.
• ▶ Add oil until you get the correct level.

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From: Operator's manual R 9200 - 410 > Control and operation > Operating and control elements

4.2 | The access and the outfit of the cab

Safely getting up
• Proceed with the same precautions to climb up or down onto the machine, as to install yourself at the operator’s seat.

• When getting up or down, position the machine on even, horizontal ground. The upper structure should be positioned with the
undercarriage in such a way that the steps and ladders are aligned with each other.

• Ensure that steps, ladders and hand-rails (grips) are in good condition. In particular, you should ensure that they are free of dirt, oil, ice
and snow. NOTE: To ensure that the doors open properly in all weather conditions, the door seals must be dusted with talc or silicon at
least every two months or more often if required. The door hinges and locks should be greased regularly.

• Face the machine when getting in or out and always use three-point support, i.e. two hands and one foot or two feet and one hand
must always be in contact with the access system at the same time.

• If you are able to reach the door handle with your free hand, open the doors before you climb any higher. External influences, such as
wind, can make it more difficult to open doors. Because of this, always use your hand for control when opening doors. Ensure that the
door is latched open to prevent it slamming open and shut.

• In case of bad weather conditions, be particularly vigilant to realise the climbing and descent from the cab with the best safety
conditions, and do or give the instructions to the execution of prior preparations to be accomplished, as enunciated above, in order to
displace yourself safely.

• Be particularly vigilant with those prerequisites conditions.

• For cab with a side door:

◦ Now continue to climb up, still using the three-point support and sit down in the operator’s seat as soon as you enter the cab.

◦ Fasten the safety belt (if available), unlock the door, using the planned lever, and close it immediately using the door handle, before
tilting down the safety lever, and start the machine.

◦ If you wish to work with the door open, it is necessary to fasten your safety belt. If unavailable, let it be installed before working with
the door open.

• For cab with a rear door:

◦ Now continue to climb up, still using the three-point support and close the door as soon as you enter the cab.

◦ Sit down in the operator’s seat and fasten the safety belt (if available) before tilt­ing down the safety lever, and start the machine.

Safely getting down

• Proceed with the same precautions to climb up or down onto the machine, as to install yourself.

• Stop the machine on level, horizontal ground. The upper structure should be positioned with the undercarriage in such a way that the
steps and ladders are aligned with each other.

• Open and lock the door. Be sure of it’s locking. Take care of weather conditions ! Unfasten the safety belt.

• Position yourself with your face toward the machine when getting out and use three-point support, i.e. two hands and one foot or two
feet and one hand must always be in contact with the access system at the same time. Climb down until you can close the doors
safely. Always use your hand for control when closing the doors. Lock the door.

• Now climb down to the ground.

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From: Operator's manual R 9200 - 410 > Control and operation

4.2.1 | Enter or leave the cab

Climb up

CAUTION!
Entering or leaving the cab incorrectly could lead to injury.

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

Figure 1. Enter or leave the cab

Getting in
If the access ladder is in its lowest position and the excavator is not running, you can climb up on the machine.

• ▶ Climb in with the ladder and with your face towards the ladders and use the pro­vided handholds.

• ▶ On the cabin catwalk, open the door.

• ▶ Go in the cabin and take place on the operator seat.

• ▶ Adjust the seat if necessary.

Getting out
• ▶ Switch to off the machine and push the safety lever up.

• ▶ Open the door fully.

• ▶ Go out of the cabin on the cabin catwalk.

• ▶ Close the door.

• ▶ Go down with your face towards the ladders, and use the appropriate handholds.

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Access ladder
The access ladder can be moved into:

• lower position to permit the access to the uppercarriage

• upper position during the operation

Before operating the excavator, the access ladder must be fully lifted to the upper­carriage and locked in upper position.

The access ladder can be automatically extended and retracted from the uppercar­riage with the control box E1022, which is located on
the catwalk near the cab door.

Figure 2. Control box E1022

H67 Warning light on E1022

S155 Push-button / access ladder up
S158 Push-button / access ladder down

DANGER!
Never actuate the 45° access ladder if you or a third person are on the ladder or in immediate proximity of the ladder.

Move the ladder into lower position

If the principal batteries are connected, you can move the access ladder in lower po­sition with the engine on or off.

• ▶ Push the button S158 to extend the ladder until it is at the lowest position.

Move the ladder into upper position (working position)

• ▶ Make sure that the Diesel engine is running.

• ▶ Push the button S155 until the ladder is at the top position (working position).

When the ladder gets its top position, it is locked and warning light H67 goes off.

CAUTION!
For safety reason, the excavator can only be operated if the ladder is locked in its top position. This means that the swing
and travel movements remain locked.

This safety measure can be momentarily by-passed by pushing and holding the but­ton S122 on the control board.

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Figure 3. Button S122: Disable of ladder control position

Switch to on the access ladder lighting

Figure 4. Button S126

S126 Cab push-button / external cab lighting

• ▶ Inside the cab, press button S126 located on the control board.

Figure 5. Button S125

E59_3 Ladder lighting

S125 External push-button / external cab lighting

• ▶ From the outside, press button S125 located on the ladder side.

Move the access ladder into lower position in case of emergency

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Figure 6. Emergency valve of access ladder

1 Manual valve

In case of failure (service batteries out of order, defective solenoid valve or wiring, ...) of the access ladder moving procedure, an
emergency valve is installed near the ac­cess ladder.

• ▶ Stop the Diesel engine.

• ▶ Open the valve 1 to move the ladder in lower position.

If an emergency stop is operated, the access ladder is automatically moved in lower position.

Emergency ladder
Two emergency ladders are installed under the cab catwalk.

Figure 7. Emergency ladder

1 Emergency catwalk door 3 Fixed emergency ladder

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2 Rope ladder box 4 Rope emergency ladder

CAUTION!
Risk of falling. The rope emergency ladder can swing.

• ▶ Obey the safety instructions given above.

• ▶ Hold the rope emergency ladder safely when you use it.

• ▶ Open the emergency catwalk door 1. Make sure that:

• It is fully open.

• It holds its position.

• ▶ Hold the cab catwalk handrails safely. Get access to the fixed emergency ladder 3.

• ▶ Open the box 2.

◦ ▷ Rope emergency ladder 4 deploys.

DANGER!
Overload!
Risk of falling.

• ▶ Do not use the rope emergency ladder more than two persons at the same time and with a maximum permitted total
load of 200 kg.

• ▶ Hold the fixed emergency ladder 3 safely. Get access to the rope emergency lad­der 4.

• ▶ Hold the emergency ladder 4 safely. Climb down to the ground.

Subsequent procedure
After you use the emergency ladder, and if it possible to use it again, roll it carefully and put it back in its initial storage location: make
sure that it does not twist and that there are no knots.

From: Operator's manual R 9200 - 410 > Control and operation > The access and the outfit of the cab

4.2.2 | Safety lever

Figure 1. Safety lever

For safety purposes, the left control panel is provided with a safety lever.

CAUTION!
The safety lever must always be pushed up into its highest position (see arrow) when entering or exiting the cab.

When the safety lever is pushed up, the pilot control circuit is disconnected. This means that:

• No work movements can be carried out when pilot control devices, e g. the joy­stick or foot pedals, are operated.

• The swing gear brake is locked (LED in swing brake switch is on).

• It is not possible to release the swing gear brake using this switch.

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When the safety lever is pushed (push up / push down) to its lowest position, the swing gear brake and the LED in swing brake switch will
return to their original states and the pilot control devices will be active.

• ▶ Before the operator starts working, he must push the safety lever down into its lowest position while seated in the operator’s seat.

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From: Operator's manual R 9200 - 410 > Control and operation > The access and the outfit of the cab

4.2.3 | Operator’s seat

Figure 1. Standard operator’s seat

1 Set horizontal, upper 4 Set seat inclination

2 Set weight 5 Set height
3 Adjust armrests 10 Set backrest

The operator’s seat must be set up before starting the machine.

▢ The Diesel engine is switched to off.

▢ The safety lever is pushed up.

• ▷ This will prevent unexpected movement of the machine.

Weight adjustment

Figure 2. Setting the weight

To adjust the seat for the driver’s weight:

• ▶ Quickly pull the lever 2.

NOTE!
The driver must be seated during the adjustment.

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Height adjustment

Figure 3. Setting the height

The seat height can be set pneumatically and is continuously adjustable.

To adjust the seat height:

• ▶ Pull the lever 5 up or down.

CAUTION!
Before adjusting the height, adjust shock absorbers to the position «soft».

Setting the armrests

Figure 4. Setting the armrests

To adjust the seat armrest:

• ▶ Turn the knurled head screw 3 in direction 1 to slope the armrest upwards.

• ▶ Turn the knurled head screw 3 in direction 2 to slope the armrest downwards.

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Setting the seat

Figure 5. Setting the seat

To adjust the angle of the seat:

• ▶ Pull lever 4 up.

• ▶ By applying pressure on the seat, move it to the correct position.

Setting the backrest

Figure 6. Setting the backrest

To set the backrests:

• ▶ Pull lever 10 up to release the backrest.

• ▶ By applying pressure on the seat, move it to the correct position.

• ▶ Release the lever 10 to lock the backrest.

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Setting the horizontal seat position

Figure 7. Setting the horizontal

To adjust the horizontal position of the seat:

• ▶ Pull up the lever 1.

• ▶ Move the seat backwards or forwards to the correct position.

Fasten / release the safety belt

Figure 8. Safety belt

The safety belt is automatic.

To adjust the belt length:

• ▶ Pull the belt and buckle 2 out of the roller mount 1.

◦ ▷ If pulled out of the roller mount suddenly, the belt can lock.

• ▶ Push the buckle into the belt lock 3 until it fastens.

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DANGER!
The safety belt is designed to protect the operator.

• ▶ Before starting the machine, always fasten the safety belt.

• ▶ Make sure that the safety belt is not twisted when it is fastened.
• ▶ For safety reasons, check the condition, function and fastening of the belt regularly and replace any damaged parts
without delay.

• ▶ To open lock 4, push down on the belt lock using your thumbs.

◦ ▷ The safety belt will slide automatically back into the roller mount 1.

From: Operator's manual R 9200 - 410 > Control and operation > The access and the outfit of the cab

4.2.4 | Auxiliary seat

Figure 1. Auxiliary seat

1 Auxiliary seat
2 Storage cabinet

The auxiliary seat 1 is a folding seat located near the operator. A storage cabinet 2 is installed under the auxiliary seat.

Move the folding seat

• ▶ Pull up or down the seat 1 to move it in position.

• ▶ When there is no one on the auxiliary seat, the folding seat automatically pulls up against the cab wall.

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From: Operator's manual R 9200 - 410 > Control and operation > The access and the outfit of the cab

4.2.5 | Sunshade

Figure 1. Cab sunshade

1 Cab sunshade

You can pull up or down the cab sunshade(s) 1 and set it for individual use.

From: Operator's manual R 9200 - 410 > Control and operation > The access and the outfit of the cab

4.2.6 | Emergency exit

Figure 1. Emergency exit and emergency hammer

1 Emergency hammer
2 Emergency exit

Only in case of emergency, you can use the rear window 2 of the cab as an emer­gency exit.

• ▶ Break the rear window 2 with the emergency hammer 1.

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From: Operator's manual R 9200 - 410 > Control and operation > The access and the outfit of the cab

4.2.7 | Internal lighting

Figure 1. Internal lighting switch button

The internal lighting is switched to on through the S8 button on the control board.

Switch to on the internal lighting

• ▶ Push the S8 button.

Switch to off the internal lighting

• ▶ Push the S8 button again.

From: Operator's manual R 9200 - 410 > Control and operation > The access and the outfit of the cab

4.2.8 | Fire extinguisher

The interior of the cab is fitted with fixing points allowing the mounting of a fire extinguisher. These fixing points are on the left of the rear
window.

Figure 1. Fire extinguisher fixing location

1 Fire extinguisher

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It is the responsibility of the owner of the machine to decide if it must be fitted with a fire extinguisher or not, considering the operating
conditions and the regulations which apply in the country and at the point of use of the machine.

CAUTION!
If your machine is fitted with a fire extinguisher:

• ▶ Always comply with the operating guide on the body of the extinguisher,
• ▶ Make sure, all the inspections of the fire extinguisher which are prescribed by the regulations applicable to the
operating place of the machine are accom­plished.

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From: Operator's manual R 9200 - 410 > Control and operation > The access and the outfit of the cab

4.2.9 | Windscreen

Windscreen wiper

Operate the windscreen wiper

• ▶ Make sure that the ignition key is switched to on.

• ▶ Push the button.
◦ ▷ Intermittent mode is activated.
◦ ▷ First LED in the button comes on.
• ▶ Push the button again.
◦ ▷ Continuous mode is activated.
◦ ▷ First LED in the button goes off.
◦ ▷ Second LED in the button comes on.
• ▶ Press the button a third time.
◦ ▷ Windscreen wiper is switched off.
◦ ▷ LED in the button goes off.

Set the interval time for the intermittent switching

You can set the interval in the submenu "Wiper" of the monitoring display.

Windshield washer installation

Operate the windshield washer

• ▶ Make sure that the ignition key is switched to on.

• ▶ Push and hold the button.
◦ ▷ Washing water is sprayed onto the windscreen through the outlet nozzles.
◦ ▷ Windscreen wiper runs continuously.
◦ ▷ First LED in the button comes on.
• ▶ Release button.
◦ ▷ First LED in the button goes off.
◦ ▷ Washing water is stopped.
◦ ▷ Windscreen wiper finish its cycle.

Fill the container of the windscreen washer fluid

Figure 1. Container of the windscreen washer fluid

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1 Cab elevation
2 Container

The container 2 for the windscreen washer fluid is located into the cab elevation 1. You can fill it through the filler neck.

• ▶ For fluid quantity, refer to the operating material chart.

Heated windscreen (optional)

A heated windscreen is installed to remove frost from the front cab window.

Figure 2. Heated windscreen

S189 Actuator for windscreen heating

• ▶ Start the Diesel engine.

• ▶ Use actuator S189 to start the windscreen heating.

• ▶ Use actuator S189 again to stop it.

From: Operator's manual R 9200 - 410 > Control and operation > The access and the outfit of the cab

4.2.10 | Field of view

Figure 1. Field of view

1 Camera 1: opposite side of the cab

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2 Camera 2: counterweight

Monitoring cameras are installed on the excavator as follows in order to extend the operator’s field of view with the operating
environment:

• camera 1: on the opposite side of the cab

• camera 2: on the counterweight

The combination of the cameras and the outside mirrors allows to see a person standing out of the hatched area illustrated on the figure
above.

DANGER!
Before using the excavator, make sure that the cameras and the outside mirrors are correctly adjusted.

• ▶ Regularly check mirrors and cameras for condition. If necessary:

• Clean them with a soft, dry cloth.

• Use an external safety device to get access to them.

• ▶ Regularly check mirrors and cameras for correct adjustment.

• ▶ For maintenance intervals, refer to the control and maintenance chart.

• ▶ Replace damaged mirrors and cameras immediately.

To cover the correct area:

• ▶ Set the cameras and adjust the outside mirrors so as to be able to see a person standing out of the hatched area defined by the
four checkpoints given on the fig. above.

From: Operator's manual R 9200 - 410 > Control and operation > The access and the outfit of the cab

4.2.11 | Lighting

• ▶ Regularly check lighting devices for condition. If necessary:

• Clean them with a soft, dry cloth.

• Use an external safety device to get access to them.

• ▶ For maintenance intervals, refer to the control and maintenance chart.

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Figure 1. Configuration of lighting

E1 Front working light / Uppercarriage (cab elevation)

E18_1 Rear working light / Counterweight
E18_2 Rear working light / Counterweight
E2 Attachment headlight / Right side
E3 Attachment headlight / Left side
E58_1 Front working light / Top of cab
E58_2 Front working light / Top of cab
E59_1 Rear working light / Top of cab
E59_2 Rear working light / Top of cab
E60_1 Front working light / Fuel tank
E60_2 Front working light / Fuel tank
E61_1 Camera lighting / Fuel tank
E61_2 Camera lighting / Counterweight

Front working lights and attachment headlights

• ▶ Press button.
◦ ▷ Front working lights on the uppercarriage are activated.
◦ ▷ First LED in the button comes on.
• ▶ Press button again.
◦ ▷ Front working lights and attachment headlights are activated.
◦ ▷ First LED and second LED in the button are on.
• ▶ Press button a third time.
◦ ▷ Front working lights are deactivated.
◦ ▷ First LED in the button goes off.
◦ ▷ Attachment headlights remain activated.
◦ ▷ Second LED in the button is still on.
• ▶ Press button a fourth time.
◦ ▷ Attachment headlights are deactivated.
◦ ▷ Second LED in the button goes off.

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Rear working lights

• ▶ Press button.
◦ ▷ Rear top of cab working lights are activated.
◦ ▷ First LED in the button comes on.
• ▶ Press button again.
◦ ▷ Rear counterweight working lights are activated.
◦ ▷ First LED and second LED in the button are on.
• ▶ Press button a third time.
◦ ▷ Rear top of cab working lights are deactivated.
◦ ▷ First LED in the button goes off.
• ▶ Press button a fourth time.
◦ ▷ Rear counterweight working lights are deactivated.
◦ ▷ Second LED in the button goes off.

From: Operator's manual R 9200 - 410 > Control and operation > The access and the outfit of the cab

4.2.12 | Heating and air-conditioning system

The machine has a standard heating and air-conditioning system and can also have an optional second air-conditioning system

• ▶ Refer to the section "Heating and air-conditioning system" in chapter 5 for the configurations of the system.

Control unit front panel

Figure 1. Front panel of the heating/air conditioning control unit

Control keys Indication on the LCD Display

1 Air-conditioning ON/OFF 9 Recirculated air mode indicator

2 Increase cab temperature 10 Reheat mode indicator
Manual setting "upwards" 11 Air conditioning mode indicator
3 Decrease cab temperature 12 Automatic mode indicator
Manuel setting "downwards" 13 Blower manual speed bar
4 Control unit ON/OFF 14 Manual blower mode indicator
5 Evaporator blower speed manu/auto 15 Heating mode indicator
6 Reheat ON/OFF 16 Cab indicator
7 Heating ON/OFF 17 Temperature set value / error code
8 Fresh air / recirculated air mode (only for heater with air flap) 18 Temperature unit
19 LCD Display

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

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Operating the heating/air-conditioning control unit

Switching on the control unit

• ▶ Press button 4.
◦ ▷ The control unit runs a self-test for approximately 5 seconds (software version and equipment function are
displayed on field 17).
◦ ▷ Then the operating hours are displayed on field 17.
◦ ▷ And then the last stored temperature adjustment is indicated on field 17.
◦ ▷ By default, control unit is in automatic mode and symbol 12 appears on display 19.

Temperature setting

• ▶ Press button 2 to increase the temperature.

• ▶ Press button 3 to decrease the temperature.
◦ ▷ The selected temperature is displayed on field 17.
◦ ▷ The new set value is stored 5 seconds after last button pressure.

Switching ON/OFF the air conditioning unit

• ▶ Press button 1.
◦ ▷ Air conditioning mode is operated.
◦ ▷ Symbol 11 appears on display 19.
• ▶ Press button 1 again.
◦ ▷ Air conditioning mode is deactivated.
◦ ▷ Symbol 11 disappears from display 19.

NOTE!
In case of high outside temperature, and especially if the cab has been heated up by the sun, decrease the temperature
inside the cab as far as possible before turn­ing on the air conditioner.

• ▶ Open the windows for a few minutes and adjust blower speed to maximum speed via buttons 5 and 2.

Switching ON/OFF the reheat mode

In order to achieve a quick dehumification of the cab when setting the machine into operation, it may be advisable to
briefly turn on the air conditioning operation when the heater is already operative.

• ▶ Press button 6.
◦ ▷ Reheat mode is operated.
◦ ▷ Symbol 10 appears on display 19.
◦ ▷ The blower speed is raised to 100%. If necessary the control unit switches the heating on, to hold ambient
temperature at the desired value.
• ▶ Press button 6 again.
◦ ▷ Reheat mode is deactivated.
◦ ▷ Symbol 10 disappears from display 19.

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

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

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Setting the evaporator blower speed manually

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

Switching ON/OFF the heating mode

• ▶ Press button 7.
◦ ▷ Heating mode is operated.
◦ ▷ Symbol 15 appears on display 19.
• ▶ Press button 7 again.
◦ ▷ Heating mode is deactivated.
◦ ▷ Symbol 15 disappear from display 19.

Fresh air / recirculated air mode (only for heater with air flap)

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

Switching the temperature unit from °Celcius to °Fahrenheit

• ▶ Press and hold button 8.

• ▶ Press button 3 additionally.
◦ ▷ Temperature unit indication 18 switches over into °Fahrenheit.
• ▶ Repeat same procedure to switch back temperature unit indication to °Celcius.

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Second air-conditioning (optional equipment)

When you start the machine, the automatic second air-conditioning system is operated by default. The two air-
conditioning units are working alternately.
The first LED and the second LED in the "Dual air conditioning" button of the control keyboard illuminate.

• ▶ Press the "Second air-conditioning" button.

◦ ▷ Automatic air-conditioning mode is deactivated.
◦ ▷ First air-conditioning unit is operated.
◦ ▷ Second air-conditioning unit is deactivated.
◦ ▷ First LED in the button comes on.
◦ ▷ Second LED in the button goes out.
• ▶ Press the button again.
◦ ▷ First air-conditioning unit is deactivated.
◦ ▷ Second air-conditioning unit is operated.
◦ ▷ First LED in the button goes out.
◦ ▷ Second LED in the button comes on.
• ▶ Press the button again.
◦ ▷ Automatic air-conditioning mode is operated again.
◦ ▷ First LED and second LED in the button come on.

Additional cab heater (optional)

An additional cab heater is installed above the operator seat. The temperature adjustment of this device is the same as the standard
heating system.

Figure 2. Additional cab heater

S234 Actuator for additional cab heater

• ▶ Start the Diesel engine.

• ▶ Use actuator S234 to start the additional cab heater.

• ▶ Use actuator S234 again to stop it.

Foot heater (optional)

A foot heater can be installed on the foot board.

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Figure 3. Foot heating zones

Figure 4. Foot heater

S235 Actuator for foot heater

• ▶ Start the Diesel engine.

• ▶ Use actuator S235 to start the foot heater.

• ▶ Use actuator S235 again to stop it.

From: Operator's manual R 9200 - 410 > Control and operation > The access and the outfit of the cab

4.3 | Setting the machine into operation

Bringing the machine safely into service

• Carry out a careful inspection tour around the machine each time before starting it.

• Ensure that no one, except an authorized person, is in the work and movement area of the machine.

• Check the machine for loose bolts, cracks, wear, leakage and damage.

• Never attempt to operate a damaged machine.

• Ensure that any damage is immediately rectified.

• Ensure that all hoods and covers are closed, but that locks are unlocked, to facil­itate the fight against fire in case of.

• Ensure that all warning signs are present.

• Keep windows and interior and exterior mirrors clean. Secure doors and windows against unintended movement.

• Ensure that no one is working on or under the machine and warn personnel in the vicinity of the machine that it is about to start by
sounding the horn.

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Adjusting the operator’s standing position

• Before starting the machine, adjust the seat, mirrors, armrests and operator’s controls in such a way that you are able to work
comfortably and safely.

• Acoustic insulation devices on the machine must be set to the insulation position throughout operation.

Protection from vibration - seat adjusting

• Keep the seat in good condition and adjust it as follows:

◦ The seat and its damping action should be adjusted depending on the weight and height of the operator.

◦ Check the seat’s damping action and adjustment mechanisms regularly and ensure that these seat characteristics remain as per
the seat manufacturer’s in­structions.

Utilisation in confined spaces

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

Starting the machine safely

• Before starting, check all control lamps and instruments for correct function, place all operator’s controls in Neutral and tilt the safety
lever up.

• Before starting, sound the horn briefly to alert people in the vicinity of the machine.

• Only start the machine from the driver’s seat.

• In the absence of any other instructions, start the engine in accordance with the regulations given in the operating instructions.

• Tilt the safety lever down and then test all display and checking devices.

• In enclosed spaces, only allow the engine to run when there is adequate ventilation. If necessary, open doors and windows to ensure
sufficient fresh air supplies.

• Bring the engine and hydraulic oil to operating temperature. Low oil temperatures make the control unit react sluggishly.

• Check that the attachment is operating correctly.

• Move the machine carefully to an open area and then check the function of the travel and swing gear brakes, the steering and the
signalling and lighting devices. Lighting devices must always be clean.

Stopping the machine safely

• Only stop the machine on level, firm ground.

• If the machine has to be stopped on an incline, chocks should be used to secure it from rolling away.

• Before stopping the machine, each time it is possible, align the uppercarriage with the undercarriage so that the sprockets locate at
the back-end. This is the only one position which enables a secured access to every maintenance locations on the uppercarriage.

• Use the stop bolts to secure the uppercarriage facing the undercarriage, if avail­able.

• Lower the attachment and anchor the grab lightly in the ground.

• Position every control lever into neutral position and apply the travel and swing brakes.

• Stop the engine in accordance with the operating instructions and tilt the safety lever up before leaving the cab.

• Lock the machine, included hoods and compartments, remove every keys and secure the machine against unpermitted use and
vandalism.

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From: Operator's manual R 9200 - 410 > Control and operation

4.3.1 | Start and stop the machine

General information

NOTE!
When using the machine at a specific height above sea level and in connection with certain outside temperatures, the
performance and service life of the turbocharged Diesel engine can be decisively affected.
Under these conditions, there is also an increased risk of overheating of the coolant circuit and of the oil.

If you must operate the Diesel engine above the recommended altitude and in spec­ified ambient temperatures:

• ▶ Refer to the manual of the Diesel engine manufacturer for the related Diesel en­gine power to prevent damages to this component.

Activities before starting

CAUTION!
It is only possible to extinguish a source of fire when this one is accessible.

• ▶ Before starting, unlock all locks on the panelling of the hydraulic excavator.
◦ ▷ In the event of fire, the doors can be opened immediately and the fire extin­guished.

• ▶ For locks configuration, refer to the chapter "Maintenance" of this manual.

CAUTION!
The activities referred below involve scald or burn hazards due to the high temperature of the coolant or of the oil when
the machine is at operating temperature.

• ▶ Please read first the maintenance chapter in order to get informations about car­rying out these activities.

• ▶ Before you start the machine, the activities that follow must be done on a daily basis.For the tasks identified with a (*), you can refer
to the maintenance chapter for more information about the procedure to follow:

• Check air filters for contamination (*).

• Check the oil level in the Diesel engine (*).

• Check the coolant level in the Diesel engine (*).

• Check fuel system and fuel level.

• Check the oil in the hydraulic system.

• Check that the cameras and the outside mirrors are correctly adjusted.

• If required, remove any ice and snow from the engine hood in the area of the cool­ing and combustion air intake.

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Turn on the electrical system

Ignition key switching positions

Figure 1. Ignition key S1 on cab control board

S1 Ignition key 1 Contact position

P Not used 2 Contact position
0 Off 3 Contact position

The ignition key S1 is located on the cab control board.

Switch on the electrical system

Figure 2. Principal battery switches

1 Pumps box
S9_1 Principal batteries circuit breaker
S9_2 Principal batteries circuit breaker

The principal batteries circuit breakers S9_1 and S9_2 are located on the side of the pumps box.

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Figure 3. Engine ECM circuit breaker S9_3

S9_3 ECM circuit breaker

The engine ECM circuit breaker S9_3 is installed on the electrical box E1086 which is located on the power pack inner side, near the
engine doors.

• ▶ Make sure that the principal battery switches S9_1 and S9_2 and the engine ECM circuit breaker S9_3 are in position "CLOSE".

• ▶ Turn the ignition key S1 to contact position 1. After a few seconds:

• The display turns on.

• On the keyboard, the first LED of the "Increase engine speed" button comes on, because the engine is at its minimum speed on start.

• The first LED on the travel brake button comes on.

• The first LED on the swing brake button comes on.

• If the dual air conditioning optional system is installed on your excavator, the first LED and the second LED on the related button come
on because the automatic air conditioning is operating by default.

If the display or the above listed LEDs do not come on when the ignition key is in the contact position:

• ▶ Check that the principal batteries switches are in position "CLOSE".

Start the engine

CAUTION!
A wrong start can cause damages for the Diesel engine!

• ▶ Only operate the starter motor when the Diesel engine is off.
• ▶ Do not operate the starter more than 30 seconds.
• ▶ If the engine does not start after 30 seconds, wait at least 2 minutes before you try to start again.

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

Above 0°C:

• ▶ Refer to the section "Starting procedure when the exterior temperature is above 0°C".

Between 0°C and -20°C:

• ▶ Refer to the section "Starting procedure when the exterior temperature is below 0°C".

Below -20°C:

• ▶ Refer to the section "Starting procedure when the exterior temperature is below -20°C".

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Starting procedure when the exterior temperature is above 0°C

• ▶ Make sure that the electrical system is switched to on.

• ▶ Push and hold the "Start/Stop" engine button on the keyboard.
◦ ▷ The engine start procedure begins and the first LED in the button comes on.
◦ ▷ First LED in the button goes off when you release the button.

Starting procedure when the exterior temperature is below 0°C

After starting the engine, the attachment must be moved slowly in order to gradually increase the oil temperature in the hydraulic system.

The starting procedure is described in the section "Warm-up procedure".

Starting procedure when the exterior temperature is below -20°C

For starting at temperatures below -20°C, it is recommended to equip the machine with a preheating system in accordance with Liebherr.
If this system is installed, refer to the section "Starting aids".

NOTE!
If the excavator is switched off and the ambient air temperature is above -10°C, or if the excavator is turned off less than
one hour and the ambient air temperature is below - 10°C (e.g. for daily maintenance):

• ▶ Follow standard procedure to park the excavator.

• ▶ Start the excavator by following the starting procedure when the exterior temper­ature is below 0°C.

Adjustment of Diesel engine speed

Figure 4. Speed indication on the main screen of the monitoring display

CAUTION!
Incorrect use of the Diesel engine!
Risk of damage to the Diesel engine.

• ▶ Do not let the Diesel engine operate at low idle for a long period.
• ▶ Stop the Diesel engine if you do not use the machine.

Manual speed adjustment

You can set the Diesel engine speed in different specified steps with the "Increase engine speed" and "Decrease engine speed" buttons,
which are located on the A168 Powerpack keypad. The main screen of the monitoring display shows the selected speed with a dial
indicator.

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Increase the engine speed

• ▶ Push and release the "Increase engine speed" button.

◦ ▷ The engine speed increases until the next higher step.
• ▶ Push and hold the "Increase engine speed" button.
◦ ▷ The engine speed increases continuously.
◦ ▷ The LED in the button flashes until you get the maximum speed.
◦ ▷ The LED in the button is on while the maximum speed is selected.

Decrease the engine speed

• ▶ Push the "Decrease engine speed" button.

◦ ▷ The engine speed decreases to the previous lower step.
• ▶ Push and hold the "Decrease engine speed" button.
◦ ▷ The engine speed decreases continuously.
◦ ▷ The LED in the button flashes until you get the minimum speed.
◦ ▷ The LED in the button is on while the minimum speed is selected.

Automatic speed adjustment

Eco / Power modes

Use this button to switch quickly between "Eco" mode and "Power" mode.

• ▶ Push "Eco / Power modes" button.

◦ ▷ Diesel engine speed is set to "Eco" mode.
◦ ▷ The LED above "Eco" in the button comes on.
• ▶ Push "Eco / Power modes" button again.
◦ ▷ Diesel engine speed is set to "Power" mode (maximum speed).
◦ ▷ The LED above "Power" in the button comes on.

Each time you push this button, the Diesel engine speed switches from one mode to the other.
You can also set the "Power" mode when you set the Diesel engine speed to the last step with "Increase engine speed"
button.

In this case, LPE - Engine Control that follows is not available.

Liebherr Power Efficiency (LPE) Engine Control

Depending on the machines, the Liebherr Power Efficiency (LPE) Engine Control (LPE - Engine Control) adapts the
Diesel engine speed automatically in relation to the machine movements.
In this case, "Eco / Power modes" which are given above are not available. Thus, "Mode" button replaces "Eco / Power
modes" button.

• ▶ Push "Mode" button.

◦ ▷ LPE - Engine Control adapts Diesel engine speed.
◦ ▷ The related LED in the button comes on.
• ▶ Push "Mode" button again.
◦ ▷ The Diesel engine speed is set to idle.
◦ ▷ The related LED in the button goes off.

Auto Idle mode

Auto Idle function decreases automatically the Diesel engine speed, for example when the machine is on but you do not operate it.

CAUTION!

• ▶ Make sure that Auto idle function is off when:

• You start the Diesel engine.
• You travel on slopes.
• ▶ To prevent Diesel engine damages, do not let it in Auto Idle mode for a long pe­riod.

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• ▶ Push "Auto Idle" button.

◦ ▷ Auto Idle function is on, but it is not activated.
◦ ▷ The LED on the button comes on.
• ▶ If you let the joysticks and pedals in neutral position during the specified Auto Idle interval:
◦ ▷ Auto Idle function is activated.
◦ ▷ The Diesel engine speed decreases automatically.
◦ ▷ The automatic speed adjustment and the Diesel engine speed are stored. The related symbol flashes on the
display.

You can set the Auto Idle interval in the submenu "Auto Idle control" of the monitoring display.

• ▶ If you push "Increase engine speed" button while Auto Idle function is activated:
◦ ▷ The Diesel engine speed does not change.
◦ ▷ The new step is stored.
• ▶ If you push "Decrease engine speed" button while Auto Idle function is activated:
◦ ▷ If the new step is higher than the Auto Idle speed, the Diesel engine speed does not change and the new step
is stored.
◦ ▷ If the new step is lower than the Auto Idle speed, Auto Idle function is deacti­vated.
• ▶ If you operate the joysticks or the pedals:
◦ ▷ Auto Idle function is deactivated.
◦ ▷ The Diesel engine speed is set to the stored value.
• ▶ Push "Auto Idle" button again.
◦ ▷ Auto Idle function is off.
◦ ▷ The LED on the button goes off.

Auto Idle if LPE - Engine Control is installed

Auto Idle function decreases automatically the Diesel engine speed, for example when the machine is on but you do not operate it.

CAUTION!

• ▶ Make sure that Auto idle function is off when:

• You start the Diesel engine.
• You travel on slopes.
• ▶ To prevent Diesel engine damages, do not let it in Auto Idle mode for a long pe­riod.

• ▶ Push "Auto Idle" button.

◦ ▷ Auto Idle function is on, but it is not activated.
◦ ▷ The LED on the button comes on.
• ▶ If you let the joysticks and pedals in neutral position during the specified Auto Idle interval:
◦ ▷ Auto Idle function is activated.
◦ ▷ The Diesel engine speed decreases automatically.
◦ ▷ The automatic speed adjustment and the Diesel engine speed are stored. The related symbol flashes on the
display.

You can set the Auto Idle interval in the submenu "Auto Idle control" of the monitoring display.

• ▶ If you push "Increase engine speed" button or "Decrease engine speed" button while Auto Idle function is activated

or

• ▶ If you operate the joysticks or the pedals:

◦ ▷ Auto Idle function is deactivated.
• ▶ Push "Auto Idle" button again.
◦ ▷ Auto Idle function is off.
◦ ▷ The LED on the button goes off.

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Notes after starting the engine

DANGER!
Danger of suffocation.

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

CAUTION!

• ▶ Bring the engine and hydraulic oil up to operating temperature. The controls operate sluggishly at low oil
temperatures.
• ▶ Move the machine carefully in an open space to test the function of the travel and swing brakes.
• ▶ Check that the attachment is operating perfectly.

Stop the Diesel engine

CAUTION!
The engine could be damaged.

• ▶ Do not switch off the engine suddenly from full throttle.

• ▶ Push the "Start/Stop" engine button on the keyboard.

◦ ▷ The engine turns at minimum speed during 180 seconds.
◦ ▷ The right LED in the button and the related symbol on the display flash.
• ▶ Turn the ignition key S1 to position "0" to switch to off the machine.
◦ ▷ Then the engine stops. The right LED and the display symbol are on.
◦ ▷ The right LED goes off.
• ▶ Remove the ignition key S1.

From: Operator's manual R 9200 - 410 > Control and operation > Setting the machine into operation

4.3.2 | Starting aids: preheating of the Diesel engine coolant with the 30 kW heater
(optional equipment)

To start the Diesel engine below specified ambient temperatures, we recommend the installation of applicable starting aids on the
machine. If starting aids are installed, a special information label in the cab gives the applicable working ambient temperature range of
the machine.

Thus, according to the configuration of your machine, you must obey the following preheating procedure and the auxiliary preheating
procedures that follow in this man­ual.

System configuration

Coolant heater installation

A coolant heater is installed to warm up the coolant and the block of the Diesel en­gine.

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Figure 1. Coolant heater installation

1 Coolant heater 4 Standard coolant shutoff valve

2 Manual valve (2x) 5 Test point / bleed screw
3 Tap

Figure 2. Coolant circuit of the starting aids: bleed the 35 kW coolant heater

S258 Control button of the circulation pump

Electrical system
Special preheating batteries supply electrical power to the starting aids. The preheating batteries and their dedicated switches are
installed in the pumps box.

Figure 3. Electrical system

1 Preheating batteries box

2 Preheating battery switch (2x)

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Control panel for the starting aids

Special operating and control elements, which are dedicated to the starting aids, are installed on the cab control board.

Figure 4. Control panel for the starting aids

#103 External generator connected #169 Temperature of the Diesel en­gine coolant
#168 Level of the special fuel tank of the coolant heater U10# Control unit of the coolant heater

Machine position
Before you stop the Diesel engine or before you start the preheating procedure, obey the following instructions:

Figure 5. Machine position

Make sure that the following preconditions are met:

▢ The machine is safely parked on firm and level ground.

• ▶ Lower the attachment until it touches the ground.

• ▶ Retract all attachment cylinders fully.

Start the electrical system

• ▶ Set the preheating battery switch(es) to the position CLOSE.

• ▶ Let the preheating battery switch(es) in the position CLOSE while the machine is in operation.

◦ ▷ The preheating batteries charge.

Operate the coolant heater

Make sure that the following preconditions are met:

▢ The Diesel engine is stopped.

▢ The coolant heater is stopped.

▢ All the valves are open.

• ▶ Start, set and operate the coolant heater with the control unit U10#, which is in­stalled on the control panel for the starting aids.

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Menu

Up selection

Down selection

Confirmation

• ▶ Use the button "Menu" to get access to a menu in the upper frame of the U10# display.

• ▶ Use the two selection buttons "Up" and "down" to select and set values.

• ▶ Use the button "Confirmation" to confirm values.

Start the coolant heater manually

• ▶ Push the "Instant heating" button.

◦ ▷ The coolant heater starts.

Set the time

• ▶ Start the control unit.

• ▶ Select the menu "Settings".

• ▶ Set the day and the time.

Record the automatic starting time

• ▶ Start the control unit.

• ▶ Select the menu "Preselection time".

◦ ▷ The memory location flashes.
• ▶ Select the memory location.
• ▶ Set the starting time of the coolant heater.

Set the duration of the operating time

• ▶ Select the menu "Operation duration".

◦ ▷ The related symbol flashes.
• ▶ Set the necessary operating time.
◦ ▷ The coolant heater stops automatically after this time.

CAUTION!
The coolant heater current time and the recorded data will be erased if the preheat­ing electrical system is opened.

• ▶ Let the preheating battery switch(es) in the position CLOSE to keep the data.

Thus, while the coolant heater is on or is in standby, the preheating batteries continue to supply electrical power to the
starting aids.

• ▶ Monitor the state of charge of the preheating batteries.

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Duration of the preheating procedure of the Diesel engine coolant

The machine start is not recommended before the preheating procedure of this sec­tion is completed with the starting aids.

CAUTION!
The preheating batteries supply electrical power to the starting aids while the ma­chine is stopped!
Risk of batteries discharge.

• ▶ Take the specified maximum time into account for the machine start. This period also depends on the site ambient
conditions and on the initial batteries level.

The standard procedure must not take more than 70 minutes.

Monitor the fuel level of the coolant heater

The coolant heater has a special fuel tank to operate independently of the machine fuel system. As it will be difficult to restart the starting
aids in case of fuel exhaustion, the warning light #168, which is installed on the control panel for the starting aids, comes on if the fuel
level in the special fuel tank is too low.

If the warning light #168 comes on:

• ▶ Stop the Diesel engine.

• ▶ Stop the coolant heater with the control unit U10#.

• ▶ Make sure that the fuel level is corrected immediately: refer to the dedicated sec­tion of this manual.

NOTE!
If the fuel supply of the coolant heater comes directly from the machine fuel tank, there is no warning light. Thus, in this
case, you must monitor the fuel level on the machine monitoring display.

Monitor the temperature of the Diesel engine coolant

While the temperature of the Diesel engine coolant is too low to start in good condi­tions, the warning light #169, which is installed on the
control panel for the starting aids, stays on.

If the warning light #169 is on:

• ▶ Do not start the Diesel engine.

◦ ▷ At the end of the preheating time of the Diesel engine coolant, the procedure stops automatically.

When the coolant heater stops:

• ▶ Do not disconnect the preheating batteries immediately.

• ▶ Wait for the fan and/or pump correct stop to prevent risks of overheating.

Subsequent procedure
Before you start the machine, you must make sure that the applicable auxiliary preheating procedures that follow are also completed:
obey the related instructions.

Diagnostic unit of the coolant heater

The control unit U10# shows the recorded error codes which occur on the coolant heater during operation.

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Get the error codes

• ▶ Select the menu "Error message".

◦ ▷ The related symbol flashes.
• ▶ Push the two selection buttons "Up" and "down" at the same time.
◦ ▷ The error codes are shown on the control unit display.

• ▶ Get the description of the error codes: refer to the manual of the coolant heater manufacturer.

From: Operator's manual R 9200 - 410 > Control and operation > Setting the machine into operation

4.3.3 | Starting aids: preheating of the Diesel engine coolant with the 35 kW heater
(optional equipment)

To start the Diesel engine below specified ambient temperatures, we recommend the installation of applicable starting aids on the
machine. If starting aids are installed, a special information label in the cab gives the applicable working ambient temperature range of
the machine.

Thus, according to the configuration of your machine, you must obey the following preheating procedure and the auxiliary preheating
procedures that follow in this man­ual.

System configuration

Coolant heater installation

A coolant heater is installed to warm up the coolant and the block of the Diesel en­gine.

Figure 1. Coolant heater installation

1 Coolant heater
2 Manual valve (3x)
3 Tap

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Figure 2. Coolant circuit of the starting aids: bleed the 35 kW coolant heater

1 Bleed screw
S258 Control button of the circulation pump

Electrical system
Special preheating batteries supply electrical power to the starting aids. The preheating batteries and their dedicated switches are
installed in the pumps box.

Figure 3. Electrical system

1 Preheating batteries box

2 Preheating battery switch (2x)

Control panel for the starting aids

Special operating and control elements, which are dedicated to the starting aids, are installed on the cab control board.

Figure 4. Control panel for the starting aids

#103 External generator connected #169 Temperature of the Diesel en­gine coolant
#168 Level of the special fuel tank of the coolant heater U10# Control unit of the coolant heater

Machine position
Before you stop the Diesel engine or before you start the preheating procedure, obey the following instructions:

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Figure 5. Machine position

Make sure that the following preconditions are met:

▢ The machine is safely parked on firm and level ground.

• ▶ Lower the attachment until it touches the ground.

• ▶ Retract all attachment cylinders fully.

Start the electrical system

• ▶ Set the preheating battery switch(es) to the position CLOSE.

• ▶ Let the preheating battery switch(es) in the position CLOSE while the machine is in operation.

◦ ▷ The preheating batteries charge.

Operate the coolant heater

Make sure that the following preconditions are met:

▢ The Diesel engine is stopped.

▢ The coolant heater is stopped.

▢ All the valves are open.

• ▶ Start, set and operate the coolant heater with the control unit U10#, which is in­stalled on the control panel for the starting aids.

Previous
This button is used to select a menu or a parameter.

Next
This button is used to select a menu or a parameter.

Filled
This button is used to confirm a selection or a setting.

Blank
This button is used to go back to the previous menu.

• ▶ Refer to the following sections for the control unit U10# operation.

Start and stop the coolant heater manually

• ▶ Push the "Filled" button for more than 2 seconds.

◦ ▷ The coolant heater starts.

• ▶ Push the "Blank" button for more than 2 seconds.

◦ ▷ The coolant heater stops.

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Set the time

• ▶ Start the control unit.

• ▶ Push the "Previous" or "Next" button to select the menu "Settings" in the upper frame of the U10# display.
◦ ▷ This symbol flashes.
• ▶ Push the "Filled" button.

• ▷ The symbol "Time" flashes in the lower frame of the U10# display.

• ▶ Push the "Filled" button to go to this submenu.

• ▶ Set the time with "Previous" or "Next" button.
• ▶ Push the "Filled" button each time to confirm the settings.
• ▶ Push the "Blank" button to go back to the menu "Settings".

• ▶ Push the "Previous" or "Next" button to select the submenu "Day" in the lower frame of the U10# display.
◦ ▷ This symbol flashes.
• ▶ Push the "Filled" button.
• ▶ Set the day with "Previous" or "Next" button.
• ▶ Push the "Filled" button to confirm the setting.

Record the automatic starting time

• ▶ Start the control unit.

• ▶ Push the "Previous" or "Next" button to select the menu "Program" in the upper frame of the U10# display.
◦ ▷ This symbol flashes.
• ▶ Push the "Filled" button.

• ▶ Push the "Previous" or "Next" button to select a program number.

• ▶ Push the "Filled" button.

◦ ▷ The program number parameters are shown.

• ▶ Push the "Previous" or "Next" button to select the submenu "Settings".

◦ ▷ This symbol flashes.
• ▶ Push the "Filled" button.

• ▶ Set the day, hours and minutes with "Previous" or "Next" button.

• ▶ Push the "Filled" button each time to confirm the settings.

Set the duration of the operating time

In the same submenu as above, you can also set the operating time of the coolant heater.

• ▶ Set the necessary operating time with the "Previous" or "Next" button.

• ▶ Push the "Filled" button to confirm the setting.

◦ ▷ The coolant heater will automatically stop after this time.

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Start and stop the coolant heater automatically

• ▶ Go to the menu "Program".

• ▶ Select a program number.

• ▶ Push the "Previous" or "Next" button to select "ON".

• ▶ Push the "Filled" button.

◦ ▷ The automatic start and stop of the coolant heater is activated, with the param­eters set in the sections above.

• ▶ Push the "Previous" or "Next" button to select "OFF".

• ▶ Push the "Filled" button.

◦ ▷ The automatic start and stop of the coolant heater is deactivated.

CAUTION!
The coolant heater current time and the recorded data will be erased if the preheat­ing electrical system is opened.

• ▶ Let the preheating battery switch(es) in the position CLOSE to keep the data.

Thus, while the coolant heater is on or is in standby, the preheating batteries continue to supply electrical power to the
starting aids.

• ▶ Monitor the state of charge of the preheating batteries.

Duration of the preheating procedure of the Diesel engine coolant

The machine start is not recommended before the preheating procedure of this sec­tion is completed with the starting aids.

CAUTION!
The preheating batteries supply electrical power to the starting aids while the ma­chine is stopped!
Risk of batteries discharge.

• ▶ Take the specified maximum time into account for the machine start. This period also depends on the site ambient
conditions and on the initial batteries level.

The standard procedure must not take more than 70 minutes.

Monitor the fuel level of the coolant heater

The coolant heater has a special fuel tank to operate independently of the machine fuel system. As it will be difficult to restart the starting
aids in case of fuel exhaustion, the warning light #168, which is installed on the control panel for the starting aids, comes on if the fuel
level in the special fuel tank is too low.

If the warning light #168 comes on:

• ▶ Stop the Diesel engine.

• ▶ Stop the coolant heater with the control unit U10#.

• ▶ Make sure that the fuel level is corrected immediately: refer to the dedicated sec­tion of this manual.

NOTE!
If the fuel supply of the coolant heater comes directly from the machine fuel tank, there is no warning light. Thus, in this
case, you must monitor the fuel level on the machine monitoring display.

Monitor the temperature of the Diesel engine coolant

While the temperature of the Diesel engine coolant is too low to start in good condi­tions, the warning light #169, which is installed on the
control panel for the starting aids, stays on.

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If the warning light #169 is on:

• ▶ Do not start the Diesel engine.

◦ ▷ At the end of the preheating time of the Diesel engine coolant, the procedure stops automatically.

When the coolant heater stops:

• ▶ Do not disconnect the preheating batteries immediately.

• ▶ Wait for the fan and/or pump correct stop to prevent risks of overheating.

Subsequent procedure
Before you start the machine, you must make sure that the applicable auxiliary preheating procedures that follow are also completed:
obey the related instructions.

Diagnostic unit of the coolant heater

The on-board diagnostic unit shows the recorded error codes which occur on the coolant heater during operation.

Start the diagnostic

• ▶ Make sure that no preheating procedure is in progress.

• ▶ Make sure that the control unit U106, which is located in the cab, is off.

Figure 6. Diagnostic unit system

1 Cab elevation
E1049 Electrical box of the starting aids
F266 Fuse 1A
U163 Diagnostic unit of the coolant heater

The diagnostic unit system is installed in the electrical box E1049, which is located in the cab elevation.

• ▶ Set the fuse F266 to on.

◦ ▷ The diagnostic unit U163 starts automatically.

Then, the diagnostic unit U163 is controlled with the buttons that follow:

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Previous
This button is usually used to go back in the menus.

Next
This button is usually used to access to the next menus.

OK
This button is usually used to confirm a selection.

• ▶ Wait until the two units U163 and U106 are interconnected.

◦ ▷ During this time, the symbol "INI" is shown on the U163 display.

• ▶ When the U163 display is blank, push the "OK" button.

◦ ▷ The diagnostic starts automatically.

Get the error codes

This section is available only for the diagnostic unit U163.

For the error codes chart, you must refer to the Troubleshooting Instructions of the coolant heater manufacturer.

• If the symbol "STOP" is shown on the display:

◦ ▷ There is no error code that is active at the moment.

• If the symbol "ERR" is shown on the display:

◦ ▷ There is an active error code.

• In the two cases:

◦ ▷ You can have a view of the recorded error codes.

◦ ▷ You can erase the error codes memory.

Get the active error code

• ▶ Push the two buttons "Previous" and "Next" at the same time.

◦ ▷ The active error code is shown with the label "AF".

Get the recorded error codes

• ▶ Push one of the two buttons "Previous" or "Next".

◦ ▷ The recorded error codes are shown with the label "F".

Erase the error codes memory

• ▶ Select the active error code or a recorded error code.

• ▶ Push the "OK" button.

◦ ▷ The symbol "DEL" is shown on the display.

• ▶ Push the "OK" button again.

◦ ▷ The error codes memory is erased.

◦ ▷ The symbol "STOP" is shown on the display.

If necessary, you can also unlock the control unit with this procedure.

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Stop the diagnostic

This section is available only for the diagnostic unit U163.

When the symbol "STOP" is shown on the display:

• ▶ Push the "OK" button.

• ▶ Set the fuse F266 to off.

From: Operator's manual R 9200 - 410 > Control and operation > Setting the machine into operation

4.3.4 | Starting aids: auxiliary preheating procedures (optional equipment)

If starting aids are installed on the machine, the auxiliary preheating procedures com­plete the preheating of the Diesel engine coolant.

Thus, according to the configuration of your machine, you must obey the auxiliary preheating procedures before, at the same time or
after the preheating of the Diesel engine coolant.

Thermal insulation
If installed, special devices make the thermal insulation of the coolers, that of the Diesel engine compartment and that of the pumps box
better.

Figure 1. Thermal insulation

1 Tarpaulin 3 Crank handle

2 Louver 4 Cover

Depending on the machines, the coolers can have tarpaulins or louvers.

• ▶ If louvers 2 are installed, open and close them with the crank handle 3, which is installed in the engine compartment, against the
counterweight.

Hydraulic oil preheating

If installed, the hydraulic oil preheating operates with the following devices:

• An external generator, which is not provided with the machine

• Immersion resistors in the hydraulic tank.

At this step, the preheating of the Diesel engine coolant is in progress and the ma­chine is off.

Make sure that the following tools are available:

▢ An external generator, which supplies the following minimum apparent power, according to your system configuration and to the local
power supply.

Table 1. External generator

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Voltage Apparent power

400 V / 50 Hz 14,5 kVA
480 V / 60 Hz 14,5 kVA

Figure 2. External socket and control box

1 External socket P603 Power supply indicator

P600 Power supply indicator QMS Circuit breaker of the control box U1090
P602 Indicator for low hydraulic oil level

• ▶ Connect the external generator to the external socket 1.

• ▶ Set the circuit breaker QMS to the position ON.

◦ ▷ The power supply indicator P600 comes on.

◦ ▷ The preheating of the hydraulic oil starts.

◦ ▷ The indicator for procedure in progress P603 comes on.

NOTE!
To prevent resistors heating with insufficient hydraulic oil in the hydraulic tank, the preheating of the hydraulic oil stops
automatically if the hydraulic oil level is too low.

• ▷ The indicator for low hydraulic oil level P602 comes on.
• ▷ The indicator for procedure in progress P603 goes off.

When the external generator is connected to the external socket 1, the warning light H68, which is installed on the cab control board,
comes on. This function is automat­ically controlled.

• ▶ Do not disconnect the external generator.

• ▶ Do not wind and/or attach the external generator cable on the machine (for exam­ple: on the catwalk).

CAUTION!
If it is necessary to start the Diesel engine during this procedure, travel and swing movements are not possible while the
external generator is connected.

Hydraulic oil preheating with circulating heating system (if installed)

Depending on the machines, it is possible that the hydraulic oil preheating also operate with a circulating heating system. In this case,
you must obey the following pro­cedure.

Figure 3. Circulating heating system

1 Circulating heating system

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2 Manual valve (1x)

At this step, the preheating of the Diesel engine coolant is in progress and the ma­chine is off.

Make sure that the following tools are available:

▢ An external generator, which supplies the following minimum apparent power, according to your system configuration and to the local
power supply.

Table 2. External generator

Voltage Apparent power for configuration with circulating heating system
400 V / 50 Hz 17,5 kVA
480 V / 60 Hz 17,5 kVA

Make sure that the following preconditions are met:

▢ The manual valve 2 is open.

Figure 4. External socket and control box U1090

1 External socket
2 Switch of the control box U1090
3 Circuit breaker of the control box U1090

• ▶ Connect the external generator to the external socket 1.

• ▶ Set the switch 2 to the position ON or LOCAL.

• ▶ Set the circuit breaker 3 to the position ON.

◦ ▷ The preheating of the hydraulic oil starts.

When the external generator is connected to the external socket 1, the warning light H68, which is installed on the cab control board,
comes on. This function is automat­ically controlled.

• ▶ Do not disconnect the external generator.

• ▶ Do not wind and/or attach the external generator cable on the machine (for exam­ple: on the catwalk).

CAUTION!
If it is necessary to start the Diesel engine during this procedure, travel and swing movements are not possible while the
external generator is connected.

Connection for warm air duct

If installed, a special interface below the uppercarriage structure lets you connect an external blower heater, which is not provided with
the machine, to warm up different environments.

At this step, the preheating of the Diesel engine coolant is in progress and the ma­chine is off.

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Figure 5. Connection for warm air duct

1 Interface for the warm air duct

2 External blower heater

Make sure that the following tools are available:

▢ A warm air duct with a diameter of approximately 250 mm.

• ▶ Connect the external blower heater 2 to the interface 1.

CAUTION!
If it is necessary to start the Diesel engine during this procedure, travel and swing movements are not possible while the
external blower heater is connected.

Fuel preheating
At this step, the temperature of the Diesel engine coolant must be in good conditions.

• ▶ Make sure that the warning light #169, which is installed on the control panel for the starting aids, is off.

• ▶ Start the machine electrical system: refer to the dedicated section of this manual.

◦ ▷ The fuel preheating automatically starts and stops.

• ▶ If installed, disconnect the external generator and the external blower heater.

Start the machine

• ▶ Make sure that all the applicable steps of the following procedures are finished:

• Preheating of the Diesel engine coolant

• Auxiliary preheating procedures.

• ▶ If installed, disconnect the external generator and the external warm air duct.

◦ ▷ Travel and swing movements are not possible while the external generator is connected, even if it is possible to start the Diesel
engine.

• ▶ Start the Diesel engine.

• ▶ Do the warm-up procedure: refer to the dedicated section of this manual.

From: Operator's manual R 9200 - 410 > Control and operation > Setting the machine into operation

4.3.5 | Warm-up procedure for Diesel engine and hydraulic circuit

If the excavator is started when the exterior temperature is below 0°C, the operator must do the warm-up procedure:

▢ Make sure that the hydraulic oil temperature is sufficient (refer to lubricating section in chapter 5) to do this procedure. If this
temperature is not sufficient when a preheating system is installed on the excavator, keep preheating.

• ▶ Let the engine idle at approximately 1/2 rated speed during the first 3 to 5 minutes and make sure that no error symbols are shown
on the monitoring display (refer to the functions of the display in chapter 3).

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NOTE!
Depending on the excavators, the engine speed can be automatically limited for the hydraulic oil warm-up. If not, use the
special button installed on the keyboard.

• ▶ Refer to speed adjustment section in chapter 3.

CAUTION!
Idling for an extended period of time damages the engine.

• ▶ Switch off the Diesel engine if the machine is not being used.

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

• If the ambient temperature is less than -20°C during the machine operation, do not open the louvers of the hydraulic oil cooler more
than one quarter.

• ▶ Step 2 - Slowly increase the engine load until the coolant temperature reaches 40°C, on the temperature indicator of the main menu
of the display.

• ▶ Step 3 - Carefully activate the working hydraulic circuits. Do not reach end positions of piston rod. Operate all movements at
reduced speed:

• Smoothly lift up attachment.

• Slowly activate each cylinder of the attachment. Activate cylinder in order below and repeat 10 times before moving to next cylinders:

◦ Shovel flap cylinders (in case of shovel attachment)

◦ Bucket tilt cylinders

◦ Stick cylinders

◦ Boom cylinders

• Slowly swing clockwise and counterclockwise on approximately 1/2 turn. Repeat 4 times in each direction.

• ▶ Step 4 - Repeat step 3 a second time.

• ▶ Step 5 - Repeat step 3, with reaching end position of piston rod.

• ▶ Step 6 - Repeat step 5 a second time.

• ▶ Step 7 - Check oil temperature in hydraulic tank. If oil temperature is under 10°C, repeat step 5 until oil temperature reaches 10°C.
If oil temperature is above 10°C, move to step 8.

▢ The step 8 that follows is applicable only to crawler excavators.

• ▶ Step 8 - Start the travel hydraulic circuits very slowly forward and backward on approximately 10 meters. Repeat 4 times.

The excavator can now be operated.

From: Operator's manual R 9200 - 410 > Control and operation > Setting the machine into operation

4.3.6 | Jump start procedure

Start with jump start cables

DANGER!
When connecting to exterior batteries, old batteries can be subject to increased gas formation.

• ▶ Wear protective goggles and gloves whenever jump starting, avoid naked flame and creating any sparks in the
vicinity of the flat vehicle battery. RISK OF EX­PLOSION!
• ▶ Only use jump starting cables with a sufficient cross section. Always follow the established jump starting procedure.

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Connect the batteries

• ▶ First connect the cable to the positive terminal (+) of the flat battery and then to the positive terminal (+) of the exterior battery.

• ▶ Connect the second cable to the negative terminal (-) of the flat battery and then to the negative terminal (-) of the exterior battery.

• ▶ Start the engine as described above.

CAUTION!

• ▶ Before removing the jump start cable, be sure to place the diesel engine of the jump started machine into low idle.
• ▶ For safety reasons, switch on large consumers such as work headlights, upper carriage lighting etc. to avoid
overvoltage. The electronics could otherwise be damaged.

Disconnect the batteries

• ▶ First remove the cable from the negative terminal (-) of the exterior battery and then from the negative terminal (-) of the flat battery.

• ▶ Remove the second cable from the positive terminal (+) of the exterior battery and then from the positive terminal (+) of the flat
battery.

• ▶ Check the electrical function of the machine.

For battery care and maintenance, see the chapter “Battery care”.

Start with auxiliary start receptacle

You can connect an external power supply to the machine through the auxiliary start receptacle.

Figure 1. Auxiliary start receptacle

1 Auxiliary start receptacle (X60 )

2 Protective cover

The auxiliary start receptacle (X60) 1 is located on the pumps box, near the engine doors.

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Connect an external power supply

The external power supply is not provided with the machine.

• ▶ Make sure that the ignition key of the machine is on "off" position.

• ▶ Switch the principal batteries switches of the machine to position "open".

• ▶ Remove the protective cover 2.

• ▶ Connect the external power source to the auxiliary start receptacle (X60) 1.

• ▶ Turn on the two electrical systems.

• ▶ Start the engine.

You can refer to section "Start and stop the machine" of this manual.

From: Operator's manual R 9200 - 410 > Control and operation > Setting the machine into operation

4.3.7 | Emergency and safety operations

Emergency stop

Location of the emergency stop buttons

Different emergency stop buttons are installed on the machine.

Figure 1. Location of the emergency stop S100_1

The emergency stop S100_1 is installed on the cab control board.

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Figure 2. Location of the emergency stop S100_2

The emergency stop S100_2 is installed on the electrical box E1086, near the engine compartment doors.

Figure 3. Location of the emergency stop S100_3

The emergency stop S100_3 is installed in the Diesel engine compartment.

Figure 4. Location of the emergency stop S100_4

You can get access to the emergency stop S100_4 below the counterweight.

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Do an emergency stop

CAUTION!
Only use this method in case of emergency.

• ▶ Turn the ignition key S1 to the "Off" position or push one of the emergency stop buttons S100_1, S100_2, S100_3 or S100_4.

◦ ▷ This action stops the Diesel engine and disconnect the electrical system.

◦ ▷ If an emergency stop is operated, the ladder is automatically lowered.

• ▶ After an emergency stop and before you unlock the emergency stop button, the machine must be examined to find the cause of the
emergency stop.

• ▶ After an emergency stop with an emergency stop button, unlock the button before you try to start again.

Test of the Diesel engine starter (optional)

The electrical box E1086 can have test switches to do a functional test of each Diesel engine starter.

Figure 5. Location of starter test switches S51_1 and S51_2

E1086 Electrical box

S51_1 Starter test switch
S51_2 Starter test switch

• ▶ Stop the Diesel engine.

• ▶ Push the starter test switches S51_1 and S51_2.

Safety controls for the Diesel engine

If you cannot start, monitor or operate safely the Diesel engine because a failure occurs in the primary electronic circuit of the machine,
you can keep it temporarily in safety modes of operation.

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Safety start of the Diesel engine

Figure 6. Safety control for the Diesel engine start

A161 Electrical plate in E1005

S1_A161 Safety switch

The electrical plate A161 is located in the cab connection box E1005. You can also refer to chapter 4 of this manual.

• ▶ Turn the ignition key S1 to the stop position.

• ▶ At the same time, push the switch S1_A161.

◦ ▷ The Diesel engine starts in safety operation.

◦ ▷ The machine stays in this mode until you turn the ignition key S1 to position "0".

Safety control of the Diesel engine speed

Figure 7. Safety controls for the Diesel engine speed

R6 Speed adjustment of the Diesel engine

S23 Diesel engine safety operation ON

• ▶ Make sure that the safety start of the Diesel engine is on.

• ▶ Push the button S23.

◦ ▷ The indicator light in the button comes on.

• ▶ Turn the knob R6 clockwise to increase the engine speed.

• ▶ Turn the knob R6 counterclockwise to decrease the engine speed.

• ▷ When you use this mode, this symbol "Speed control off" is shown on the dis­play.

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Safety stop of the Diesel engine

CAUTION!
Do not suddenly turn the engine off when it is running at high idle.

• ▶ Decrease the Diesel engine speed to low idle with the knob R6.

• ▶ Let the Diesel engine run at low idle for 3-5 minutes to decrease the temperature.

• ▶ Then turn the ignition key S1 to the position "0" and remove it.

Safety control for swing and travel brakes

Figure 8. Safety control for swing and travel brakes

A1002 Electrical plate in E1005

S73 Safety switch

The electrical plate A1002 is located in the cab connection box E1005. You can also refer to chapter 4 of this manual.

If the swing and/or travel brake(s) does/do not operate correctly, because of the fail­ure of the keypad A168:

• ▶ Push the switch S73.

In this mode, you can operate the brakes with the safety lever.

• ▶ Push the safety lever down.

◦ ▷ The brakes are disengaged.

• ▷ When you use this mode, this symbol "Brakes manu" is shown on the display.

• ▶ Push the safety lever up.

◦ ▷ The brakes are engaged.

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Safety controls for hydraulic pumps

Figure 9. Safety controls for hydraulic pumps

A1002 Electrical plate in E1005

S74_1 Safety switch for pumps power safety control
S74_2 Safety switch for pumps flow safety control

The electrical plate A1002 is located in the cab connection box E1005. You can also refer to chapter 4 of this manual.

Pumps power safety control

During safety operation, a specified value for the power of the hydraulic pumps is ac­tivated.

• ▶ Push the switch S74_1.

• ▷ When you use this mode, this symbol "Power control off" is shown on the dis­play.

Pumps flow safety control

During safety operation, a specified value for the flow of the hydraulic pumps is acti­vated.

• ▶ Push the switch S74_2.

• ▷ When you use this mode, this symbol "Flow control off" is shown on the dis­play.

Safety fans control

Figure 10. Safety fans control

A1002 Electrical plate in E1005

S74_3 Safety switch

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The electrical plate A1002 is located in the cab connection box E1005. You can also refer to chapter 4 of this manual.

If the engine cooling and/or oil cooling fan(s) does/do not operate correctly:

• ▶ Push the switch S74_3.

◦ ▷ The fans operate at maximum speed.

• ▷ When you use this mode, this symbol "Fan control off" is shown on the dis­play.

Tow the machine

It is not permitted to tow the machine.

• ▶ If you must move or recover a defective or unserviceable machine, contact Lieb­herr customer service.

From: Operator's manual R 9200 - 410 > Control and operation > Setting the machine into operation

4.3.8 | Travel movements

Travel straight ahead

Figure 1. Travel straight ahead

1 Idler 5a / 5b Pedal for the left travel gear

2 Sprocket 6a / 6b Pedal for the right travel gear

CAUTION!
When you travel forward, the uppercarriage must be turned to the undercarriage to have the idler 1 at the front and the
sprocket 2 at the rear.

Travel forward
• ▶ Push the two pedals forward (5a and 6a).

Travel rearward

CAUTION!
Before you travel rearward, make sure that you can safely go into the area behind you.

• ▶ Push the two pedals down (5b and 6b).

Turn on the spot

Figure 2. Turn on the spot

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Turn left (A)

• ▶ Push the left pedal down (5b) and at the same time push the right pedal forward (6a).

Turn right (B)

• ▶ Push the right pedal down (6b) and at the same time push the left pedal forward (5a).

Turn with one track chain

Figure 3. Turn with one track chain

Turn to the left (A)

• ▶ Push the right pedal forward (6a).

Turn to the right (B)

• ▶ Push the left pedal forward (5a).

NOTE!
If possible, do not turn rearward for the preservation of the track components.

Operate the travel movements manually

Figure 4. Hand levers to operate the travel movements manually

If you must operate the travel movements very carefully and gradually:

• ▶ Put the hand levers 1 and 2 into the two travel pedals.

• ▶ Control the travel movements manually.

NOTE!
For safety reasons, you must control the travel movements manually when the machine must travel onto or off a low
loader.

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Control the speed

The "High speed gear" button of the control keyboard controls the travel speed. The travel motors can be operated in
two different positions:

• Normal drive (position 1):Maximum tensile force of the two travel gears at moderate speed.
• Fast drive (position 2):Reduced tensile force of the two travel gears at maximum speed.

• ▶ Push the "High speed gear" button.

◦ ▷ The first LED in the button comes on.

◦ ▷ Transfer from normal drive to fast drive is operated.

While travelling, the machine will automatically switch from normal drive to fast drive as the ground conditions permit. If the ground
conditions become more difficult again, the system will automatically switch from fast drive to normal drive.

• ▶ Push the "High speed gear" button again.

◦ ▷ The first LED in the button goes off.

◦ ▷ Transfer from normal drive to fast drive is deactivated.

When the button is switched off, the travel motors stay in position 1.

Brake the machine

Stop the machine while travelling

• ▶ Release the travel pedals.

◦ ▷ The pedals go back to the neutral position.

◦ ▷ The travel gear stops.

◦ ▷ The machine stops.

When the travel pedals are in the neutral position, the hydrostatic travelling mecha­nism prevents the machine from rolling off.

CAUTION!
The machine stops suddenly if you release the travel pedals quickly!

• ▶ Always fasten the safety belt before you start the machine.

Apply and release the travel brake

The travel brake is applied by default when you start the machine.

• ▶ Push the "Travel brake" button on the related keypad.

◦ ▷ The first LED in the button goes off.
◦ ▷ The travel brake is released.
◦ ▷ The undercarriage is unlocked.
• ▶ Push the "Travel brake" button again.
◦ ▷ The first LED in the button comes on.
◦ ▷ The travel brake is applied.
◦ ▷ The undercarriage is locked.

The travel brake is applied if the safety lever is up or the access ladder is down (if installed) or the service trap is down (if installed).

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From: Operator's manual R 9200 - 410 > Control and operation > Setting the machine into operation

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4.4 | Working with the machine

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Working safely with the machine

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• Before you start working, acquaint yourself with the special features of the job site and any special precautions and warning signals.
Examples of particular work environments would be on-site or traffic obstructions, the load-carrying capacity of the ground and any
requirements to make the job site safe from public use.

• Always maintain a safe distance from overhangs, edges, slopes and unsafe ground.

• Be particularly careful in conditions of reduced visibility and changeable ground conditions.

• Familiarize yourself with the location of power and gas lines on the job site and take particular care when working near them. If
necessary, inform the responsible authorities.

• When working in areas with underground lines (gas, electricity), adhere to the laws, regulations and rules applicable at the place of
use.

• Maintain a safe distance from electrical aerial lines. Do not allow the attachment to come near cables when working near electrical
aerial lines. Risk of fatality! In­form yourself about required safety distances.

• The following actions must be carried out in the event of any transfer of electricity:

◦ do not move the machine or its attachment,

◦ do not leave the driver’s cab,

◦ warn any personnel in the vicinity not to come close to the excavator and not to touch it,

◦ instruct or initiate that someone turns off the voltage,

◦ move the machine, if possible, from the danger zone to a sufficient distance,

◦ do not leave the machine until you are absolutely sure that voltage in the line, which had been touched or damaged, has been
turned off!

• Before moving the machine, always ensure that any attachments are safely se­cured.

• When driving onto public roads, paths and squares, observe current traffic regulations and if necessary, ensure that the machine has
been made safe as per reg­ulations beforehand.

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

• Do not permit any passengers in the machine.

• Only work when seated properly and with the safety belt securely fastened (if available).

• Report all function faults and ensure that all necessary repairs are carried out im­mediately.

• Assure yourself that no one is endangered when you start the machine moving.

• Before you start working, test the brake system in accordance with the regulations given in the operating instructions.

• Never leave the driver’s seat while the machine is moving.

• Never leave the machine unattended while the engine is running.

• The machine must be positioned, moved and operated in such a way that it is stable and that there is no danger of overturning. Only
known loads may be moved with the attachment; this applies particularly when using the grab.

• Position the upper structure in the longitudinal direction when moving and hold the load as close to the ground as
possible.EXCEPTION: excavators used for loading and unloading, see the part Safe use when loading and unloading (particularly
when loading and unloading wood).

• Adjust your driving speed to suit site conditions.

• Avoid any working movements which may tip the machine. Should the machine start to tip or slide sideways, however, turn the upper
structure to face downhill and lower the attachment at the same time.

• As far as possible, work downhill or uphill and not side on to the slope.

• Drive safely on stony, slippery or inclined ground.

• Always travel in the direction of the slope and not perpendicular to the slope, with the uppercarriage aligned with the undercarriage.

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• Only drive downhill at the permitted speed or you could lose control of the ma­chine.

• Always shift down to a lower running step before a slope. When doing this, the diesel engine must run at maximal speed and the
speed may only be reduced us­ing the foot pedals.

• Load an occupied truck only if all safety requirements are fulfilled, notably in order to protect the truck operator.

• For demolition work, digging and crane operations etc., always use protective de­vices specifically designed for the purpose.

• For terrain which is difficult to gain an overview of and whenever necessary, ask for the assistance of a spotter. Only permit one
person to give you signals.

• Authorize only experienced people to attach load and to give indications to the machine operator. This people must be in the
operator’s sight or in radio contact with him.

• Depending on the attachment combination, there is a risk of collision between the work tool and the machine (uppercarriage and
undercarriage). The greatest de­gree of care must be taken to avoid damage.

• Depending on the attachment combination, there is a risk of collision between the work tool and the cab, the cab protection or the
boom cylinders. The greatest de­gree of care must be taken to avoid damage when the hoe teeth come within this area.

• Depending on the attachment combination, there is a risk of collision between the work tool and the attachment parts. The greatest
degree of care must be taken to avoid damage.

• Depending on the attachment combination, there is a risk of collision between the lift ring of the attachment and the cab or the cab
protection. Before operating, ensure that there is no risk of collision, especially on excavator with cab elevation. If necessary remove
the lift ring.

• In case of a thunderstorm:

◦ lower the attachment to the ground and if possible anchor the digging tool into the soil.

◦ leave the cab and move away from the machine before the storm breaks out. Otherwise, you must stop the excavator, turn off the
radio and keep inside the closed cab until the end of the storm.

• Auxiliary control units can have various functions. Always check their functions when starting up the machine.

• Stop the swinging motion of the uppercarriage when lowering the attachment into a ditch without striking the attachment on the ditch
walls.

• Inspect the machine for damage if the attachment has been swung into a wall or any other obstacles.

• Applications in which the attachment is to be used to strike the material being extracted are not permitted, even when working in a
longitudinal direction.

• Repeated strikes against an object leads to damage to the steel structures and machine components.

• Please refer to your Liebherr dealer if special teeth for heavy-duty or special ap­plications are required.

• Do not attach too large bucket or bucket with side cutters or that are during operations with rocky material. This would prolong the
work cycles and may lead to damage to the bucket as well as further machine components.

• With the 2x45° offset articulation, the offset position may only be employed if the working tool or the attachment does not touch the
material.

• Operation of the offset articulation to drill into the material is not permitted.

• Do not lift the machine during operation. Should this happen, lower the machine slowly back to the ground.

• Do not let the machine fall heavily on the ground and do not hold it back with the hydraulics. This would damage the machine.

• During operation with the attachment it is forbidden to raise the machine with the dozing blade (e.g. carving at the ceiling when
tunnelling).

• Do not dig under the undercarriage. Take all necessary measures to prevent ground collapse under the machine.

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• The operation of Liebherr Mining machines in the following Mining applications is not approved or condoned by Liebherr:

◦ Batter pulling (also known as Scaling), without exception.

◦ Double benching (also known as Split benching or Double flitching) when the material is un-blasted and non-fragmented material
which requires the boom down (rod side) pressure to exceed 50 bar.The use of these Mining methods will result in increased
fatigue levels to steel structures and components of the respective Liebherr Mining Machine and therefore will significantly reduce
the expected lifetime of structures and/or com­ponents.

Working safely with the machine used for demolition appli­cation

• Machines used for demolition application are subject to specific conditions and must be fitted with special safety devices (for further
information, contact Liebherr customer service).

• If the machine can be used for demolition application, you must also obey the ad­ditional safety instructions that follow.

Before the operation of the machine

• Make sure that no persons are in the hazard area of the machine.

• Make sure that the working conditions are in the specified limits.

• Make sure that the special safety devices necessary for the task operate correct­ly.

• Always obey the applicable local regulations.

Incorrect use of the machine used for demolition application

• Demolition works must be carried out only by trained specialist personnel.

• Do not operate the machine if the counterweight is not suitable for the attachment or special tool you use.

• Do not operate the machine if applicable and approved operator protective structures (e.g. FOPS, front protective grid) are not
installed.

• Do not move suddenly and jerkily.Do not stop it suddenly.Always move the attachment or special tool slowly and with constant speed
movements.

• Because of the possible effects on the machine stability, reduce the height and the speed of the movement.

• Do not lift the machine with the attachment or special tool.

• Make sure that there is no rubble on the attachment or special tool.

• Operate the machine in the position that follows:

◦ Align the uppercarriage with the undercarriage so that the sprockets locate at the back-end.

◦ Work over the idler.

• Keep a sufficient distance between the machine and the object to demolish.

• Do not use the inertia of the attachment or special tool as an additional force.

• Never leave the machine unattended while the attachment or special tool is not safely positioned on the ground.

• Lay down the attachment or special tool on the ground to park the machine.

• Obey the symbols shown on the display and the acoustic warning signals.

• Prevent unwanted lateral forces on the attachment or special tool when the up­percarriage turns.

• Do not drive at a right angle to the slope.

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Incorrect use of the attachment or special tool used for demolition ap­plication
• Make sure that you use an attachment or special tool exclusively designed for the task.

• Only use attachment or special tool approved by Liebherr.

• Only operate the attachment or the special tool with closed windshield and with a front protective grid.

• Only operate the attachment or the special tool with closed door.

• Do not clean the ground with the special tool.

• Make sure that the special tool works in its specified limits. For more information, also refer to the Operator’s Manual of the tool
manufacturer.

Safe use of a hydraulic hammer or a hydraulic ripper

• According to the severity of the application, the use of a hydraulic hammer or a hydraulic ripper can result in vibrations, shocks or
stresses which are higher than in normal use. It may reduce the expected lifetime of structures and/or compo­nents.

• The hydraulic hammer or the hydraulic ripper must be selected with particular care. When using a hydraulic hammer or a hydraulic
ripper not permitted by Lieb­herr, warranty for steel structures and machine components will be ceased.

• Before beginning breaking tasks, position the machine on firm and level ground.

• Use a hydraulic hammer or a hydraulic ripper designed exclusively for breaking stone, concrete and other breakable materials.

• Only operate the hydraulic hammer or the hydraulic ripper in the longitudinal direction of the machine and with the windshield closed
or with a front protective grid.

• Ensure during hammer or ripper operation that no cylinder is entirely extended or retracted and that the stick is not in the vertical
position.

• In order to avoid damages to the machine, try not to break stone or concrete while performing retraction and extension motions of the
hydraulic hammer.

• Do not apply the hydraulic hammer uninterrupted for more than 15 seconds at a time to the same place. Change the breaking point.
Too long uninterrupted oper­ation of the hydraulic hammer leads to an unnecessary overheating of the hydrau­lic oil.

• Do not use the drop force of the hydraulic hammer or of the hydraulic ripper to break stone or other materials. Do not move obstacles
with the hydraulic hammer. Misuse of this nature would damage both the hammer and the machine.

• Do not use the hydraulic hammer or the hydraulic ripper to lift objects.

• Before beginning breaking tasks, the pressure of the dampening accumulator of the hydraulic ripper must be adjusted depending on
the nature of the ground and the excavator model.

Safe use of a ripper

• Rippers are generally used in applications where the use of a bucket is not efficient to break out rocks. Thus, these applications are
more severe than in normal use.

• According to the severity of the application, the use of a ripper can result in vibrations, shocks or stresses which are higher than in
normal use. It may reduce the expected lifetime of structures and/or components.

• Special hydraulic devices can be necessary. Contact the Liebherr customer ser­vice.

• The ripper must be selected with particular care. When using a ripper not permitted by Liebherr, warranty for steel structures and
machine components will be ceased.

• Before beginning breaking tasks, position the machine on firm and level ground.

• Do not use the ripper to lift objects.

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Safe use when loading and unloading (particularly when loading and unloading wood)
• According to use, it can be necessary when working with a grab to move with the attachment raised and the load lifted up; this applies,
for example, when loading and unloading wood.

• Here, the centre of gravity of the machine will be displaced upwards in the vertical direction. The driving characteristics of the machine
will thus be influenced persistently, e.g. through reduction of the dynamic stability.The following instructions are therefore to be
observed at all times:

◦ Adjust vehicle handling to suit the altered machine characteristics and environ­mental conditions.

◦ Reduce your speed to prevent the need for sudden braking and steering ma­noeuvres.

◦ Avoid sudden speed changes, such as braking, accelerating and changing di­rection.

◦ Only rotate the uppercarriage when the undercarriage is stationary.

◦ Only rotate the uppercarriage after you have picked up the load.

◦ Only move the machine when you have picked up and lifted the load and rotat­ed the upper structure to the driving position.

◦ There is a danger of possible swinging movement and dropping of the load when the attachment is raised.

◦ A protective grid (FOPS) in accordance with ISO 10262 must be attached to the cab.

◦ A protective roof (FOPS) in accordance with ISO 10262 must be attached if there is a risk of objects falling from above.

◦ Only the maximum permissible load may be taken up using the grab.

• NOTE: The weight of absorbent materials, such as logs, is dependent on length, diameter and specific weight. The influencing
variables present in a natural prod­uct, such as moisture, must be noted.

• Working procedures when using machines with grabs require the machine oper­ator to receive special instruction and training.

• Use as part of the work process is only permitted when the machine operator has sufficient training and practical experience.

Safe use of machines with tower elevation

• Due to the tower elevation, the centre of gravity of the machine will be displaced upwards in the vertical direction. The driving and work
characteristics of the ma­chine will thus be influenced persistently, e.g. through reduction of the dynamic stability.

• Due to the heightened centre of gravity, the machine must be aligned horizontally before use. In horizontal alignment, the centre of
gravity of the uppercarriage is over the centre of the undercarriage, which reduces the risk of tilting.

• The machine can still sway and tilt despite being aligned!The following instructions are therefore to be observed at all times:

When moving the machine:

• Rotate the uppercarriage parallel to the undercarriage (transport position).

• Draw the attachment as close as possible to the machine.

• Only at this point may the support feet be retracted and the machine moved.

• Moving with loads is not permitted.

• Check the terrain to be covered to ensure that the ground is solid and even. Potholes and uneven surfaces jeopardize the stability of
the machine.

• Adjust vehicle handling to suit the altered machine characteristics (high centre of gravity) and environmental conditions.

• Reduce your speed to prevent the need for sudden braking and steering ma­noeuvres.

• Avoid sudden speed changes, such as braking, accelerating and changing di­rection.

• Ascending gradients and obstacles may only be approached in the longitudinal direction in order to prevent unacceptable banking of
the machine.

• Special care should be taken when driving through narrow passages - drive slowly!

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When loading and unloading:

• The machine must be supported and aligned horizontally before moving (swing) the uppercarriage out of the transport position.

• It is imperative that you check the contact surface of the support (load carrying capacity of the substrate). A support subsiding would
have disastrous conse­quences!

• Carry out all movements with increased care.

• To slew the load, move the attachment as close as possible to the machine (Caution! swinging grab) and hold the load close to the
undercarriage and above the substrate.

• Avoid braking or accelerating the attachment or uppercarriage abruptly.

• Do not lift any loads which are heavier than those given in the load chart.

Protection from vibration

• Vibrational loads on mobile building machinery are mainly the result of the type and method of use. The following parameters in
particular are decisive influences:

◦ Terrain conditions: Uneven areas and potholes;

◦ Operational techniques: Speed, steering, brakes, controlling the machine’s control elements when driving and working.

• To a large extent, the machine operator determines the vibrational loads since he selects the speed, gearbox ratio, working method
and route himself.This means that there is a wide range of different vibrational loads for the same machine type.

Whole-body vibrational load for the machine operator can be reduced if the following recommendations are observed:

• Select suitable machines, attachment parts and auxiliary devices for each part of the job.

• Use a machine that has a suitable seat (i.e. for earth-moving machinery such as hydraulic excavators, this should be a seat which
corresponds with EN ISO 7096).

• Keep the seat in good condition and adjust it as follows:

◦ The seat and its damping action should be adjusted depending on the weight and height of the operator.

◦ Check the seat’s damping action and adjustment mechanisms regularly and ensure that these seat characteristics remain as per
the seat manufacturer’s in­structions.

• Check the maintenance status of the machine, particularly with respect to: tyre pressure, brakes, steering, mechanical connections
etc.

• Do not steer, brake, accelerate, shift gears, move or load the machine’s attach­ment jerkily.

• To reduce vibrational load, adjust the machine speed to suit the route as follows:

◦ Reduce speed when driving on difficult terrain;

◦ Drive around obstacles and avoid driving on very difficult terrain.

• Keep the terrain on which the machine is working and driving in good condition:

◦ Remove large stones and obstacles;

◦ Fill in ruts and holes;

◦ Have machines ready to prepare and maintain suitable ground conditions and calculate in sufficient time to carry out any work
required.

• Drive longer distances (e.g. on public roads) at an appropriate (medium) speed.

• Use special auxiliary systems (if available) which reduce vibration for machines that are driven frequently.If such auxiliary systems are
not available, regulate speed to avoid "oscillating" the machine.

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From: Operator's manual R 9200 - 410 > Control and operation

4.4.1 | Uppercarriage swing movements

Turn the uppercarriage

The uppercarriage is turned using the left joystick.

Figure 1. Turn the uppercarriage

• ▶ Move the left joystick to the left c.

◦ ▷ Uppercarriage turns left.

• ▶ Move the left joystick to the right d.

◦ ▷ Uppercarriage turns right.

Brake the uppercarriage

The machine has a hydraulic and a mechanical swing gear brake.

Hydraulic swing gear brake

• ▶ Move the left joystick to neutral.

◦ ▷ A sufficient deceleration of the uppercarriage is achieved.

• ▶ Move the left joystick to the opposite direction.

◦ ▷ Maximum hydraulic braking action of the uppercarriage is achieved.

Mechanical swing gear brake

The uppercarriage can be locked in any position using a multi disk brake integrated in the swing gear.

The brake is negatively acting, hydraulically actuated and serves as a holding or parking brake.

CAUTION!
Damage to the machine.

• ▶ Only lock the mechanical swing gear brake when the uppercarriage is station­ary.

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• ▶ Push "Swing brake" button on the keyboard.

◦ ▷ Swing brake is engaged.
◦ ▷ Uppercarriage is locked.
◦ ▷ First LED in the button comes on.
• ▶ Push button again.
◦ ▷ Swing brake is released.
◦ ▷ Uppercarriage is unlocked.
◦ ▷ First LED in the button goes out.

The swing brake is engaged if the safety lever is up or the access ladder is down (if installed) or the service trap is
down (if installed).
In option, a buzzer can be activated in the cab if you operate the joystick to turn the uppercarriage while the swing
brake is engaged.

CAUTION!
The brake only applies when the uppercarriage is near standstill and if no swing movement is actuated with the joystick.
To stop the uppercarriage when working on a slope:

• ▶ Use the joystick to reduce the uppercarriage speed.

• ▶ Push "Swing brake" button to operate the swing brake.
• ▶ Move the joystick back to "0" position only after the brake operates.

Semi-automatic swing brake control (optional)

▢ Make sure that the swing brake does not operate.

• ▶ Tilt down the rocker switch S57 on the right joystick handle.
◦ ▷ The semi-automatic control of the swing brake is on.

When the semi-automatic control of the swing brake is on:

• When the uppercarriage speed is less than a limit value:

◦ The swing brake is applied.
◦ The first and the second LEDs in the "Swing brake" button come on.
◦ The swing brake symbol shows on the monitoring display.
• When the uppercarriage speed is more than the limit value:
◦ The swing brake is released.
◦ The first and the second LED in the "Swing brake" button go off.
◦ The swing brake symbol disappears from the monitoring display.
• ▶ Tilt up the rocker switch S57.
◦ ▷ The semi-automatic control of the swing brake is off.
◦ ▷ The swing brake is released.

CAUTION!
The brake only applies when the uppercarriage is near standstill and if no swing movement is actuated with the joystick.
To stop the uppercarriage when working on a slope:

• ▶ Tilt down the rocker switch S57.

• ▶ Use the joystick to reduce the uppercarriage speed.
• ▶ Move the joystick back to "0" position only after the brake operates.

Emergency stop of the uppercarriage swing movement

The swing brake can be applied independently of the uppercarriage RPM by pushing "Swing brake" button into position "applied".

CAUTION!
Perform this braking with the "Swing brake" button only in case of emergency as it causes fast abrasion of the brake
discs.

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Check the mechanical swing gear brake

▢ Uppercarriage must be stationary.

• ▶ Push "Swing brake" button.

◦ ▷ Swing gear brake is engaged.

◦ ▷ LED in switch comes on.

• ▶ Move the left joystick to the right and then to the left to stop.

◦ ▷ Uppercarriage must not turn.

◦ ▷ Swing gear brake function is operational.

From: Operator's manual R 9200 - 410 > Control and operation > Working with the machine

4.4.2 | Working position

Figure 1. Working position – machine

Work with the machine is generally to be carried out over the idler-wheel.

• ▶ Drive backwards when you are working lengthwise with the backhoe bucket.

From: Operator's manual R 9200 - 410 > Control and operation > Working with the machine

4.4.3 | Joystick functions when setting up the machine

Operating the stick cylinder

The stick cylinder is operated using the left joystick 4.

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Figure 1. Operating the stick cylinder

• ▶ Move the joystick rearward a.

◦ ▷ Stick will be drawn in.

• ▶ Move the joystick forward b.

◦ ▷ Stick will be extended.

Operating the boom cylinder

The boom cylinder is operated using the right joystick 3.

Figure 2. Operating the boom cylinder

• ▶ Move the joystick rearward h.

◦ ▷ Attachment will be raised.

• ▶ Move the joystick forward g.

◦ ▷ Attachment will be lowered.

Boom down with pressure

If it is necessary to lower the boom with pressure:

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Figure 3. Operating the boom down with pressure

A Joystick
B Joystick with analog stick (if installed)

• ▶ Move the joystick forward g.

◦ ▷ The attachment will be lowered pressureless (see section above).

• ▶ Push the button S6R right on top of the right handle at the same time you actuate the joystick.

◦ ▷ The boom is lowered with pressure.

Float position of boom cylinder (with shovel attachment only)

Figure 4. Float position

• ▶ Move the right joystick 3 forward g.

◦ ▷ Now the bucket can be used for grabing work while moving the joystick 4 for­ward to extend the crowd cylinders.

◦ ▷ The attachment can then move freely up or down depending on grade and the bucket will automatically follow the ground
contour.

Operating the bucket

The bucket is operated using the right joystick 3.

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Figure 5. Operating the bucket cylinder

• ▶ Move the joystick to the left e.

◦ ▷ Bucket will be tilted inwards.

• ▶ Move the joystick to the right f.

◦ ▷ Bucket will be tilted outwards.

Shake the bucket (with backhoe attachment only)

You can shake the bucket to remove dirt collected in the backhoe bucket.

• ▶ Operate very quickly the right joystick 3 as follows:

• Move the joystick fully to the right or to the left.

• Move the joystick to the neutral position.

• Move the joystick fully to the right or to the left again.

• ▶ While you do this sequence, the bucket shakes.

CAUTION!
Repetitive shakings cause fast wear of the components.

Operating the bottom dump bucket for shovel attachment

DANGER!
Additional operating and control elements (joysticks/pedals) can have different functions.

• ▶ Always check functions of operating and control elements when you start a machine which has an additional
attachment.

Manual flap control

You can control the bottom dump shovel bucket with the pedal or with the joystick.

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Figure 6. Rotary switch for control selection

• ▶ Use the rotary switch S256 to select one of the two control modes:

• with the pedal

• with the joystick

Manual flap control with the pedal

• ▶ Make sure that the related mode is selected with the rotary switch S256.

Figure 7. Operating the bottom dump shovel bucket

The bottom dump shovel bucket is moved with the two pedals 7a and 7b.

• ▶ Push pedal 7a.

◦ ▷ Shovel bucket will be opened.

• ▶ Push pedal 7b.

◦ ▷ Shovel bucket will be closed.

Manual flap control with the analog stick

• ▶ Make sure that the related mode is selected with the rotary switch S256.

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Figure 8. Flap control with the analog stick

• ▶ Push the analog stick on the right joystick 3 to the right 7a.

◦ ▷ Shovel flap will be opened.

• ▶ Push the analog stick on the right joystick 3 to the left 7b.

◦ ▷ Shovel flap will be closed.

Semi-automatic flap closing

Figure 9. Semi-automatic flap closing

A Joystick
B Joystick with analog stick (if installed)

• ▶ Push the button S6L left on the down of the right joystick 3.

◦ ▷ Shovel flap will be closed automatically with full speed.

• ▶ Push the button S6L again during semi-automatic flap movement.

◦ ▷ Shovel flap movement will be stopped.

NOTE!
If you keep the button S6L pushed, the semi-automatic flap closing movement will not start.If you operate the shovel
bucket pedal 7a or 7b during semi-automatic flap closing movement, the automatic movement will be stopped and flap
control is switched to manual operation through pedals 7a and 7b.

Combined movements
Moving a joystick diagonally results in the work functions concerned being combined. This allows different attachment movements to be
activated at the same time.

The operator can do the following movements without any additional manipulations.

When the swing movement is actuated, all working functions / movements are pos­sible without affecting the swing movement.

During travel, every attachment movement is possible, but the swing movement has priority. In this case, the travel movement is reduced.

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Lowering the work equipment when the engine is not run­ning

In an emergency, the attachment can be lowered when the diesel engine is not run­ning.

Figure 10. Lowering the attachment when engine is not running

• ▶ Turn the ignition key to contact position 1.

• ▶ Operate the joystick or the foot pedals until the attachment has lowered.

The attachment can be lowered because of the control oil unit’s pressure reserve. This reserve is limited and is only sufficient for small
movements of the pilot control devices.

• ▶ Only operate the joystick in the directions for lowering the attachment.

Bucket Filling Assistant (for backhoe attachment only) (op­tional equipment)

If installed, the Bucket Filling Assistant helps the operator during the bucket filling phase, before the machine lifts out the loaded bucket.

Figure 11. Attachment movements

1 Bucket filling
2 Loaded bucket lifting

Thus, when the Bucket Filling Assistant is on, the following functions are available:

• The Anti-Stalling function automatically controls the attachment movements to prevent blockage of the bucket.

• The Semi-Automatic Bucket Filling function automatically controls the attachment movements of the bucket filling phase.

• ▶ Start the machine.

◦ ▷ The Bucket Filling Assistant is automatically on.
◦ ▷ The first LED on the dedicated button on keypad A170 is on.

• ▶ With the machine in digging position, start to work as given in the section "General working methods" of this manual.

◦ ▷ The Anti-Stalling function operates automatically and permanently while the Bucket Filling Assistant is on.

◦ ▷ In addition, you can operate the Semi-Automatic Bucket Filling when you want.

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Operate the Semi-Automatic Bucket Filling

Figure 12. Operate the Semi-Automatic Bucket Filling

4 Left joystick
S55 Down: Activation rocker switch

• ▶ Tilt down and hold rocker switch S55 on left joystick 4. At the same time, do not operate boom and bucket movements manually.

◦ ▷ The machine automatically moves the attachment for the bucket filling phase.

• ▶ Release rocker switch S55.

or
Operate the boom or the bucket manually.

• ▷ The control of the attachment movements becomes manual again.

• ▶ Push the button on keypad A170.

◦ ▷ The functions of the Bucket Filling Assistant are off.
◦ ▷ The first LED in the button goes off.
• ▶ Push the button again.
◦ ▷ The functions of the Bucket Filling Assistant are on again.
◦ ▷ The first LED in the button comes on.

The Anti-Stalling and the Semi-Automatic Bucket Filling operate independently.

From: Operator's manual R 9200 - 410 > Control and operation > Working with the machine

4.5 | General working methods

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From: Operator's manual R 9200 - 410 > Control and operation

4.5.1 | Minimum impact working methods for your machine

To increase the service life of the machine and avoid unnecessary damage and the resulting repairs, please note the following points:

• Do not stop the rotary motion of the upper carriage when slewing into a ditch by stopping the equipment on the walls of the ditch.

• Using the machine for applications where the equipment is knocked against the material to be removed, in the longitudinal direction
too, is not permitted. Repeatedly hitting the work equipment against rock or other hard material will damage steel parts and machine
components.

• With specific combinations of boom, stick and work tool, the work tool could hit or break through into the cab. This could damage the
cab and injure the machine’s operator.

• Do not attach buckets which are too big or side cutters when using the machine in rocky material. This will extend the work cycles and
could result in damage to the bucket and other machine components.

• Please contact your LIEBHERR contractual partner if special teeth are required for heavy or special applications.

• Operating the drag bearing to bore into material is not permitted.

• Do not raise the machine when working. If this should occur, slowly lower the machine to the ground. Do not permit the machine to
lower quickly and do not inter­cept the falling movement using the hydraulics, since this could result in damage to the machine.

From: Operator's manual R 9200 - 410 > Control and operation > General working methods

4.5.2 | Preparatory activities

DANGER!
Risk of fatal injury and damage to the machine when working.

• ▶ Observe the safety information “Notes for safe working” at the start of these op­erating instructions.

Figure 1. Working position – machine

• ▶ Position the machine so that the load material can be taken up above the idler.

DANGER!
Insufficient support and machine damage.

Figure 2. Hazard area

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DANGER!
Risk of fatal injury due to rotating the machine.

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

CAUTION!
Risk of injury when working.

• ▶ Always wear safety shoes and, particularly when leaving the cab when demolition work is going on, a protective
helmet and safety glasses.
• ▶ Always wear the seat belt.
• ▶ Use the horn to give a short warning signal before starting work.

From: Operator's manual R 9200 - 410 > Control and operation > General working methods

4.5.3 | Positioning of the machine

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

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

Figure 1. Recommended digging

The recommended digging range is about a 90° arc in front of the machine (A).

NOTE!
Avoid digging at right angles to the tracks.
From: Operator's manual R 9200 - 410 > Control and operation > General working methods

4.5.4 | Working with the backhoe bucket

DANGER!
Risk of fatal injury and damage to the machine when moving the backhoe bucket.

• ▶ Ensure that the backhoe bucket is not slewed too close to the cab.
◦ ▷ The backhoe bucket could damage the cab and injure the machine’s opera­tor.
• ▶ Ensure that nobody is standing within the hazard area of the backhoe bucket.

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Digging

Figure 1. Optimal angle for digging

Figure 2. 30° forward to the vertical.

• ▶ Align the shovel arm in such a way that its underside is at an angle of approx. 30° forward to the vertical.

• ▶ Align the backhoe bucket in such a way that its underside can enter the ground at an angle with the axle of the shovel arm between
10° and 20°.

Figure 3. Taking up grab material

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

Figure 4. 45° backward to the vertical

• ▶ As soon as the shovel arm is at an angle of approx. 45° backward to the vertical, raise the boom slowly and evenly in addition to
slewing in the shovel arm and the backhoe bucket. Stopping suddenly will result in impact loads and vibrations.

• ▶ When the backhoe bucket is full or the shovel arm can no longer be slewed in, raise the boom and backhoe bucket until the filled
surface is parallel to the ground.

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NOTE!
For a efficient digging, the depth of the excavated face shouldn’t exceed the length of the shovel arm.

Loading the transport vehicle

DANGER!
Risk of fatal injury due to falling grab material.

• ▶ Do not load the transport vehicle so high that the grab material could drop out over the walls of the vehicle.
• ▶ Ensure that nobody is standing in the danger.
• ▶ Load an occupied truck only if all safety requirements are fulfilled, notably in or­der to protect the truck operator.
• ▶ Do not slew the equipment over the driver’s cab.

Figure 5. Emptying grab material

▢ If possible, the machine should stand higher than the transport vehicle to avoid having to lift the grab material unnecessarily.

• ▶ Stop the transport vehicle in a position that allows it to be loaded from the rear or the side.

• ▶ Slew the machine's equipment above the loading area of the transport vehicle.

• ▶ Distribute the grab material evenly over the loading area of the transport vehicle by slewing the backhoe bucket and shovel arm out,
slewing the upper carriage and possibly also moving the boom.

• ▶ If the backhoe bucket is not sufficiently emptied or there is still grab material in the backhoe bucket, slew the backhoe bucket in and
out several times to loosen the grab material.

From: Operator's manual R 9200 - 410 > Control and operation > General working methods

4.5.5 | Working with the Shovel bucket

Digging
To maximise machine power and breakout, maintain grade and fill the bucket, correct digging angles and technique should be used.

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Figure 1. Digging

• ▶ Most digging should be started with the bucket almost fully crowded back (50mm off stops or end of cylinders).

• ▶ When cleaning up or digging at floor level, angle the teeth aggressively to break out any toe that may be encountered.

• ▶ Keeping the heel of the bucket off the ground therefore creating a void under the rear of the bucket.

• ▶ Operate with the teeth and bucket lip doing all the work.

NOTE!
Avoid digging at right angles to the tracks.

CAUTION!

• ▶ Each time the stick is crowded back to commence a cut, extreme caution must be taken not to hit the tracks.
• ▶ The clam must always be closed when digging, although don’t slam it shut. Avoid working on the cylinder limits and
bucket stops during the digging cycle. Continual use of these practises will lead to premature failure of seals and O-
rings and can cause stress fractures to the clam, stick and bucket and damage to the boom and superstructure.
• ▶ Crowd the bucket in (down) while closing the clam. This practise makes use of gravity to help minimise shock
loading on the bucket cylinders.
• ▶ Never dig, or attempt to bring down any material overhang, with the bucket while the clam is open or partly open.
• ▶ Do not attempt to dig or clean the floor or face with the clam open. These practises can cause considerable damage
to the clam cylinders.

Unload the bucket

Figure 2. Unloading of the bucket

When dumping the load, tip the bucket forward slightly as the clam opens. This helps direct the material to fall centrally into the tray and
avoids spillage.

The position of the bucket backboard when the clam opens, directly affects the posi­tion of the load in the tray.

Bucket in ideal position resulting in material falling straight down. Loading centre of the haul truck.

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Attaching and removing attachment parts safely

• Equipment or attachments made by other manufacturers or those which do not have general approval from Liebherr for installation or
attachment may not be in­stalled or attached to the machine without Liebherr’s prior written consent.

• Liebherr must be provided with the appropriate technical documentation neces­sary for this purpose.

• Obey the instructions of the manufacturer of the approved working tool and of re­lated approved devices.

• Before carrying out any major repair work on the attachment, position the ma­chine on level, firm ground.

• Do not work beneath the equipment if it is not safely positioned on the ground or supported with appropriate supports.

• Before loosening lines or unscrewing bolts, you must store the equipment, switch off the engine and press the start key to the contact
position and both joysticks and the push-buttons to “Turn grapple” in order to reduce the pressure in the hy­draulic system.

• Do not attempt to lift heavy parts. Use devices which are suitable for this purpose and which have sufficient load carrying capacity.

• Do not use cable which is damaged or does not have sufficient load carrying capacity. Wear work gloves when working with wire
cables.

• When working on the attachment: switch off the engine and keep the safety lever tilted up. Never use your fingers to locate bores; use
the correct punch for the pro­cedure.

• During repair work: ensure that the hydraulic lines are secured correctly and that all bolts and connections are tight.

• When you have removed and chocked an attachment part, close open areas of the hydraulic circuit to stop dirt entering. Only allow
authorized persons in the vi­cinity of the machine or the lifting device used.

Removing and installing attachment pins safely

• If possible, always use a hydraulic bolt press to press out the attachment’s bolts.

• If you have to remove a bolt using a sledge-hammer, a driving punch and a bore hole conductor held by another person must be used.

• To drive in a bolt, screw the drive screws provided in the toolbox if provided into the bolt's threaded hole and only hammer these
screws.

• When installing bolts locked by means of castle nuts and cotter pins, first drive the bolt to the stop, then screw the castle nut by hand
until contact and then only pull it far enough to push in the cotter pin.

From: Operator's manual R 9200 - 410 > Control and operation > General working methods

4.6 | Transport

From: Operator's manual R 9200 - 410 > Control and operation

4.6.1 | Travelling procedures for mining machine

The life expectancy of undercarriage components is based on standard working conditions with a maximum travel ratio of 5% per service
meter unit. Working and / or travelling on uneven ground and / or abrasive material will influence the lifetime of the components and
attract additional cost for the undercarriage components.

Downhill or uphill travel on a slope has also an effect on the life expectancy of undercarriage components and on their wear rate. Indeed,
even if the slope angle is below the maximum permitted travelling angle, the increase of the slope angle causes the increase of the force
and of the contact pressures applied on all track components (track pad assembly, sprocket, ...). On an indicative basis, the travel force
applied on the track components is multiplied by two from a slope angle of 5° (8,7%) and is multiplied by 2,5 from a slope angle of 10°
(17,6%).

In general travel action has to be kept to the lowest level that is possible. Minimize travelling with turning through a narrow turning circle
and long distance travel.

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To minimize the travel ratio, professional mine planning with longfront winning sections is preferred. If digging operations at various spots
are necessary, a proper short term and long term plan of winning operations has to be employed to guarantee long term use of the
excavator at one place before moving to another location.

However, if frequent machine movement is necessary, the following set of procedures defined by Liebherr to minimize possible machine
damage, downtime and wear have to be taken into consideration.

General
In order to move the machine forwards: with the excavator in standard forward position, depress travel pedals all the way forward with the
toes. Direction of travel is in the direction of idlers.

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

Moving the machine during loading operations

Moving the machine during loading operations means adjustment of excavator dig­ging and / or truck loading position of some meters.

Important procedures:

• Before moving the machine, empty the bucket and close up the attachment to a position as close as possible to the excavator
undercarriage.

• The practice of placing the attachment on the ground and lifting the machine, then counter turning the undercarriage, is not allowed,
because it could cause prema­ture structural damage to the machine.

• If there is a build up of material around the tracks where the machine will not turn, you must move the machine several meters
forwards and / or backwards and at­tempt to turn again.

• If mine safety regulations allow, the operator can use the swing function to assist in turning the tracks, i.e. if turning to the right, swing
upper deck to the left and vice versa.

Walking the machine over distance

Figure 1. Hazard area r

Walking the machine distances means any movement of the machine of more than 100 m or for a time period longer than 3 minutes,
whatever comes first.

In addition to above mentioned guidelines, when moving the machine during loading operations, the following procedures apply:

• Before the start of the travel movement, clean all very dirty parts of the undercar­riage and remove the unwanted materials.

• It is required to have somebody standby with a heat gun, to monitor the temperature of the drive components, including the track and
carrier rollers.

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DANGER!
During the movement of the machine, the person which is checking the temperature of the different rollers must always be
out of the hazard area r of the machine and always be in the operator’s sight and in radio contact with him.
For the checking of the temperature, the excavator should stop moving. And only when the excavator is stopped, the
person could go in the hazard area r to check the temperature of the different rollers.
The machine could only start moving again when the driver has seen the operator out of the hazard area r.

• If temperature of any moving part is growing up about 20°C above ambient temperature, interrupt travel and only commence again
after parts have sufficiently cooled.

• To prevent overheating during travelling or to speed up cooling procedure it is advisable to have a water truck standby, to hose the
heating components during travelling or cooling break.

• Move with idler and attachment forwards. Whenever possible, and not to contravene with mine safety regulations, swing whilst
travelling to equally load track roll­ers. However, always ensure that clear forward vision is maintained.

Travelling the machine down grades or upgrades

In addition to above mentioned guidelines, when moving the machine during loading operations or when walking the machine distances,
the following procedures apply:

• Always travel in the direction of the slope and not perpendicular to the slope, with the uppercarriage aligned with the undercarriage.

• When travelling down grades greater than 5,7° (10%), it would be better to walk the machine down with the track motor first, i.e. the
machine is moved backwards.

• When travelling up an incline, the final drives must be at the rear of the excavator.

• When walking down from a bench, firstly prepare a ramp. Respect the angle value indicated in the "Technical data" section of this
manual (machine must be able to walk up unaided). When moving down the ramp never allow the machine to fall down on the
attachment. When walking up the ramp never use attachment to assist the movement by pushing with the hydraulic power of the
bucket, stick or boom.

Travelling the machine first time

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

NOTE!
Warranty may become void if failure to recognize and comply with the recommended travel operating procedures, as
outlined in this document, is noted.
From: Operator's manual R 9200 - 410 > Control and operation > Transport

4.6.2 | Excavator lifting and lashing operations

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

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Lifting precautions
Lift element:

• always checking and respecting the lifting configuration indicated on the corre­sponding transport drawing,

• only with the provided lifting appliances,

• with adequate and approved lifting devices of other kind (cables, chains, slings) if necessary,

• only after mounting the lifting appliances in accordance with the regulations,

• only at the declared threads or lugs shown on the assembly drawing,

• with the best possible equal load distribution,

• only being sure that the lifted element has been already dismounted,

• only after having drained tanks (hydraulic, fuel…),

• if no specific value is indicated on the corresponding transport drawing, always respecting the angles given on the sticker for lifting and
lashing operations (refer to the description below).

Additional lifting precautions for backhoe buckets

When you lift the backhoe bucket, also obey the precautions that follow:

• Only use the lifting points shown in the stickers placed on the bucket.

• You can use the bucket teeth as lifting points.

• Be careful about the position of the center of gravity of the bucket.

• The bucket has two possible transport positions. The height B1 gives the correct transport position as shown in the transport drawing.

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

Additional lifting precautions for shovel buckets

When you lift the shovel bucket, also obey the precautions that follow:

• Only use the lifting points shown in the stickers placed on the bucket.

• Do not use the bucket teeth as lifting points.

• Do not use the welded beam to lift the bucket.

• Be careful about the position of the center of gravity of the bucket.

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Lashing precautions
Lash element:

• always using necessary and appropriate devices or tools (e.g. elevating platform) in order to ensure safe lashing,

• always checking and respecting the lashing configuration indicated on the corre­sponding transport drawing,

• if no specific value is indicated on the corresponding transport drawing, always respecting the angles given on the sticker for lifting and
lashing operations (refer to the description below),

• always ensuring a sufficient coefficient of friction (0,6 or higher) between load and supporting surface so as to avoid element to slip
(e.g. using wooden parts, non-slip mats...),

• when using non-slip mats:

◦ always ensuring that the coefficient of friction is guaranteed by manufacturer certificates,

◦ always positioning the non-slip mats between each contact surface (e.g. between the load and the support, between the support
and the flatbed trailer),

• always ensuring that the contact surfaces between the flatbed trailer and the load carried are free of dirt, ice, snow, oil and grease.

Additional lashing precautions for backhoe buckets

When you lash the backhoe bucket, also obey the precautions that follow:

• Only use the lashing points shown in the stickers placed on the bucket.

• You can use the bucket teeth as lashing points.

• Be careful about the position of the center of gravity of the bucket.

• Wedge the bucket during transport.

• The bucket has two possible transport positions. The height B1 gives the correct transport position as shown in the transport drawing.

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

Additional lashing precautions for shovel buckets

When you lash the shovel bucket, also obey the precautions that follow:

• Only use the lashing points shown in the stickers placed on the bucket.

• You can use the bucket teeth as lashing points.

• Do not use the welded beam to lash the bucket.

• Be careful about the position of the center of gravity of the bucket.

• Wedge the bucket during transport.

Sticker for lifting and lashing operations

The following sticker is placed next to each transport drawing on the related part and package. It shows rules and precautions which you
must obey for transport opera­tions.

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Figure 1. Sticker for lifting and lashing operations

The Lashing Capacity LC is the maximum force that the lashing ring can hold in accordance with the angles given on the transport
drawing.

The Safe Working Load SWL is the maximum load that the lifting ring can hold in accordance with the angles given on the transport
drawing.

Transport drawings
The following drawings indicate the different lashing and lifting points on the elements of the excavator. Weight (with and without
transport tooling and packaging), overall dimensions as well as center of gravity are also given.

The aim of these drawings is to ensure safe operation during transport, handling and storage.

NOTE!
The lashing and lifting points are indicated on the concerned elements of the excavator by specific labels (see § "Signs on
the machine"). To be easily recognized, lifting points are painted in yellow (in red if excavator is yellow) as well.

DANGER!
The lifting points given on a transport drawing for an element are designed to lift this element only and nothing else.

• ▶ Never lift an assembly of several elements by the lifting points of only one of these elements.

From: Operator's manual R 9200 - 410 > Control and operation > Transport

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5 | Malfunctions
Warning messages and fault messages:

• Various faults are displayed on screen in the form of indicator lights or symbols (see chapter “Control and operating elements”).

• Warning functions can also be supported acoustically (buzzer).

Identifying and rectifying faults and errors:

• Faults can very often be traced back to incorrect operating or maintenance of the machine.For each fault, therefore, read the relevant
chapter in the operating instruc­tions carefully once more.

• Analyse the cause of the fault and rectify it immediately.

• Describe the fault and all accompanying circumstances as precisely as possible if you contact LIEBHERR customer service.Precise
information makes it possible to find and rectify the cause of the fault quickly. Additionally, therefore, precise information on the type
and serial number of the machine is also required.

• Do not carry out any work which you have not been trained to do.

Figure 1. LIEBHERR service

If the cause of the fault cannot be recognised or rectified using the error codes and fault charts, please consult LIEBHERR
customer service.

From: Operator's manual R 9200 - 410

5.1 | Error code charts

DANGER!
When you use the emergency and safety modes of operation, you can no longer operate and monitor the Diesel engine,
the pumps and fans controls, the swing and travel brakes with the standard devices (display, control keyboard) (in case of
elec­tronic failure).

• ▶ Please also note the section “Emergency and safety operations” in the chapter “Control and operation” of this
manual.

From: Operator's manual R 9200 - 410 > Malfunctions

5.1.1 | Heating and air-conditioning system

The error codes that follow related to the heating and air-conditioning system are dis­played directly on the front panel of its control unit.

Error code Affected elements Description / possible causes Possible effects / measures
F0 Room temperature Short circuit or disconnection of Control function no longer
sensor cable, connector or control unit. opera­tional.
Defective sensor.

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Error code Affected elements Description / possible causes Possible effects / measures
F1 Exhaust air Short circuit or disconnection of Control function no longer
temperature sensor cable, connector or control unit. opera­tional.
Defective sensor.
F2 Exhaust air Short circuit or disconnection of Control function no longer
temperature sensor cable, connector or control unit. opera­tional.
(head area) Defective sensor.
F3 Outside temperature Short circuit or disconnection of Control function no longer
sen­sor cable, connector or control unit. opera­tional.
Defective sensor.
F4 High-/Low pressure Failure on condenser fan, Control function no longer
switch evaporator blower, expansion opera­tional.
valve, compressor or
refrigerant circuit.
From: Operator's manual R 9200 - 410 > Malfunctions > Error code charts

5.2 | Faults and remedies

From: Operator's manual R 9200 - 410 > Malfunctions

5.2.1 | Diesel engine and fuel system

Fault / error Cause Solution

Diesel engine does not start Fuel tank almost or Fill tank and
completely emp­ty vent fuel
system
Shut off valve closed Open the
shut off
valve
Fuel filter dirty Clean or
change filter
and vent
fuel system,
drain fuel /
clean tank
Outside temperature For
below 0°C operation
under
specific
climatic
conditions,
see
operating
instruc­tions
Starter motor not Check line
drawing through connections,
overhaul
starter
motor
Batteries have no Charge /
power replace
Engine starts but stops immediately after or runs irregularly Fuel tank empty (low Fill tank and
pressure in tank) vent fuel
system

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Fault / error Cause Solution

Fuel filter dirty Clean or
change filter
and vent
fuel system
(tank)
Particularly in winter: Use engine
too viscous engine oil oil suitable
used for the out­‐
side
temperature
Dry-air filter dirty Change
main filter
element
Air in fuel system Bleed fuel
system
Ventilation in fuel tank Clean
obstructed
Fuel line bent Check line
and repair if
required
Diesel engine emitting grey or black smoke Dry-air filter dirty Change
filter
Diesel engine continually emitting white smoke (steam) Water in combustion Consult
chamber customer
service
Diesel engine does not reach full speed Speed adjustment not Set speed
set to maxi­mum value adjustment
to maximum
value
Injection system is set Consult
incorrectly customer
service
Dry-air filter dirty Replace
filter
Bad fuel supply Clean or
change fuel
filter, check
lines, drain
water from
tank
Diesel engine becomes too hot Too little coolant Fill coolant,
check for
leaks
Water pump defective Repair
Thermostats do not Change
work thermostats
Coolant contaminated Clean
coolant
Diesel engine has insufficient oil pressure Oil level too low Correct oil
Note!Switch off diesel engine immediate­ly level
Oil pressure display Change oil
faulty pressure
switch

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Fault / error Cause Solution

Diesel engine consumes too much oil External leak on diesel Retighten
engine screws,
replace
seals if
required
Oil in coolant or coolant in oil Consult
customer
service
Unusual noise / sound development on exhaust side Exhaust system Check
leaking exhaust
system /
repair
From: Operator's manual R 9200 - 410 > Malfunctions > Faults and remedies

5.2.2 | Hydraulic system

Fault / error Cause Solution

Unusual noise / sound development at hydraulic pumps Shutoff valve on Open the
Note!Switch off diesel engine immediate­ly hydraulic tank closed shutoff
valve
Hydraulic pumps Check oil
taking in air level in
hydraulic
tank,
check
intake
lines for
leaks
Hydraulic oil temperature too high Coolant contaminated Clean
coolant
Fan or fan control Rectify
defective error /
consult
customer
ser­vice
Hydraulic oil level too low Oil loss Repair
leaks,
exchange
hoses,
refill oil
via
return-
line filter
Cannot drive Push the safety lever Push the
up safety
lever
down
Swing gear not functioning No servo control Push the
safety
lever
down
Switch on
servo
control
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Fault / error Cause Solution

Swing gear brake Push the
activated safety
lever
down
Release
swing
gear
brake
No working movement No servo control Push the
safety
lever
down
Switch on
servo
control
No servo pressure Consult
present customer
service
No pump high Consult
pressure present customer
service
From: Operator's manual R 9200 - 410 > Malfunctions > Faults and remedies

5.2.3 | Transmission

Fault / error Cause Solution

Oil flowing out on track rollers, sup­port rollers or leading wheel Seal defective Replace
seal

Insufficient crawler tracking on lead­ing wheel Leading wheel Adjust the

tracking on track roller leading
mounting has too wheel
much play tracking
play

Chain jumps off or over Chain tension too low Adjust

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

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From: Operator's manual R 9200 - 410 > Malfunctions > Faults and remedies

5.2.4 | Electrical system

Fault / error Cause Solution

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

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From: Operator's manual R 9200 - 410 > Malfunctions > Faults and remedies

5.2.5 | Heating/air-conditioning system

Fault / error Cause Solution

Heating not giving out warm air Shutoff valves for Open
coolant line on diesel shutoff
engine closed valve
Engine not at operating Bring
temperature engine to
operating
tempera­‐
ture
Heating fan does not operate No power supply Check
fuse and
wiring /
repair
Fan motor defective Change
fan
motor
Only low air flow in cab Outside air filter / Clean air
recirculated air filter intake
dirty opening,
replace
outside
air filter
Air vent closed Open air
vent
From: Operator's manual R 9200 - 410 > Malfunctions > Faults and remedies

5.2.6 | Work equipment

Fault / error Cause Solution

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

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From: Operator's manual R 9200 - 410 > Malfunctions > Faults and remedies

5.3 | Fuses and relays

DANGER!
Incorrect or bypassed fuses do not let have the necessary degree of protection of the machine's operator or the electrical
system.

• ▶ Only use original fuses.

• ▶ Never bypass electrical fuses.
• ▶ If required, order replacement fuses from Liebherr.

From: Operator's manual R 9200 - 410 > Malfunctions

5.3.1 | Power electrical box E1003

The access door of the power electrical box E1003 is located on the outer rear side of the cab.

Figure 1. Access door of E1003 electrical box

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Figure 2. Fuses of power electrical box E1003

F20_1 Fuse 100 A F135 Fuse 25 A

F20_2 Fuse 100 A F136 Fuse 25 A
F90 Fuse 15 A F142_1 Fuse 15 A
F91 Fuse 15 A F142_2 Fuse 15 A
F92 Fuse 15 A F142_3 Fuse 15 A
F93 Fuse 15 A F142_4 Fuse 15 A
F95 Fuse 15 A F143 Fuse 15 A
F96 Fuse 15 A F144 Fuse 15 A
F119 Fuse 15 A F169 Fuse 15 A
F120 Fuse 50 A F190 Fuse 15 A
F121 Fuse 50 A F216 Fuse 15 A
F131 Fuse 15 A F235 Fuse 15 A
F132 Fuse 15 A F236 Fuse 15 A
F133 Fuse 15 A F246 Fuse 7,5 A
F134 Fuse 15 A F247 Fuse 15 A

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Figure 3. Relays of power electrical box E1003

K19_1 Relay K275 Relay for air-conditioning system / 50 A

K23 Relay K301 Relay
K27 Relay K302 Relay
K28 Relay K304 Relay
K54_1 Relay for centralized lubri­cation system K305 Relay
K54_2 Relay for centralized lubri­cation system K398_1 Relay
K56 Relay K398_2 Relay
K99 Relay K400 Relay
K103_1 Relay for air-conditioning system / Pressure switch KT51 Relay
K103_2 Relay for air-conditioning system / Pressure switch KT53 Relay
K122 Relay KT54_1 Relay
K123 Relay KT54_2 Relay
K124 Relay KT56_3 Relay
K141 Relay KT57_1 Relay
K141_1 Relay KT57_2 Relay
K273 Relay KT277 Relay
K274 Relay for air-conditioning system / 50 A K_RES Reserve
From: Operator's manual R 9200 - 410 > Malfunctions > Fuses and relays

5.3.2 | Cab connection box E1005

The cab connection box E1005 is located in the cab, behind the operator’s seat.

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Figure 1. Locations of the electrical plates in E1005

A161 Electrical plate A1004 Electrical plate

A1002 Electrical plate A1014 Electrical plate

Figure 2. Fuses and relays of cab connection box E1005

F21-1 Fuse 100 A F267 Fuse 15 A (if installed)

F21-2 Fuse 100 A K19-2 Relay
F160 Fuse 7,5 A K126 Relay
F161 Fuse 15 A K184 Relay
F162 Fuse 15 A K185 Relay
F170 Fuse 15 A K257 Relay
F171 Fuse 15 A K351 Relay
F172 Fuse 7,5 A Kres_11 Relay
From: Operator's manual R 9200 - 410 > Malfunctions > Fuses and relays

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6 | Maintenance

From: Operator's manual R 9200 - 410

6.1 | Servicing the machine safely

General safety instructions

• Maintenance and repair work may only be carried out by specially trained person­nel.

• Observe statutory timetables or intervals given in the operating instructions for repeat tests / inspections. It is imperative that a suitably
equipped workshop is avail­able in order to carry out maintenance work.

• The inspection and maintenance schedule given at the end of these operating instructions defines precisely who is required /
permitted to carry out what work.Jobs listed as daily / weekly work may be carried out by the machine's driver or maintenance
personnel when they have received appropriate instruction.The remaining work may only be carried out by specialist personnel with
appro­priate training.

• Replacement parts must correspond to the technical requirements determined by the manufacturer. Original replacement parts are
always guaranteed to meet these criteria.

• Always wear safe work clothes when carrying out maintenance work. Avoid the wearing of rings, wrist watches, ties, scarves, open
jackets, baggy clothing etc... There is a risk of injury from, for example, getting caught up or being drawn in.Protective goggles, safety
helmets, safety shoes and gloves, reflective vests and ear protection etc. are required for specific jobs.

• Do not remain in direct proximity of the diesel engine while the diesel engine is running.Persons with pacemakers should not approach
within 20 cm of the running diesel engine.Do not touch voltage-carrying parts on the electrical connection of the individual solenoid
injection pumps (Unit Pumps UP) while the diesel engine is running.

• Do not permit unauthorised persons to approach the machine during mainte­nance work.

• Cordon off a wide maintenance area if required.

• Inform operational personnel before starting to carry out any special work and repair work. Designate persons in charge of
supervision.

• In the absence of any other information in the operating instructions, carry out all maintenance work on the machine on level, firm
ground with the working equip­ment set aside and the engine switched off.

• For some machines, the only one position which enables a secured access to every maintenance locations on the uppercarriage, is
when the uppercarriage is aligned with the undercarriage so that the sprockets locate at the back-end.The ladder situated on the
undercarriage only corresponds with the uppercar­riage’s access when the excavator is in this configuration.

• Pull out the ignition key and shut off the main battery switch.

• Always tighten any loose screw connections during maintenance and repair work.

• The mounting bolts of the main components, of the hydraulic hoses and of the counterweight must be replaced after every removal.

• If safety devices have to be dismantled during set-up, maintenance and repair work, they must be immediately reinstalled and
checked at the end of the work.

• When carrying out repair work, particularly when working under the machine, hang a “Do not start” warning sign in a clearly visible
position on the control panel. Pull out the start key and shut off the main battery switch.

• Operate combustion motors and fuel operated heaters only in well ventilated ar­eas. Before operating these units, check ventilation.

• In addition, always follow applicable local regulations.

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Cleaning
• Clean oil, fuel or care products off the machine before starting maintenance or repair work and pay particular attention to connections
and screw fittings.Do not use aggressive cleaning products and use lint-free cleaning cloths.

• Do not use aggressive cleaning products or steam jet devices to clean the machine for the first two months after initial set-up of the
machine (or after repaint­ing).

• Do not use combustible liquids to clean the machine.

• Before cleaning the machine with water or steam jets (high pressure cleaner) or other cleaning materials:

◦ lubricate all bearing points, bolt connections and the rim bearing to prevent wa­ter or steam entering the bearing points.

◦ cover or glue shut all openings into which for safety or functional reasons water or steam may not be permitted to enter.Electric
motors, electrical components, control boxes, plug connections and air filters are particularly at risk.

• Ensure that the fire warning systems and fire extinguishers of the engine compartment’s temperature sensor do not come into contact
with hot cleaning products during cleaning work.The fire extinguisher could start.

• If you use a high pressure cleaner with steam or hot water to clean the machine, observe following recommendations:

◦ the distance between the nozzle and the surface to be cleaned must be no low­er than 20 inches

◦ the water temperature should not exceed 60°c (140°F)

◦ limit the water pressure to 80 bar maximum (1160 PSI)

◦ if you employ cleaning fluid, only use neutral cleaning agents such as custom­ary car shampoos diluted to 2 or 3 percent maximum

• After cleaning:

◦ remove all covers completely.

◦ check all fuel, engine oil and hydraulic lines for leakage, loosened connections, chafing and damage.

◦ rectify any defects found immediately.

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

Corrosion protection
• The corrosion protection of the machine must be inspected and renewed at regular intervals. For further information, refer to the
Maintenance manual for corro­sion protection.

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Field of view
• Mirrors and cameras, which were possibly removed for the transport, must be inevitably reinstalled and correctly adjusted before the
initial set-up of the machine.

• Regularly check that the interior and exterior mirrors as well as the cameras are correctly adjusted.

• Control the surroundings, and particularly the nearness area of the machine, dur­ing operation or when travelling.

• Mirrors are installed on the machine:

◦ on the left to check the left side of the machine.

◦ on the front to check the front side of the machine.

◦ on the right to check the right side of the machine.

◦ above the counterweight to check the rear side of the machine.

• On some machines, some mirrors may be replaced with cameras.

• At each extension, construction or change on the machine, the sight conditions must be maintained. These conditions must otherwise
be checked according to ISO 5006.

• Mirrors and cameras must always be clean.

• Damaged mirrors and cameras must be immediately replaced.

• The site has to be organised so that the dangers due to a restricted field of view are minimized, particularly for machines with an
operating weight which is supe­rior to 40 tons.

Crack testing
• Even when the machine is operated carefully, there is a possibility of individual cases of overloading occurring, which could lead to
cracks or loose connections. The machine should therefore be checked regularly for cracks, loose connections or other visible
damage to maintain operational safety.

• In order to be able to check for cracks, it is essential that the machine is kept clean and cleaned regularly.

• The tests should be carried out in accordance with the monitoring and mainte­nance plan:

◦ every 250 operating hours by the machine owner’s maintenance personnel.

◦ every 500 operating hours by authorised specialist personnel.

• It is advisable to carry out these tests: supported, on firm, horizontal substrate, with the equipment in longitudinal and cross direction
for variable loads. Current accident prevention regulations must be adhered to.

• Especially check the supporting components, in particular:

◦ framed construction undercarriage with axle and gearbox storage, support outriger, lower slewing ring support with tower and
slewing ring.

◦ framed construction uppercarriage with bearing for boom and hoist cylinder, upper slewing ring support, cab suspension, mounting
for slewing gear and coun­ter weight.

◦ framed construction components of attachments, e.g. boom, stick, quick change adapter, digging tool and grapple.

◦ hydraulic cylinders, axles, steering, pins and pin connections, ascents, ladders and mounting elements.

• The crack test should be carried out visually. If a crack is suspected, the dye penetration test should be carried out as a crack test on
areas which do not have good visibility, such as the ring bearing support, in order to increase testing safety.

• Any damage found must be rectified immediately. Welding work on load-bearing parts of the earth-moving machinery, loading devices
and transport devices may only be carried out by trained specialist personnel and only in accordance with the accepted rules of
welding engineering. In case of doubt, contact the LIEBHERR customer support service to discuss suitable remedies.

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Welding, drilling, firing and grinding work

• Any welding on structural parts (as undercarriage, uppercarriage, equipment parts,…) may only be done by the manufacturer, or
authorized official dealer. If this rule is neglected, the warranty is voided.

• Only carry out welding, drilling, firing and grinding work on the machine with express authorization. Clean dust and combustible
materials off the machine and its surrounding areas before welding, drilling, firing or grinding.Ensure adequate ventilation. Risk of fire
or explosion.

• Before welding repairs on other parts, always disconnect the battery. Always re­move the negative terminal first and reconnect it last.

• Nevertheless if welding repair should be done on components which may contain inflammable gases (welded counterweight, hydraulic
tank, fuel tank, …), these components must be previously and sufficiently ventilated with pressurized air to avoid all fire or explosion
hazard

• Before welding, connect the ground cable as close as possible to the welding point, so the welding current will not run through parts
like the swing ring, rotary connection, gears, bushings, bearings, hinges, joints, hydraulic hoses, sockets, rubber parts or seals.

Process materials
• When working with oils, greases and other chemical substances, observe the ap­propriate current safety regulations for the product.

• Ensure that process materials and replacement parts are disposed of in a safe and environmentally acceptable manner.

• Take care when handling hot process materials (Risk of burning and scalding).

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Repair work
• Do not attempt to lift heavy parts. Use devices which are suitable for this purpose and which have sufficient load capacity. When
replacing single parts and larger subassemblies, carefully secure them on lifting devices so that they do not present a risk. Only use
suitable and correctly functioning lifting devices and load take-up devices with adequate load capacity.Do not stand or work under
swinging loads.

• Do not use lifting devices which are damaged or do not have sufficient load carrying capacity.Wear work gloves when working with
wire cables.

• Authorize only experienced people to attach load and to give indications to the crane operator. This people must be in the operator’s
sight or in radio contact with him.

• When working above body height, use safe climbing devices and working platforms which are appropriate for the job.Do not use
machine parts as climbing devices if they are not designed for this purpose.When working at height, wear a harness to prevent
falling.For further information, see section "Maintenance anchor points" or contact Lieb­herr customer service.

• Ensure that all grips, steps, rails, platforms and ladders are free of dirt, snow and ice.

• Pneumatic cylinders do not have to be used as handles. Open doors and covers carefully, so that pneumatic cylinders do not hit their
stops, because this could cause mechanical damages.

• Make sure the equipment on which you will operate is securely supported before working (e.g. replacing teeth). Prevent metal
touching metal when doing this.

• For safety reasons, never open and remove a track chain unless having previously totally released the pretension of the chain
tensioning unit.

• Never lay under the machine if it is raised with work equipment and has not been securely supported with appropriate supports.

• Always jack the machine up in such a way that any weight displacement does not jeopardize stability and prevent metal touching
metal while doing this.

• Work on the suspension, brake and steering systems may only be carried out by trained specialist personnel.

• If the machine has to be repaired on a slope, secure the crawler with chocks and connect the upper structure to the chassis using stop
bolts.

• Only personnel with special training and experience may work on hydraulic equip­ment.

• When searching for leakage, wear protective gloves. A fine jet of liquid under pressure can penetrate the skin.

• Do not unscrew any lines or connections before you have set aside the equipment, switched off the engine and depressurized the
hydraulic system. After switching off the engine, with the start key in contact position and with the safety lever down into its lowest
position, you must operate all pilot control devices (joystick and pedals) in all directions in order to reduce the actuating and dynamic
pressures in the work circuits. You must then reduce the internal tank pressure as described in these operating instructions.

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Electrical system
• Check the electrical system regularly.Have all faults, such as loose connections, blown fuses and lamps and clogged or abraded
cables rectified by personnel.

• Only use original fuses with approved current strength.

• For machines with electrical neutral and high tension leads:

◦ switch the machine off immediately in the event of malfunctions in the power supply.

• Work on the machine’s electrical equipment may only be carried out by skilled electrical personnel or by trained personnel under the
supervision of an electri­cian 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 in­sulated tools.

• When working on neutral and high tension subassemblies, after releasing the voltage, briefly disconnect the supply cable at earth and
electronic devices such as capacitors using an earthing rod.

• First test the released parts to make sure that they are off circuit, earth them and then disconnect them briefly. Insulate adjacent live
parts.

• Disconnect the battery before working on the electrical system or carrying out any electric arc welding on the machine.First disconnect
the negative, then the positive pole. When reconnecting, proceed in the reverse order.

Hydraulic accumulator
• All work on the hydraulic accumulators must be carried out by trained specialist personnel.

• Inexpert assembly and handling of hydraulic accumulators can cause serious ac­cidents.

• Do not operate damaged hydraulic accumulators.

• Before working on a hydraulic accumulator, you must reduce the pressure in the hydraulic system (hydraulic system including
hydraulic tank), as described in these operating instructions.

• Do not carry out welding or soldering or do any mechanical work on the hydraulic accumulator.The hydraulic accumulator can be
damaged by heat penetration and can be made to rupture by mechanical working. RISK OF EXPLOSION!

• Only charge the hydraulic accumulator with nitrogen. There is a RISK OF EXPLO­SION if oxygen or air is used.

• The accumulator body can become hot during operation; there is a risk of burning.

• New hydraulic accumulators must be charged with the pressure required for the purpose of use before installation.

• The operating data (minimum and maximum pressure) are marked permanently on hydraulic accumulators. Ensure that this marking
remains visible.

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Hydraulic lines and hoses

• It is forbidden to carry out repair work on hydraulic lines and hoses!

• All lines, hoses and bolt connections must be checked regularly for externally visible damage and any possible damage must be
immediately checked for leakage.

• Never check for leaks with your bare hands, use a sheet of paper or something else.

• Any damaged parts must be removed immediately! Spurting oil can lead to injury and burns.

• Even with correct storage and permitted load, lines and hoses are subject to the natural aging process. This restricts their duration of
use.

◦ Incorrect storage, mechanical damage and unauthorized load are the most common causes of failure.

◦ In relation to duration of use, current norms, regulations and guidelines pertaining to lines and hoses at place of use must be
adhered to.

◦ Use at the limit range of permissible load can shorten duration of use (e.g. high temperatures, frequent movement cycles, extremely
high pulse frequencies, multiple shift usage).

• Lines and hoses should be replaced if the following are found during inspection:

◦ Damage to the outer sheath as far as the liner (e.g. chafing, cuts and cracks);

◦ Brittleness of the outer sheath (fracture formation in hose material);

◦ Deformations which do not correspond to the natural form of the line or hose, whether in a unpressurized or pressurized state or on
bends e.g. sheath sepa­ration, blistering;

◦ Unsealed areas;

◦ Non-adherence to requirements during installation;

◦ Damage or deformations to the hose fittings which reduce the tightness of the fittings or the hose / fitting connection;

◦ Hoses working themselves out of the fittings;

◦ Corrosion of the fittings which reduces function and tightness;

• When replacing lines and hoses, use only original replacement parts.

• Install and mount lines and hoses correctly. Do not mix up the connections.

• The following is to be noted when replacing lines and hoses:

◦ Always ensure that the lines and hoses are installed free of torsion. For high-pressure hoses, the screws from the half-clamps or full
flange must always be attached to both hose ends and should only be tightened afterwards.

◦ When tightening the flange on high-pressure lines and hoses with bent fittings, the side with the bent fitting must always be
tightened first and then the side with the straight fitting tightened afterwards.

◦ Any mounting clamps which are located in the centre of the hose may only be attached and tightened subsequently.

◦ Check daily to ensure that all clamps, covers and protective devices are properly fastened. Doing this will prevent vibration and
damage during operation.

◦ Install the lines and hoses in such a way that they cannot chafe on other lines, hoses or parts.

◦ A minimum distance from other parts of approx. half the exterior diameter of the hose is recommended. The distance should not,
however, be less than 10 to 15 mm.

◦ When replacing the lines or hoses on moving parts (e.g. from the boom to the stick), check before initial start-up that there are no
chafing areas in the entire area of movement.

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Disposal

Disposal of the machine

• Make sure that the individual elements of the machine are disposed of correctly after the service life in accordance with all applicable
national, regional or local regulations for waste disposal and environmental protection.

• Remove fuel, lubricants and operating fluids from all components before disposal.

Disposal of gas tanks and pressurized tanks

• Release the pressure fully from the pressurized tanks before disposal.

• Remove all fluids or gas from the tanks before disposal.

• Obey the instructions of the tank manufacturer for disposal.

Disposal of fuel, lubricants, operating fluids and consumables

• Collect and store fuel, lubricants and operating fluids in applicable containers be­fore disposal.

• Have fuel, lubricants and operating fluids disposed of in an applicable recycling point.

• Have refrigerant disposed of only by a trained air-conditioning and refrigeration technician.

• Obey the instructions of the fuel, lubricants and operating fluids manufacturer for disposal.

• Have metal parts disposed of in an applicable recycling point.

• Have plastic parts disposed of in an applicable recycling point.

• Have rubber parts disposed of in an applicable recycling point.

• Have electronic components disposed of in an applicable recycling point.

From: Operator's manual R 9200 - 410 > Maintenance

6.2 | Access points for the maintenance

From: Operator's manual R 9200 - 410 > Maintenance

6.2.1 | Access points overview

You can get access to compartments and components of the machine through the access points that follow. Before you start the
machine, you must make sure that the access doors are closed but not locked.

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Figure 1. Access points for the maintenance

1 Pumps box doors 5 Engine cooler access

2 Engine compartment doors 6 Oil cooler access
3 Cab elevation door 7 Left side door
4 Engine compartment covering

CAUTION!
For oil and engine coolers access, use an external safety device (e.g. a ladder or stepladder).

CAUTION!
Access doors can close accidentally and trap the operator or maintenance person­nel.

• ▶ When you have opened the access doors, latch them using the retainer.

From: Operator's manual R 9200 - 410 > Maintenance > Access points for the maintenance

6.3 | Maintenance anchor points

You must always access to the machine through the access provided.

For installation, maintenance and repair work, it is possible that the service personnel is obliged to remove fall protection elements such
as handrails to get access to or to remove some parts of the machine.

DANGER!
Risk of falling when fall protection elements are removed.
The machine has anchor points for safe installation, maintenance and repair work.
Even if appropriate fall-arrest equipment is installed to the anchor points, fall-arrest equipment cannot prevent falls.
Common sense and fall hazard awareness are im­portant safety precautions for work that is done from above the ground.

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From: Operator's manual R 9200 - 410 > Maintenance

6.3.1 | Approved anchor points

There are four types of approved anchor points on the machine:

• welded anchor points

• drilled anchor points

• lifeline (optional)

• screwed anchor point (optional)

The welded and the drilled anchor points have a specific label (see § "Signs on the machine"). To be
easily identified, the welded and the drilled anchor points are also painted in blue (in white if the
excavator is blue).

The lifting points given in the section "Transport drawings" can also be used as an­chor points.

The horizontal middle bar on handrails can also be used as anchor point (as illustrated below). The used handrail must have at least two
vertical posts.

Figure 1. Horizontal middle bar on handrail (example)

Welded anchor points

Figure 2. Welded anchor point (example)

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Drilled anchor points

Figure 3. Drilled anchor point (example)

From: Operator's manual R 9200 - 410 > Maintenance > Maintenance anchor points

6.3.2 | Use the anchor points

• ▶ Before you use an anchor point, always do a check of its condition.

• ▶ If an anchor point has been used to arrest a fall, or if you are not sure about its safe condition, do not use this anchor point until it
has been inspected and, if nec­essary, tested by a competent person.

• ▶ Always use the anchor points with applicable fall-arrest equipment.

• ▶ Use a harness with a maximum arrest force of 6 kN.

• ▶ Only attach to approved anchor points.

• ▶ Never attach more than three persons to a lifeline.

• ▶ Never attach more than one person to another type of approved anchor point. If several persons must attach themselves to the
machine, they must use different anchor points.

• ▶ Never use an anchor point to attach parts or material.

• ▶ Persons who must work with fall-arrest equipment must be specially trained.

• ▶ All the anchor points and the tightening of the handrails mounting screws must be examined by authorized specialist personnel. For
maintenance intervals, refer to the control and maintenance chart.

From: Operator's manual R 9200 - 410 > Maintenance > Maintenance anchor points

6.4 | Lubricants and operating fluids

From: Operator's manual R 9200 - 410 > Maintenance

6.4.1 | General information on changing lubricants and operating fluids

NOTE
The quantities given in the lubrication and operating material chart and on the lubrication chart in the cab are only guide
values.

• ▶ After each oil change or refill, check the level in the relevant unit.

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NOTE!
Adhering to regulations for lubrication, level checks and operating material changes guarantees a high degree of reliability
and a long service life for the machine.
It is particularly important to adhere to the oil change intervals and use the specified type of lubricant.

• ▶ Observe the following when using and checking lubricants and operating fluids:
• see "Lubricants and operating fluids"
• see "Inspection and maintenance schedule"

All lubricants and operating materials are not miscible or compatible.

• ▶ When you change the lubricant or the operating material for a component or a system, make sure that the old and
the new lubricants or operating materials are miscible and compatible with each other.
• ▶ If not, flush the component or the system first with new approved lubricant or new approved operating material.

NOTE!
Cleanliness is of the utmost importance when changing oil.

• ▶ Clean all filler plugs, filler covers and drain plugs and their surroundings before opening.
• ▶ For preference, drain off oil when it is at operating temperature.
• ▶ Ensure that old oils are collected and disposed of in an environmentally acceptable manner using the removable oil
filter cartridges.

DANGER!
When checking and changing lubrication and operating materials, ensure that the following precautions are adhered to:

• ▶ Unless otherwise indicated, carry out all work on the machine on level, solid ground and with the engine switched
off.
• ▶ Whenever you reach into the engine compartment, always secure the cover and side doors against accidentally
falling back or closing.
• ▶ Only refuel the machine when the engine is switched off, do not smoke and avoid naked flame.
• ▶ Turn the main battery switch to position 0 (off) and remove the ignition key.

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From: Operator's manual R 9200 - 410 > Maintenance > Lubricants and operating fluids

6.4.2 | Lubrication chart

Figure 1. Lubrication chart

Symbol Display
Diesel engine

Engine coolant

Hydraulic system

Swing gear

Travel gear

Lifetime sealing
interspace (optional)
Splitterbox

Fuel

Principal grease

Grease for swing ring

teeth
Windshield washer

Check oil level

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Symbol Display
Oil change

First oil change

Oil analysis

(1) If filled with OIL-2 or

OIL-3 gear oil
(2) If filled with OIL-1 gear
oil
(3) Refer to the Operating
manual (section
"Lubricating and
operating material
specifications")

Lubrication chart key

From: Operator's manual R 9200 - 410 > Maintenance > Lubricants and operating fluids

6.4.3 | Lubricant chart

Designation Medium Symbol Quantity*

Diesel engine Refer to the manual 142 l
of the Diesel engine
manufacturer.
Hydraulic tank See section 3400 l in
"Lubricating and whole cir­‐
operating material cuit
specifica­tions". 2000 l in
Refer also to the hydraulic
fluids and lubricants tank
specification in ap­‐
pendix of this manual.
Swing gear See section 2 x 32 l
"Lubricating and
operating material
specifica­tions".
Refer also to the
fluids and lubricants
specification in ap­‐
pendix of this manual.
Travel gear See section 2 x 38 l
"Lubricating and
operating material
specifica­tions".
Refer also to the
fluids and lubricants
specification in ap­‐
pendix of this manual.
Travel gear with lifetime sealing interspace (option­al equipment) See section 2 x 38 l
"Lubricating and
operating material
specifica­tions".
Refer also to the
fluids and lubricants
specification in ap­‐
pendix of this manual.

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Designation Medium Symbol Quantity*

Lifetime sealing inter‑space (optional equipment) Use same oil as used 2 x 3,4 l
for hydraulic tank.

Travel brake Use same oil as used 2 x 0,4 l

for hydraulic tank.
Splitterbox Refer to the fluids and 10 l
lubricants
specification in
appendix of this
manual.
Swing ring roller bearing races and general lubrica­tion points Refer to the fluids and 213 l
lubricants
specification in
appendix of this
manual.
Swing ring teeth Refer to the fluids and 20 l
lubricants
specification in
appendix of this
manual.
Track roller Refer to the fluids and 16 x 2,7 l
lubricants
specification in
appendix of this
manual.
Carrier roller Refer to the fluids and 4 x 3,35 l
lubricants
specification in
appendix of this
manual.
Idler Refer to the fluids and 2 x 3,3 l
lubricants
specification in
appendix of this
manual.
Hydraulic rotary connec­tion Refer to the fluids and -
lubricants
specification in
appendix of this
manual.
Hinges, joints, locks Engine oil. -
Rubber seal on doors and trim panels Silicon spray or talc. -

Lubricant chart

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

From: Operator's manual R 9200 - 410 > Maintenance > Lubricants and operating fluids

6.4.4 | Operating material chart

Designation Medium Symbol Quantity*

Fuel tank Refer to the manual 4477 l
of the Diesel engine
manufacturer.

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Designation Medium Symbol Quantity*

Engine coolant Liebherr Antifreeze 300 l
OS or refer to the
manual of the Diesel
engine manufacturer.
Windshield washer system Commercially 30 l
available windshield
washer fluid or dena­‐
tured alcohol.
Air-conditioning sys­tem with belt driven compressor Refrigerating agent: - 2,2 kg
Refer to the fluids and
lubricants
specification in
appendix of this
manual.
Refrigerant oil in a - 0,2 l
new compressor:
Refer to the fluids and
lubricants
specification in
appendix of this
manual.
Refrigerant oil to add - 0,153 l
in the system after a
compressor re­‐
placement:
Refer to the fluids and
lubricants
specification in
appendix of this
manual.
Refrigerant oil in the - 0,353 l
full system:
Refer to the fluids and
lubricants
specification in
appendix of this
manual.
Air-conditioning system with hydraulically driven compressor (if the optional second Refrigerating agent: - 3,6 kg
air-conditioning system is installed: front con­denser unit) Refer to the fluids and
lubricants
specification in
appendix of this
manual.
Refrigerant oil in a - 0,2 l
new compressor:
Refer to the fluids and
lubricants
specification in
appendix of this
manual.

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Designation Medium Symbol Quantity*

Refrigerant oil to add - 0,202 l
in the system after a
compressor re­‐
placement:
Refer to the fluids and
lubricants
specification in
appendix of this
manual.
Refrigerant oil in the - 0,402 l
full system:
Refer to the fluids and
lubricants
specification in
appendix of this
manual.
Optional second air-conditioning system with hydraulically driven compressor: rear Refrigerating agent: - 2,2 kg
condenser unit Refer to the fluids and
lubricants
specification in
appendix of this
manual.
Refrigerant oil in a - 0,2 l
new compressor:
Refer to the fluids and
lubricants
specification in
appendix of this
manual.
Refrigerant oil to add - 0,086 l
in the system after a
compressor re­‐
placement:
Refer to the fluids and
lubricants
specification in
appendix of this
manual.
Refrigerant oil in the - 0,286 l
full system:
Refer to the fluids and
lubricants
specification in
appendix of this
manual.

Operating material chart

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

From: Operator's manual R 9200 - 410 > Maintenance > Lubricants and operating fluids

6.4.5 | Service trap

For safety reasons and ease of maintenance, you must drain and fill the oil of the connected components only through the couplings of
the service trap, which is in­stalled below the machine uppercarriage.

These components also have oil drain valves. Refer to the oil change procedures of these components.

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Description

Figure 1. Service trap

• ▶ Refer to the sections below for couplings adapters to use with each component.

Primary components couplings

Symbol Component Wiggins adapter (with maximum flow) Banlaw adapter (with maximum flow)
Diesel OSP2 (50 l/min) Aus 29W (100 l/min)
engine
Swing gear To fill with oil: To fill with oil:
ONC2A (50 l/min) Aus 34A (100 l/min)
To drain the oil: To drain the oil:
OSP2 (50 l/min) Aus 41A (100 l/min)
Splitterbox C-1807 (50 l/min) Aus 32W (100 l/min)

Hydraulic oil 6000B12 (100 - 200 l/min) Aus 29W (100 l/min)

Fuel ZZ9A 1 (500 l/min) BPM800 (170 - 800 l/min)

Couplings of the centralized lubrication system

Depending on the machines, the centralized lubrication system can be different. The system that is installed on your machine is given by:

• The brand of the related components

• The service trap configuration.

Figure 2. Configurations A and B of centralized lubrication systems

A Configuration "SKF / Lincoln " 1 Manual valves (2x)

B Configuration "Beka " 2 Gauges (2x)

• ▶ Obey the applicable section given below.

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Couplings of the "SKF / Lincoln" configuration (A)

• The components are "SKF / Lincoln" devices

• The related couplings on the service trap are:

Symbol Component Adapter (with maximum flow)

Principal grease WIGGINS OSP2 (15-30 l/min)
Pmini 100 bar
Grease for swing WIGGINS 6000B12 (15-30 l/
ring teeth min)
Pmini 100 bar

Couplings of the "Beka" configuration (B)

• The components are "Beka" devices

• The service trap has two manual valves 1 with two gauges 2

• The related couplings on the service trap are:

Symbol Component Wiggins adapter (with maximum flow) Banlaw adapter (with maximum flow)
Principal 6005A12 (15-30 l/min) GTXRB (31 l/min)
grease Pmax 160 bar Pmax 160 bar
Grease for 6000B12 (15-30 l/min) GTXNBN (31 l/min)
swing ring Pmax 160 bar Pmax 160 bar
teeth

You must also obey the procedure that follows to disconnect the couplings.

When the related pumps are stopped:

• ▶ Open the two manual valves 1.

• ▶ On the two gauges 2, check that the hydraulic pressure is zero.

• ▶ Disconnect the couplings.

• ▶ Close the two manual valves 2.

Operate the service trap

The service trap is manually moved up and down from the ground level. As a help way, you can use the special lever 1, which is installed
on the access ladder.

Figure 3. Service trap lever

1 Service trap lever

One more lever is installed in the cab elevation.

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Move the service trap into lower position

CAUTION!
Risk of damage.

• ▶ Only move down the service trap when the uppercarriage and the undercarriage are aligned.

Figure 4. Lower the service trap

1 Service trap lever 3 Handle

2 Locking hook 4 Opening rope

• ▶ Engage the service trap lever 1 into the locking hook 2.

• ▶ Push the lever 1 up to unlock the hook 2. You can also do it with your hands.

◦ ▷ The service trap moves down.

Depending on the machines, you can also move the service trap into lower position with the opening rope 4.

If the opening rope 4 is installed:

• ▶ Pull down the opening rope 4 to unlock the hook 2.

Then, in the two cases:

• ▶ Lower the service trap fully with the handle 3. You can use your hands or lever 1.

Move the service trap into upper position

Figure 5. Close the service trap

3 Handle

• ▶ Push the service trap up fully with the handle 3. You can use your hands or the lever.

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Figure 6. Locking hook correct position

2 Locking hook

CAUTION!
Risk of damage.

• ▶ Make sure that the position of the locking hook 2 is correct.

◦ ▷ The locking hook 2 must be aligned with the vertical axis.

Figure 7. Warning light H68: trap control lock

When the service trap gets its top position, the warning light H68 on the control board goes off.

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.

This safety measure can be bypassed as long as the button S122 on the control board is activated.

Figure 8. Button S122: Disable trap control lock

Grease control

Grease control box

The open service trap lets also access to the control box E1043, which monitors the levels of attachment and swing ring greases.

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Figure 9. Grease control box E1043

E1043 Control box for greases levels

H58 Swing ring grease
H59 Attachment grease

When a grease level is maximum:

• ▷ The related warning light H58 or H59 goes off.

Grease warning light

The warning light H109 comes on if there is a fault of the grease system. It is installed next to the cab elevation door.

Figure 10. Grease warning light H109

H109 Grease warning light

From: Operator's manual R 9200 - 410 > Maintenance > Lubricants and operating fluids

6.5 | Lubricating and operating material specifica­tions

Liebherr-Mining Equipment Colmar SAS only gives approval for the Liebherr-branded lubricants and operating materials given in this
manual.

For other lubricants, fluids or greases, Liebherr-Mining Equipment Colmar SAS gives technical specifications for their related
applications. It is the responsibility of the lubricant, fluid or grease supplier to check, justify and ensure to the owner of the machine that
the lubricant, fluid or grease obeys these specifications sustainably.

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From: Operator's manual R 9200 - 410 > Maintenance

6.5.1 | Lubricating oil for the Diesel engine

Standard or with the Oil reserve system (optional) or with the Centinel system (op­tional).
Refer to the Operation and Maintenance Manual for the CUMMINS Diesel en­gine.

From: Operator's manual R 9200 - 410 > Maintenance > Lubricating and operating material specifica­tions

6.5.2 | Fuel

Refer to the Operation and Maintenance Manual for the CUMMINS Diesel en­gine.

From: Operator's manual R 9200 - 410 > Maintenance > Lubricating and operating material specifica­tions

6.5.3 | Coolant

Liebherr recommends the use of the Liebherr Antifreeze OS coolant.Do not add corrosion-inhibiting additives to this
coolant. Do not use coolant filters which contain corrosion inhibitor with this coolant. This will decrease the properties of
the coolant.
If you want to use another coolant, refer to the Operation and Maintenance Manual for the CUMMINS Diesel
engine.Depending on the type of coolant that you use in this case, corrosion-inhibiting additives and coolant filters which
contain corrosion inhibitor can be necessary.
It can be necessary to flush the full coolant circuit if you change from one type of cool­ant to another.
From: Operator's manual R 9200 - 410 > Maintenance > Lubricating and operating material specifica­tions

6.5.4 | Hydraulic oil

Refer to the fluids and lubricants specification in appendix of this manual.

Non-compliance with these requirements shall void all warranty and liability by LIEB­HERR.

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%.

Hydraulic oil change intervals

Oil changes at pre-set intervals (mineral oils and PAO oils only)
This procedure is applicable only for mineral oils and PAO oils. If you use HEES bi­odegradable oil, refer to the next section.

Figure 1. Oil changes at pre-set intervals

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A Mineral oils and PAO oils

hOperating hours

• ▶ Liebherr recommends that you sample the hydraulic oil every 500 operating hours (refer to the section "Condition monitoring with oil
analysis").

• ▶ Change the hydraulic oil every 2000 operating hours.

Oil changes at optimized intervals

This procedure is applicable for mineral oils, PAO oils and HEES biodegradable oils.

Figure 2. Oil changes at optimized intervals

A Mineral oils and PAO oils 1 First oil sample

B HEES biodegradable oils 2 Second oil sample
h Operating hours 3 Next oil samples at regular intervals

You can extend the oil change intervals (up to 6000 operating hours and possibly even more) as long as the properties of the oil are
satisfactory.

• ▶ Get a sample of the new hydraulic oil.

• ▶ If you use mineral oil or PAO oil, you must sample the hydraulic oil every 500 op­erating hours after the first 1500 operating hours.

• ▶ If you use HEES biodegradable oil, you must sample the hydraulic oil every 250 operating hours.

• ▶ Change the hydraulic oil immediately if the results of the analysis are not satisfactory (refer to the section "Condition monitoring with
oil analysis").

From: Operator's manual R 9200 - 410 > Maintenance > Lubricating and operating material specifica­tions

6.5.5 | Swing 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.

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.

Refer to the fluids and lubricants specification in appendix of this manual.

From: Operator's manual R 9200 - 410 > Maintenance > Lubricating and operating material specifica­tions

6.5.6 | 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.

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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.

Refer to the fluids and lubricants specification in appendix of this manual.

From: Operator's manual R 9200 - 410 > Maintenance > Lubricating and operating material specifica­tions

6.5.7 | Splitterbox oil

Refer to the fluids and lubricants specification in appendix of this manual.

From: Operator's manual R 9200 - 410 > Maintenance > Lubricating and operating material specifica­tions

6.5.8 | Lubricating grease

Refer to the fluids and lubricants specification in appendix of this manual.

From: Operator's manual R 9200 - 410 > Maintenance > Lubricating and operating material specifica­tions

6.5.9 | Other lubricants

• ▶ Refer to the table that follows for other lubricants.

Lubricant Description / manufacturer

Contact spray for slip rings Cramolin
Lubricant for pistons, piston nuts and piston bearing in­stallations on the hydraulic cylinders Gleitmo 800
Special anti-corrosive materi­al for installation areas of sealing e
­ lements on hydraulic cylinders Castrol-Tarp
Anti-corrosion grease for open piston rods (cylinders that do not move often or transportation) Liebherr Cylinder Protect
From: Operator's manual R 9200 - 410 > Maintenance > Lubricating and operating material specifica­tions

6.6 | Condition monitoring with oil analysis

From: Operator's manual R 9200 - 410 > Maintenance

6.6.1 | General information

Oil analysis helps to monitor the main components condition by observing oil chemical 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 recom­mended 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 component lifetime, possibly to prevent further damage (preventive exchange) and potentially 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 relation 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.

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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)

From: Operator's manual R 9200 - 410 > Maintenance > Condition monitoring with oil analysis

6.6.2 | 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 sup­plier.

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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.

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If you get the oil sample with a sampling pump:

Figure 1. Sampling pump

• ▶ Use a sampling pump if you get the sample directly in the tank or on the compo­nent (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.

Ident Nr. Description Quantity Illustration

8145660 Sampling kit for mineral 1
10029626 and synthetic oils: 4
7018368 6
• sample bottle
7018369 12
• envelope addressed
to
OELCHECK GmbH
• sample information
sheet

7026817 Sampling kit for 1

biodegradable oils:

• sample bottle
• envelope addressed
to
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• sample information
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Ident Nr. Description Quantity Illustration

7026088 6
8145666 Sampling hand pump: 1

• hand pump
• sampling hose

5613844 Sampling valve 1

7019068 1

Compact sampling
valve:
12203274 /12272204 • for hydraulic oil 1

12203276 • for engine oil 1

12203277 • for swing gear oil 1

12203278 • for engine coolant 1

12203279 • for splitterbox oil 1

12203794 Fitting for sampling 1

hose(for compact
sampling valve)

7023359 ADR spill kit 1

(International Carriage
of Dangerous Goods
by Road):

• pads
• absorbent socks
(SOCs)
• disposable bag
• pair of gloves
• instruction sheet

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Oil sampling points

Splitterbox

Figure 2. 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 split­terbox.

Travel gear

Figure 3. 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.

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Hydraulic oil

Figure 4. 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.

Diesel engine

Figure 5. 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 Die­sel engine.

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From: Operator's manual R 9200 - 410 > Maintenance > Condition monitoring with oil analysis

6.6.3 | Sample processing

Analysis standards
LIEBHERR recommends to submit the oil samples to OELCHECK GmbH for oil anal­ysis.

If another laboratory is used, the oil analysis must be done according to these stand­ards:

• DIN 51 396-1, DIN 51391-3 (wear metals, contamination and additives by ICP)

• DIN 51 562 (viscosity)

• 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 level value Action

Splitterbox 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
250 hours).

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Component Parameter Action level value Action

Water content 0,10% Change oil
(get a
sample
again after
250 hours).
Viscosity change(at <15%(*) Change oil
40°C and 100°C) (get a
sample
again after
250 hours).
Additives change ±20%(*) Change oil
(get a
sample
again after
250 hours).

(*) Difference compared to new oil value.

Swing gear

Component Parameter Action level value Action

Swing gear Iron level 400 ppm Change oil
(get a
sample
again after
250 hours).
Copper level 150 ppm Change oil
(get a
sample
again after
250 hours).
Silicon level 15 ppm Check
component
for
entrance of
dust
(sealing,
breath­‐
ers...).Flush
and
change oil
(get a
sample
again after
250 hours).
Water content 0,10% Change oil
(get a
sample
again after
250 hours).
Viscosity change(at <15%(*) Change oil
40°C and 100°C) (get a
sample
again after
250 hours).

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Component Parameter Action level value Action

Additives change ±20%(*) Change oil
(get a
sample
again after
250 hours).

(*) Difference compared to new oil value.

Travel gear

Component Parameter Action level value Action

Travel gear Iron level 400 ppm Change oil
(get a
sample
again after
250 hours).
Copper level 50 ppm Change oil
(get a
sample
again after
250 hours).
Silicon level 30 ppm Check
component
for
entrance of
dust
(sealing,
breath­‐
ers...).Flush
and
change oil
(get a
sample
again after
250 hours).
Water content 0,10% Change oil
(get a
sample
again after
250 hours).
Viscosity change(at <15%(*) Change oil
40°C and 100°C) (get a
sample
again after
250 hours).
Additives change ±20%(*) Change oil
(get a
sample
again after
250 hours).

(*) Difference compared to new oil value.

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Hydraulic oil

Component Parameter Action level value Action

Hydraulic oil Silicon level 15 ppm Check for
entrance of
dust
(cylinders,
breathers...)
(get a sample
again after
250 hours).
Viscosity change(at <15%(*) Change oil
40°C and 100°C) (get a sample
again after
250 hours).
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.
• If not
available,
change oil.

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Component Parameter Action level value Action

Particle Quantifica­‐ 50 1. Change the
tion (PQ Index) return filters,
pilot oil filters,
leak oil filters
and
replenishing
filters.
2. Get a
sample again
after
250 hours.
If the results
are still out-
of-range:

• Use an
external
filtration
system
until you
get PQ
Index < 20
or less.
• If not
available,
change oil.

Cleanliness 21/19/16 1. Change the

level(ISO 4406) return filters,
pilot oil filters,
leak oil filters
and
replenishing
filters.
2. Get a
sample again
after
250 hours.
If the results
are still out-
of-range:

• Use an
external
filtration
system
until you
get
contam­‐
inant code
20/18/15
or less.
• If not
available,
change oil.

(*) Difference compared to new oil value.

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Diesel engine

Component Parameter Action level value Action

Diesel Please contact your engine manufacturer
engine local representative.
From: Operator's manual R 9200 - 410 > Maintenance > Condition monitoring with oil analysis

6.7 | 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.

From: Operator's manual R 9200 - 410 > Maintenance

6.7.1 | Check the engine oil level

The dipstick for the oil level indication is installed on the two sides of the engine.

Figure 1. 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.

• ▶ 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.

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From: Operator's manual R 9200 - 410 > Maintenance > Diesel engine

6.7.2 | Change the engine oil

Drain the oil

Drain the oil with the service trap

Figure 1. 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.

Figure 2. 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.

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Fill with oil

Figure 3. 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.

• ▶ For detailed description of maintenance work to be performed, see also Cummins operation and maintenance manual.

From: Operator's manual R 9200 - 410 > Maintenance > Diesel engine

6.7.3 | 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 min­utes after stopping the engine before disassembling the filter.

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Figure 1. 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.

• ▶ For detailed description of maintenance work to be performed, see also Cummins operation and maintenance manual.

• ▶ Check after every oil change, or after adding oil, that you get the correct oil level on the dipstick 10.

From: Operator's manual R 9200 - 410 > Maintenance > Diesel engine

6.7.4 | Mounting screws

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

Figure 1. Engine mounting screws

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Torque Quantity
112 Screw M20x120 560 Nm 2
117 Screw M24x130 965 Nm 4
145 Screw M30x300 (if installed) 1920 Nm 2

• ▶ Check the mounting screws on the engine brackets and the engine gear mounts regularly for tightness. Retorque if necessary.

• ▶ For maintenance intervals, see control and maintenance chart.

CAUTION!

• ▶ Apply Loctite nr. 243 on the mounting screws 112, 117 and 145 when you install, in order to avoid possible damages
on the parts.
• ▶ Only tighten the screws 112, 117 and 145 after the engine and the splitterbox have been positioned on the
uppercarriage structure as a complete unit, to avoid a pretentioning of the rubber mounting.

From: Operator's manual R 9200 - 410 > Maintenance > Diesel engine

6.7.5 | Elastic bedding

Figure 1. Engine elastic bedding

• ▶ The four rubber buffers 115 at the front face of the engine must be checked and replaced at regular intervals.

• ▶ For maintenance intervals, see control and maintenance chart.

From: Operator's manual R 9200 - 410 > Maintenance > Diesel engine

6.7.6 | Belts

• ▶ Regularly check belts for correct condition, tension, alignment...

• ▶ For maintenance intervals, see control and maintenance chart.

• ▶ For detailed description of maintenance work to be performed, refer to the Cum­mins operation and maintenance manual.

From: Operator's manual R 9200 - 410 > Maintenance > Diesel engine

6.8 | Splitterbox

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From: Operator's manual R 9200 - 410 > Maintenance

6.8.1 | Splitterbox mounting screws

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

Figure 1. Splitterbox mounting screws

Torque Quantity
1 Screw M20x100 560 Nm 8 (2x4)
2 Screw M24x130 965 Nm 4 (2x2)

• ▶ Check the mounting screws on the splitterbox brackets regularly for tightness, re­torque if necessary.

• ▶ For maintenance intervals, see control and maintenance chart.

CAUTION!

• ▶ Apply Loctite nr. 243 on the mounting screws 1 and 2 when you install, in order to avoid possible damages on the
parts.
• ▶ Only tighten the screws 1 and 2 after the engine and the splitterbox have been positioned on the uppercarriage
structure as a complete unit, to avoid a preten­tioning of the rubber mounting.

Figure 2. Splitterbox mounting screws on engine

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Torque Quantity
11 Screw 1/2" UNC X2 3/4" 130 Nm 16

• ▶ Check the tightness of mounting screws 11 from the splitterbox to the Diesel en­gine housing regularly, retorque if necessary.

• ▶ For maintenance intervals, see control and maintenance chart.

CAUTION!

• ▶ Apply Loctite nr. 243 on the mounting screws 11 when you install, in order to avoid possible damages on the parts.

From: Operator's manual R 9200 - 410 > Maintenance > Splitterbox

6.8.2 | Elastic bedding

Figure 1. Elastic bedding

• ▶ The four rubber buffers 3 at the splitterbox sides must be checked and replaced at regular intervals.

• ▶ For maintenance intervals, see control and maintenance chart.

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From: Operator's manual R 9200 - 410 > Maintenance > Splitterbox

6.8.3 | Breather filter

Figure 1. Breather filter on splitterbox

The breather filter 1 on the splitterbox must be checked, cleaned and replaced reg­ularly.

Clean the breather filter

• ▶ Open breather filter 1 by pushing it and turning it 1/4 turn.

• ▶ Remove the filter element 2 from the breather housing.

• ▶ Check filter condition and clean it with fuel.

• ▶ Reinstall the filter element in the breather housing.

• ▶ Close breather 1.

• ▶ For check, clean and change intervals, see maintenance and control chart.

From: Operator's manual R 9200 - 410 > Maintenance > Splitterbox

6.9 | Coupling

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From: Operator's manual R 9200 - 410 > Maintenance

6.9.1 | Check the coupling rubber rollers

Figure 1. Check the coupling rubber rollers

1 Rubber roller (new)

2 Rubber roller (with oval deformation because of normal wear)
A Test distance

Make sure that the following preconditions are met:

▢ The machine is safely parked on firm and level ground.

▢ The Diesel engine is stopped.

• ▶ Examine the condition of the rubber rollers.

If a rubber roller is damaged:

• ▶ Replace all the rubber rollers immediately.

• ▶ Measure distance A of the rubber rollers.

If distance A is smaller than the minimum permitted distance of 75 mm:

• ▶ Replace all the rubber rollers immediately.

From: Operator's manual R 9200 - 410 > Maintenance > Coupling

6.10 | Cooling system

From: Operator's manual R 9200 - 410 > Maintenance

6.10.1 | Check and clean the cooling system

To get optimal cooling, the cooler must be kept clean.

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Figure 1. Expansion tank

1 Coolant expansion tank

2 Level indicator
3 Filler neck

• ▶ Check the engine, fan and cooler for damage.

• ▶ If necessary, clean with pressurized air.

• ▶ If the cap of the filler neck 3 is leaking, replace the cap.

• ▶ Regularly check the connector hoses between the radiator and the engine.

• ▶ Regularly check the heater hoses for condition and leaks.

• ▶ Check the tightness of hose clamps.

From: Operator's manual R 9200 - 410 > Maintenance > Cooling system

6.10.2 | Check the coolant level

DANGER!
At near operating temperature, the engine coolant is hot and under pressure.

• ▶ Avoid contact with components containing coolant as it can cause dangerous burns.

• ▶ Make sure the engine coolant is cold and the radiator is sufficiently cool to touch.

• ▶ Check the coolant level.

The coolant level must be at the middle of the level indicator 2.

From: Operator's manual R 9200 - 410 > Maintenance > Cooling system

6.10.3 | Coolant antifreeze and anti-corrosion fluid

The system must be filled with antifreeze all year round.

Depending on the type of coolant that you use, corrosion-inhibiting additives and coolant filters which contain corrosion inhibitor can be
necessary.

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It can be necessary to flush the full coolant circuit if you change from one type of cool­ant to another.

• ▶ For volume, see operating material chart.

• ▶ For specifications, refer to the section "Lubricating and operating material speci­fications".

• ▶ If you use a coolant which requires corrosion inhibitor, you must check the concentration of the corrosion inhibitor in the coolant
circuit regularly.

From: Operator's manual R 9200 - 410 > Maintenance > Cooling system

6.10.4 | Change the coolant

DANGER!
Risk of burning because of hot coolant.

• ▶ Only change the coolant when the engine is cold.

• ▶ For coolant change interval, see Cummins operation and maintenance manual.

• ▶ For the detailed procedure to drain and fill the engine cooling system, refer to the Cummins engine operation and maintenance
manual.

• ▶ If an optional coolant heater is installed, bleed it after maintenance works on the Diesel engine cooling system. Refer to section
"Starting aids" in chapter 5.

Drain the coolant

Two drain plugs 2 are located on the tubes connected to the radiator 1.

Figure 1. Coolant drain

1 Engine coolant radiator

2 Drain plug

Fill the coolant

CAUTION!
When you fill the system, the coolant level in the expansion tank must be correct and stable.

• ▶ Make sure that the expansion tank is filled to correct level on the indicator 2 and until coolant level no longer drops.

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From: Operator's manual R 9200 - 410 > Maintenance > Cooling system

6.10.5 | Replace the coolant filters

The coolant filters are installed on the Diesel engine.

Figure 1. Coolant filters location

Figure 2. Coolant filters

• ▶ Turn the shutoff valve of the coolant filters to the OFF position.

• ▶ Loosen and remove the filter elements.

• ▶ Lightly oil the seal rings on the new filter element.

• ▶ Tighten the new filters elements until the seal ring touches the filter housing.

• ▶ Then turn it manually by one more 1/2 - 3/4 turn. Do not use any tools to tighten the filters.

• ▶ Turn the shutoff valve to the ON position.

• ▶ For detailed description of maintenance work to be performed, see also Cummins operation and maintenance manual.

From: Operator's manual R 9200 - 410 > Maintenance > Cooling system

6.11 | Fuel system

DANGER!
Risk of explosion!

• ▶ Avoid naked flame when working on the fuel system and when refuelling.
• ▶ Do not smoke.
• ▶ Only work on the diesel engine when it is switched off.

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From: Operator's manual R 9200 - 410 > Maintenance

6.11.1 | Refuel

The display shows the fuel level.

• ▶ If the fuel level is too low, fill the fuel tank before you start the work.

The machine has different refuelling devices.

Refuel through the fuel tank cap

Figure 1. Lockable fuel tank cap

1 Fuel tank
2 Fuel tank cap
3 Padlock of fuel tank cap

• ▶ Unlock padlock 3.

• ▶ Remove tank cap 2.

• ▶ Add fuel.

Refuel through the service trap

Figure 2. Service trap

• ▶ Use the related coupling on the service trap.

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From: Operator's manual R 9200 - 410 > Maintenance > Fuel system

6.11.2 | Drain the fuel tank

Figure 1. Drain valves of fuel tank

1 Drain valve
2 Drain valve cap

The two drain valves 1 are installed below the fuel tank.

Drain the water of the fuel tank

• ▶ Put an applicable container below the drain valve 1 of the fuel tank.

• ▶ Loosen cap 2 about two turns.

• ▶ Drain the water until water free fuel flows out.

• ▶ Close cap 2.

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

Drain the fuel tank

• ▶ Remove cap 2 from the drain valve 1.

• ▶ Attach a drain hose. Drain the fuel into an applicable container.

• ▶ Remove the drain hose.

• ▶ Close the cap 2 again.

• ▶ For maintenance intervals, refer to control and maintenance chart.

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From: Operator's manual R 9200 - 410 > Maintenance > Fuel system

6.11.3 | Clean the fuel tank

Cleaning access to the tank is possible through the covers located on the tank.

• ▶ Drain the fuel tank. Refer to the related section above.

• ▶ Always use an applicable container to collect water and fuel.

• ▶ Check and clean the fuel tank.

• ▶ Close covers back.

From: Operator's manual R 9200 - 410 > Maintenance > Fuel system

6.11.4 | Fuel filtering system

The fuel filtering system has preliminary filters and fuel filters. Depending on the ma­chines, their configuration A or B can be different.

Figure 1. Fuel filters assembly

A Configuration A 1 Preliminary filters

B Configuration B 2 Fuel filters
3 Engine cooler box

With configuration A, the fuel filtering system has:

• one preliminary filter 1

• three fuel filters 2.

With configuration B, the fuel filtering system has:

• two preliminary filter 1

• two fuel filters 2.

• ▶ For preliminary and fuel filters maintenance intervals, refer to the control and maintenance chart.

Drain the water separator

The water separator is installed on the preliminary filter 1.

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Figure 2. Water separator on the preliminary filter

1 Preliminary filter
2 Drain valve

• ▶ Stop the Diesel engine.

• ▶ Open manually the drain valve 2 of the water separator installed at the bottom of the preliminary filter 1.

• ▶ Turn the drain valve 2 counterclockwise until it falls down.

• ▶ Drain water of the preliminary filter 1 until clear fuel is visible (approximately 3,5 turns).

• ▶ Lift the drain valve 2 and turn it clockwise manually to close it.

• ▶ For detailed description of maintenance work to be performed, refer also to the Cummins operation and maintenance manual.

CAUTION!
The drain valve must be tightened manually.
To prevent damages to the threads, do not tighten the drain valve too much.

Replace the filter elements

CAUTION!
Risk of damage to the fuel injection system!
It is important to keep all parts clean during the procedures that follow.

• ▶ For detailed description, refer to the Cummins operation and maintenance man­ual.

Location of the fuel shutoff valve

Figure 3. Fuel shutoff valve

1 Fuel shutoff valve

2 Preliminary filters

The fuel shutoff valve 1 is installed upstream the preliminary filters 2.

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On the preliminary filter

Figure 4. Filter element on preliminary filter

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1 Vent cap 6 Spring

2 O-ring 7 Filter element
3 Drain valve 8 O-ring
4 Collar 9 Seal
5 Bell

• ▶ Stop the Diesel engine.

• ▶ Close the fuel shutoff valve.

• ▶ Put an applicable container under the filter.

• ▶ Remove the vent cap 1.

• ▶ Remove the vent cap O-ring 2 and discard it.

• ▶ Open the drain valve 3 and drain the fuel into the container.

• ▶ Close the drain valve 3.

• ▶ Loosen the collar 4 and remove it.

• ▶ Remove the bell 5, the spring 6 and the filter element 7.

• ▶ Remove the O-ring 8 and the seal 9 and discard them.

• ▶ Carefully clean the filter housing.

• ▶ Install a new O-ring 8.

• ▶ Install a new filter element 7 with a new seal 9.

• ▶ Install the spring 6 and the bell 5 again.

• ▶ Install the vent cap 1 again with a new O-ring 2.

• ▶ Install the collar again 4. Tighten with your hand.

• ▶ Remove the container.

• ▶ Open the fuel shutoff valve.

• ▶ Refer also to the Cummins operation and maintenance manual.

• ▶ Prime the fuel system. Refer to the related procedure in this section.

On the fuel filter

Figure 5. Fuel filters

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1 Fuel filter

• ▶ Stop the Diesel engine.

• ▶ Close the fuel shutoff valve.

• ▶ Clean the area around the filter and the filter head.

• ▶ Loosen and remove the filter with an applicable wrench.

• ▶ Clean the sealing surfaces on the filter head with a clean and free-lint cloth.

Then:

• ▶ Do not fill the new filter with fuel.

• ▶ Apply a light film of clean engine oil on the filter element seal.

CAUTION!
You tighten the filter element too much!
Risk of damage to the threads.

• ▶ Tighten the filter element with your hand.

• ▶ Install and tighten the filter element on the filter head with your hand.

• ▶ For detailed description of maintenance work to be performed, refer also to the Cummins operation and maintenance manual.

• ▶ Open the fuel shutoff valve.

• ▶ Prime the fuel system. Refer to the related procedure in this section.

Prime the fuel system

You must prime the fuel filters and the preliminary filter after replacement and before to start the Diesel engine. The procedure that
follows is available for the two types of filter.

• ▶ Check that the drain valve of the preliminary filter is closed.

• ▶ Close the fuel shutoff valve.

• ▶ Remove the vent cap from the top of the preliminary filter.

• ▶ Fill the filter with clean fuel.

• ▶ Install the vent cap again.

• ▶ Tighten the vent cap with your hand.

• ▶ Open the fuel shutoff valve.

• ▶ Actuate the ignition key two to three times to prime the fuel system.

The fuel priming pump operates during 120 seconds when the ignition key is switched to contact position.

• ▶ When the fuel priming pump stops, turn the ignition key to the "OFF" position for approximately 30 seconds before you do it again.

• ▶ For detailed description of maintenance work to be performed, refer also to the Cummins operation and maintenance manual.

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From: Operator's manual R 9200 - 410 > Maintenance > Fuel system

6.11.5 | Replace the dust filter for the vent valve

Figure 1. Dust filter for the vent valve

1 Dust filter

• ▶ Replace the filter element of the optional dust filter 1 at regular intervals.

• ▶ For maintenance intervals, refer to the control and maintenance chart.

From: Operator's manual R 9200 - 410 > Maintenance > Fuel system

6.12 | Dry air filter

Maximum engine protection against premature wear due to dust is only possible if the air intake system and filters are checked and
serviced at regular intervals.

Figure 1. Air intake system

1 Engine compartment covering 14 Precleaner

10 Housing of dry air filter 16 Vacuum indicator

The air cleaner, with precleaner 14, primary and safety elements, is designed to give maximum protection at long maintenance intervals.

Maintenance also includes the replacement of the filter elements.

The vacuum indicator 16 storages the maximum recorded vacuum pressure on the filter outlet, during the Diesel engine operation.

Depending on the machines, the vacuum indicator can be different. Thus, you can have:

• a vacuum indicator - restriction gauge

• a vacuum indicator - switch

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Figure 2. Vacuum indicator

A Vacuum indicator - restriction gauge B Vacuum indicator - switch

17 Red stripe 20 Indicator
18 Warning window
19 Reset button

If you have the vacuum indicator - restriction gauge A:

• ▷ When the red stripe 17 is shown in the window 18, the air intake system is at the maximum permissible vacuum.

If you have the vacuum indicator - switch B:

• ▷ When the indicator 20 is at the red range, the air intake system is at the max­imum permissible vacuum.

In the two cases:

• ▶ You must replace the primary filter element:

• Immediately when the maximum vacuum pressure has been reached.

• At the intervals specified in the control and maintenance chart, if the maximum vacuum pressure has not been reached first.

• ▶ Press the button 19 to reset the vacuum indicator.

If the filter elements are removed and installed too often, the seals between the filter elements and the filter housing can be damaged.

The safety elements must be replaced after the primary elements have been replaced three times, or at intervals specified in
maintenance schedule.

Before installing a new element, carefully clean the seal and the sealing surface of the filter housing.

From: Operator's manual R 9200 - 410 > Maintenance

6.12.1 | Replace the primary filter element

Figure 1. Primary filter element

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1 Primary filter element

2 Wing nut

• ▶ Stop the engine.

• ▶ Remove the wing nut 2.

• ▶ Remove the dirty primary filter element 1.

• ▶ Clean the inner surface of the air filter housing.

• ▶ Wipe off the sealing surface in the filter housing with a moist rag.

• ▶ Do not blow the housing with compressed air.

• ▶ Insert the new primary filter element.

• ▶ Make sure it is installed correctly.

• ▶ Tighten wing nut 2.

From: Operator's manual R 9200 - 410 > Maintenance > Dry air filter

6.12.2 | Replace the safety element

Figure 1. Safety element

3 Safety element
4 Wing nut

We recommend that the safety elements are replaced by a qualified maintenance or Liebherr service technician.

• ▶ Remove the primary filter element as given before.

• ▶ Remove wing nut 4.

• ▶ Remove the dirty safety element 3.

• ▶ Carefully clean the inner surface of the air filter housing with a moist rag.

• ▶ Clean the sealing surfaces in the housing and check for damage.

• ▶ Carefully insert the new safety element.

• ▶ Tighten wing nut 4.

• ▶ Install the primary filter element as given before.

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From: Operator's manual R 9200 - 410 > Maintenance > Dry air filter

6.12.3 | Clean the precleaner

CAUTION!
Incorrect cleaning procedure and incorrect cleaning tools!
Risk of damage.

• ▶ Do not tap or hit the components to remove dirts.

• ▶ Clean the components with water, with a weak solution of soap and water or with compressed air.

• ▶ Do a check of the condition of the precleaner at the intervals specified in the con­trol and maintenance chart.

Figure 1. Precleaner

1 Cover 5 Clamp
2 Upper baffle and gasket 6 Screen screws
3 Lower baffle 7 Precleaner outlet hose
4 Screen

• ▶ Stop the engine.

• ▶ Remove the hose 7 from the precleaner outlet. Then, remove the clamp 5.

• ▶ Remove the precleaner from the housing of the dry air filter. Make sure that no dirt goes into the housing of the dry air filter.

• ▶ Install the precleaner with the head down.

• ▶ Remove the screws 6. Then, disassemble the precleaner.

• ▶ Clean all the parts.

• ▶ Examine the gasket carefully for damages. Replace it if necessary.

• ▶ Make sure that the gasket is installed correctly in the upper baffle.

• ▶ Keep the precleaner with the head down and assemble it again.

• ▶ Torque the screws 6 to 2,3 ± 0,6 Nm.

• ▶ Install the precleaner on the housing of the dry air filter again and install the hose 7 again.

• ▶ Torque the screw of the clamp 5 to 11,3 ± 2 Nm.

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From: Operator's manual R 9200 - 410 > Maintenance > Dry air filter

6.12.4 | Clean the housing of the air filter elements

Figure 1. Housing of air filter elements

1 Housing of air filter elements

2 Filter cover

• ▶ Do a check of the condition of the dry air filter housing 1 at the intervals specified in the control and maintenance chart.

• ▶ Open the filter cover 2 and check the inner housing.

• ▶ If the inner housing is clogged with dust, use compressed air to blow it from the inlet side inside the housing.

CAUTION!
Do not use steam.
The safety elements must stay in position.
Do not point the air flow through the filter elements.
From: Operator's manual R 9200 - 410 > Maintenance > Dry air filter

6.12.5 | Check the air intake system, hoses, elbow tubes, clamps

Figure 1. Air intake hoses, tubes and elbow tubes

30 Tubes between the filters and the Diesel engine

31 Tubes between the precleaners and the exhaust system
35 Elbow tubes

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You must check the hoses and tubes 30, 31 and the elbow tubes 35 between the filter housings and the Diesel engine for damage, wear,
tightness and leaks when you re­place the filter elements.

• ▶ If necessary, tighten the screws on the clamps.

• ▶ Do a visual check of the air intake system at the intervals given in the control and maintenance chart.

• ▶ Do a sealing control of the air intake system at the intervals given in the control and maintenance chart.

• ▶ Do also a sealing control of the air intake system each time you replace a com­ponent of the air intake duct.

• ▶ Use the Liebherr special tool which is dedicated for this purpose to do the sealing control of the air intake system.

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From: Operator's manual R 9200 - 410 > Maintenance > Dry air filter

6.13 | Hydraulic system

Maintenance work on the hydraulic system is restricted mainly to the hydraulic tank. All other units on the system do not require any
special maintenance.

Strict cleanliness is of particular importance for the hydraulic system.

• ▶ Obey the intervals given to:

• Replace the return filter and the leak oil filter

• Replace the breather filter of the hydraulic tank

• Clean the oil cooler

• Change the oil

• Check pipe and hose network for leaks.

From: Operator's manual R 9200 - 410 > Maintenance

6.13.1 | Preparatory activities

Figure 1. Machine check position for hydraulic oil level check or level adjustment

Preparatory activities before to check or adjust the oil level

• ▶ The machine must stay on level ground.

• ▶ The attachment must stay on the ground, with stick and tilt cylinders fully extend­ed and bucket closed.

• ▶ Stop the engine.

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From: Operator's manual R 9200 - 410 > Maintenance > Hydraulic system

6.13.2 | Check the oil level in the hydraulic tank

Figure 1. Oil level in the hydraulic tank

1 Maximum oil level (warm and with fully retracted cylinders) 4 Minimum oil level (cold and with fully extended cylinders)
2 Warm oil check level (in check position) 5 Cold sight gauge
3 Cold oil filling level (in check posi­tion) 6 Warm sight gauge

The "MAX" mark 1 shows the maximum oil level if all cylinders are fully retracted with excavator at nominal operating temperature.

The "MIN" mark 4 shows the minimum oil level if all cylinders are fully extended with oil at minimum temperature.

Fill the hydraulic tank with oil initially (e.g. for first start, after maintenance...)
• ▶ Make sure that the machine and the hydraulic oil are at ambient temperature.

• ▶ Set the machine in the check position given before in this section.

• ▶ Add oil to the hydraulic tank until the oil level is at level 3.

Check the oil level in the hydraulic tank

• ▶ Do the check of the hydraulic oil level only when the hydraulic oil is at nominal operating temperature (warm). You can get the
nominal operating temperature as given below:

• Start the engine.

• Operate the machine with standard movements until the hydraulic oil temperature is more than 50°C.

CAUTION!

• ▶ During this warm-up, make sure that the hydraulic oil level is not above the "MAX" mark 1.

• ▶ Set the machine in the check position given before in this section.

• ▶ Check that the oil level is at level 2.

• ▶ If the oil level is below level 2, add oil through the filling coupling or through a re­turn filter until you get correct oil level.

• ▶ If the oil level is over level 2, drain the unwanted oil until you get correct oil level.

During the operation, if the oil level falls below a safety level, this warning symbol is shown on the display.

The oil level gauge on the hydraulic tank does not show this safety level.

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From: Operator's manual R 9200 - 410 > Maintenance > Hydraulic system

6.13.3 | Release the pressure from the hydraulic system

DANGER!
A fine stream of liquid can penetrate the skin when under high pressure and cause serious injury.

• ▶ Before working on the hydraulic system, always release the pressure.

• ▶ Do not inspect leaks with bare hands.

Release the hydraulic pressure

• ▶ Set the machine in the check position given before in this section.

• ▶ Stop the engine.

• ▶ Make sure that the ignition key is on contact position.

• ▶ Move the operating and control elements (joystick and pedals) in all directions.

DANGER!
The hydraulic oil is hot when at operating temperature.

• ▶ Do not allow the hot oil or oil-bearing parts to touch the skin.

Figure 1. Release the hydraulic pressure

1 Hydraulic tank
2 Breather filter
3 Locking pin

• ▶ Put the locking pin 3 into the breather filter 2.

• ▶ Loosen the breather filter 2 only one turn.

The pressure in the hydraulic system will decrease.

• ▶ At the end of the work, tighten the breather filter 2.

• ▶ Remove the locking pin 3.

It is no longer possible to loosen the breather filter.

The breather filter 2 must be replaced at regular intervals.

• ▶ For maintenance intervals, refer to the control and maintenance chart.

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From: Operator's manual R 9200 - 410 > Maintenance > Hydraulic system

6.13.4 | Drain and fill the hydraulic tank

CAUTION!

• ▶ Before draining the oil or before adding oil through the service trap or a filter cover, always release the hydraulic tank
pressure.
• ▶ After each hydraulic oil change, bleed the hydraulic pumps.

Fill the oil through the service trap

Figure 1. Hydraulic oil change coupling on service trap

• ▶ Set the machine in the check position given before in this section.

• ▶ Release the hydraulic pressure as given before.

• ▶ Use the related quick change coupling of the service trap to refill hydraulic oil until you get the correct oil level.

• ▶ Close the breather filter.

Add oil manually

Figure 2. Return filter on the hydraulic tank

1 Leak oil filter

2 Return filter

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As a help way, or for small quantities, you can add hydraulic oil manually.

• ▶ Set the machine in the check position given before in this section.

• ▶ Release the hydraulic pressure as given before.

• ▶ Remove the cover of the return filter 2. Refer to the section below for return filter opening.

CAUTION!
Contamination!
Risk of damage to the hydraulic system.

• ▶ Make sure that the return filter is installed.

• ▶ Add oil through the return filter until you get the correct oil level.

• ▶ Install the cover again.

• ▶ Close the breather filter.

Drain the oil

Figure 3. Draining valves of the hydraulic tank

1 Bleeding valve 4 Lateral access cover

2 Oil inlet compartment 5 Lateral access cover (if installed)
3 Lateral drain plug (if installed) 6 Lateral access cover (if installed)

• ▶ Lay down the attachment on the ground to have a maximum quantity of oil in the hydraulic tank:

• Stick and bucket cylinders fully retracted

• Bucket on the ground.

• ▶ Release the hydraulic pressure as given before.

• ▶ Remove the cover of the return filter.

• ▶ Attach a drain hose on the bleeding valve 1. Let the oil flow into an applicable con­tainer.

• ▶ Remove the drain hose.

• ▶ Install the cover of the return filter again.

• ▶ Close the breather filter.

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NOTE!
The hydraulic tank has different lateral access covers.
Depending on the machines, oil inlet compartments can also have lateral drain plugs.

• ▶ For use of these devices, refer to the section "Cleaning procedure for the hy­draulic circuits" of this manual.

Drain the water of the hydraulic tank

• ▶ Refer to the control and maintenance chart for the bleeding intervals.

• ▶ Release the hydraulic pressure as given before.

• ▶ Attach a drain hose on the bleeding valve 3. Drain the water until water free oil flows out.

• ▶ Close the breather filter.

From: Operator's manual R 9200 - 410 > Maintenance > Hydraulic system

6.13.5 | Hydraulic oil coolers

Cleaning hydraulic oil coolers is necessary to get optimum hydraulic oil cooling.

• ▶ Clean hydraulic oil coolers with compressed air or a steam cleaner at the intervals given in the control and maintenance chart, and
more often if working conditions make it necessary.

From: Operator's manual R 9200 - 410 > Maintenance > Hydraulic system

6.13.6 | Leak oil filter and return filter

The leak oil filter and the return filters are installed on the top of the hydraulic tank.

Figure 1. Leak oil filter

1 Filter housing 5 Cover

2 Screw 6 Hexagonal screw
3 Filter element 7 Magnetic rod
4 Seal kit

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Figure 2. Return filter

1 Filter housing 5 Cover

2 Screw 6 Hexagonal screw
3 Filter element 7 Magnetic rod
4 Seal kit

• ▶ Clean the magnetic rods 7 of the two types of filters at fixed intervals.

• ▶ Replace the filter element 3 at fixed intervals.

• ▶ For maintenance intervals, refer to the control and maintenance chart.

Clean the magnetic rod and replace the filter element

This section is available for the two types of filters.

• ▶ Release the hydraulic pressure as given before.

• ▶ Loosen the screws 6 on the filter cover 5. Remove cover 5 and magnetic rod 7.

• ▶ Carefully clean any metal particles collection on the magnetic rod 7.

• ▶ Remove the used filter element 3 from the filter housing 1.

CAUTION!
Contamination!
Risk of damage to the hydraulic system.

• ▶ Make sure that dirt, unwanted material or oil which is possibly dirty does not go into the filter housing.
• ▶ Carefully clean the filter housing.

• ▶ Insert a new filter element on the bracket vertically in the tank and press down lightly.

CAUTION!

• ▶ Make sure that the filter insert is standing vertical in the tank.

• ▶ Make sure that the seal kit 4 is put correctly and it is in good condition.

• ▶ Each time you replace the filter element 3, also replace the filter element of the piloting filter (refer section below).

• ▶ Install the cover 5 again.

• ▶ For the return filter, torque screws 6 to 120 Nm.

• ▶ For the leak oil filter, torque screws 6 to 80 Nm.

• ▶ Close the breather filter.

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If necessary, you can remove filter housings 1 through screws 2 (tightening torque of 40 Nm).

From: Operator's manual R 9200 - 410 > Maintenance > Hydraulic system

6.13.7 | Servo oil and replenishing filters

Two hydraulic filters do the filtration of the auxiliary circuits:

• A servo oil filter 1

• A replenishing filter 2 for the swing circuit.

Figure 1. Location of servo oil and replenishing filters

1 Servo oil filter

2 Replenishing filter

They are installed in the pumps box, near the pumps.

• ▶ Replace the filter elements at fixed intervals.

• ▶ For maintenance intervals, refer to the control and maintenance chart.

It is not permitted to clean the filter element.

• ▶ Replace the filter element each time you open the filter housing.

Replace the filter element

Figure 2. Servo oil and replenishing filters

1 Filter head 3 O-ring

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2 Filter housing 4 Filter element

• ▶ Release the hydraulic pressure as given before.

• ▶ Make sure the filter head 1 and housing 2 are in good conditions.

• ▶ Make sure sealings and o-ring 3 are correctly installed.

• ▶ Lightly lubricate the threads of the filter housing 2.

• ▶ Manually, fully tighten the filter housing 2 in the filter head 1.

• ▶ Close the breather filter.

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From: Operator's manual R 9200 - 410 > Maintenance > Hydraulic system

6.13.8 | High pressure filters in working circuit

Four high pressure filters are installed on the inlet ports of the valve blocks.

Figure 1. High pressure filters on valve bank

1 High pressure filter 3 Compression ring

2 Compression ring 4 Coupling

• ▶ Check or replace the filter elements at fixed intervals.

• ▶ For maintenance intervals, refer to the control and maintenance chart.

CAUTION!
The related filter elements must be replaced after each replacement or repair of a working pump.

Check or replace the filter element

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

Figure 2. High pressure filter

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1 Filter head 4 O-ring

2 Filter element 5 O-ring
3 Compression spring 6 Filter housing

• ▶ Release the hydraulic pressure as given before.

• ▶ Remove the filter housing 6.

• ▶ Remove the filter element 2, check it and clean it with non flammable cleaning flu­id, or replace it if necessary with a new element.

The filter element 2 can be cleaned up to three times. Then it must be replaced by a new one.

• ▶ Clean the filter housing 6 and the filter head 1 and install it again. Make sure that the o-rings are correctly installed.

• ▶ Fully tighten the filter housing 6 in the filter head 1.

• ▶ Loosen the filter housing 6 by 1/6 turn.

• ▶ Close the breather filter.

• ▶ Check for leaks each time you check or you replace the filter element:

• Start the engine.

• Operate the machine for a short period.

• Check for leaks between the filter housing 6 and the filter head 1.

From: Operator's manual R 9200 - 410 > Maintenance > Hydraulic system

6.13.9 | Servo oil circuit

Figure 1. Accumulator on the valve bank

DANGER!
The pressure accumulator keeps the servo oil circuit under pressure for certain operations that also take place after the
Diesel engine has been stopped. Before you work on the servo oil circuit, you must release the servo pressure as follows:

• ▶ Put the attachment on the ground.

• ▶ Stop the engine.
• ▶ Operate the two joysticks (with ignition key in contact position).

It is not necessary to do special maintenance on the servo oil circuit.

• ▶ Examine the pipe network and connections on all units (pressure accumulator, pressure limiting valve, pressure filter, etc.) for leaks
regularly.

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From: Operator's manual R 9200 - 410 > Maintenance > Hydraulic system

6.13.10 | Remove the pumps intake hoses

Figure 1. Pumps intake hoses (aspiration)

1 Hydraulic tank 3 Screws

2 Hydraulic shutoff valve 4 Screws

Remove intake hoses and compensators

• ▶ Release the pressure from the hydraulic system as given before.

• ▶ Turn hydraulic shutoff 2 valve from position A to position B to close it.

• ▶ Drain the leak oil circuit.For more information refer to section "Appendix" of this manual.

• ▶ Remove related intake hose and compensator.

• ▶ Drain the hydraulic oil in an applicable container.

• ▶ Install intake hoses and compensators:

• Apply Loctite 243 on screws 3 and torque it to 35 +17 Nm.

• Apply Loctite 243 on screws 4 and torque it to 180 +90 Nm.

• ▶ When the repair work is completed, turn hydraulic shutoff 2 valve from position B to position A to open it.

• ▶ Close the breather filter.

From: Operator's manual R 9200 - 410 > Maintenance > Hydraulic system

6.13.11 | Bleed the hydraulic pumps

After working on the pumps or after oil change in the hydraulic system, you must bleed the hydraulic pumps.

• ▶ Make sure that the breather filter is closed.

• ▶ Slightly loosen the plugs (shown by the arrows in the drawings that follow) and let the air to escape.

• ▶ As soon as hydraulic oil flows out densely, close the plugs.

Before you start the pump for the first time after repairing or replacing the pump, the pump housing must be filled with hydraulic oil
through the same hole.

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Bleed the working pumps

There are four working pumps on the machine (two double-pumps).

Figure 1. Bleeding of the working pumps

P1 Working pump 1 P3 Working pump 3

P2 Working pump 2 P4 Working pump 4

Bleed the swing pump

Figure 2. Bleeding of the swing pump

P5 Swing pump

Bleed the cooling pumps

Figure 3. Bleeding of the cooling pumps

P6.1 Engine cooling pump

P6.2 Oil cooling pump

Bleed the pump for the air-conditioning system

Depending on the machine, there can be a special hydraulic pump for the air-condi­tioning system.

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Figure 4. Bleeding of the pump for the air-conditioning system

P70 Pump for the air-conditioning system

• ▶ Refer to the section "Heating and air-conditioning system" in chapter 5 for the configuration of the system.

From: Operator's manual R 9200 - 410 > Maintenance > Hydraulic system

6.13.12 | Bleed the hydraulic cylinders

DANGER!
If the cylinder is not correctly bled, gas bubbles can form in the system (mixture of air and hydrocarbon). At high operating
pressures in the cylinder, these gases can explode (Diesel effect).

You must bled the cylinders after each cylinder replacement and after work carried out on the cylinders (replacement of seals, etc.) or the
hydraulic circuits (replacement of hose, etc.).

• ▶ Operate the engine at low idle.

• ▶ If possible, move the attachment to put the cylinder side to be bled (not-supplied side) in the upper position.

• ▶ Slowly extend the cylinder to the extreme position and then slowly fully retract it again. Make sure that all movements are slow and
smooth. Do this process a min­imum of 5 minutes.

From: Operator's manual R 9200 - 410 > Maintenance > Hydraulic system

6.13.13 | Bleed the valve blocks

After working on the control circuit (servo oil circuit), you must bleed the valve blocks. You can also do this procedure when the
attachment moves jerkily.

• ▶ Make sure that the breather filter is closed. Refer to the related section above.

• ▶ Operate the engine at low idle.

• ▶ Slowly move up and down the boom four times to pressurize the hydraulic sys­tem.

• ▶ Lay down the attachment on the ground.

• ▶ Stop the engine.

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Figure 1. Bleeding of valve blocks

1 Bleed screw
2 Top cover of valve blocks

The top covers 2 are installed on the top of the valve blocks.

• ▶ Do the steps that follow on the covers 2:

• Loosen the bleed screw 1 by 0,5 turn.

• Let the oil escape until free-air oil flows out.

• Torque the bleed screw 1 to 8 ± 0,8 Nm.

• ▶ Operate the engine at low idle.

• ▶ Check that the attachment is operating correctly.

From: Operator's manual R 9200 - 410 > Maintenance > Hydraulic system

6.13.14 | Oil cooler protection filters (optional)

Figure 1. Oil cooler protection filter

Protection filters 15 can be installed between the valve bank and the oil cooler in order to reduce the impact on the operating conditions
of the excavator in case of pos­sible hydraulic component failure.

• ▶ Check and clean filters regularly.

• ▶ Check filters in case of hydraulic component failure.

• ▶ Change filter in case of impact or mesh rupture.

• ▶ For maintenance intervals, see control and maintenance chart.

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CAUTION!
If filters maintenance isn’t correctly carried out, filters clogging due to regular operation of the excavator could lead to
following risks:

• cooling capacity drop,

• negative impact on oil quality.

To check or change a filter:

▢ Shutoff valve between hydraulic tank and pumps must be closed.

• ▶ Use a vacuum pump connected to the hydraulic tank in order to minimize oil loss.

NOTE!
During maintenance operation, if one or several filter(s) is/are defective and if no replacement filter is available, the
excavator can still be operated with one or sev­eral filter(s) missing. This until delivery of a new filter.

• ▶ Make sure to always have sufficient operational filter in order to reduce mainte­nance time.

From: Operator's manual R 9200 - 410 > Maintenance > Hydraulic system

6.13.15 | Servicing the hydraulic cylinder

Checking the condition of the piston rod mounting

Figure 1. Piston rod mounting

NOTE
When a leak comes into view on the hydraulic cylinder piston rod mounting (see arrow above), the sealing kit must be
replaced by a Liebherr dealer.

Protecting the piston rods

Figure 2. Machine with piston rods retracted

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When the machine is out of service for more than 4 weeks and particularly for transportation by sea, the following measures must be
taken:

• ▶ Position or transport the machine in such a way that the piston rods are fully re­tracted into the cylinders.

• ▶ Apply a thick layer of non-corrosive anti-corrosion fluid on all exposed sections of loose piston rods.For grease quality, refer to the
section “Lubricating and operating materials”.

• ▶ For sea transportation (salt water), or in winter (road salt), check the condition of the piston rods once more after loading the
machine, because the wiper ring can remove the anti-corrosive grease.

• ▶ Additionally, cover piston rods with anti-corrosion fluid if a cylinder only has a low stroke for certain work, meaning that the piston
rod is not regularly moistened with hydraulic oil (for example: cylinder on slewing arm when working over ground).

• ▶ Check the condition of hydraulic cylinders which are not moved a great deal reg­ularly.

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From: Operator's manual R 9200 - 410 > Maintenance > Hydraulic system

6.13.16 | Replacement of the hydraulic hoses

Service life

DANGER!
It is necessary to replace the hydraulic hoses at specified intervals to maintain their maximum operating performance and
to reduce the risk of personal injury and/or machine damage.

• ▶ Obey the replacement intervals given below.

Natural ageing of the hose assemblies

Two types of hose assemblies are installed on the machine, with different natural ageing:

• the critical hoses

• the non-critical hoses

Critical hoses
The critical hoses are all the hoses in which oil and fuel flow, except the oil suction hoses.

• ▶ When you check a hose assembly or you install a new one, refer to the date of assembly marked on the hose assembly fittings.

T Date when the hose assembly has been made

T+2 Date T + 2 years
T+4 Date T + 4 years
T+6 Date T + 6 years

• ▶ If the hose assembly is in storage, install it on the machine (or on a preassembled module) before the date T + 2 years. If not,
dispose of it.

• ▶ If the hose assembly is installed on a machine which was never in operation, put the hose assembly in operation before the date T
+ 4 years. If not, dispose of it.

• ▶ When the hose assembly is T + 6 years old, dispose of it even if it is installed on a working machine.

Non-critical hoses
All other hoses are non-critical:

• oil suction hoses

• all the hoses in which other fluids flow (coolant, grease, heating and air-condition­ing fluid)

• ▶ When you check a hose assembly or you install a new one, refer to the date of assembly marked on the hose assembly fittings.

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T Date when the hose assembly has been made

T+2 Date T + 2 years
T+6 Date T + 6 years
T+8 Date T + 8 years

• ▶ If the hose assembly is in storage, install it on the machine (or on a preassembled module) before the date T + 2 years. If not,
dispose of it.

• ▶ If the hose assembly is installed on a machine which was never in operation, put the hose assembly in operation before the date T
+ 6 years. If not, dispose of it.

• ▶ When the hose assembly is T + 8 years old, dispose of it even if it is installed on a working machine.

Operating stress
• ▶ For the replacement intervals given in working hours of the hydraulic hoses, refer to the section "Control and maintenance chart" of
this manual.

General information

Figure 1. SAE flanges

1 Flat single-part flange 4 Half flange with boss

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

DANGER!
A defective hydraulic hose can cause accidents and injuries.

• ▶ Replace defective hydraulic hoses (bubbles, moisture, damaged top edge etc.) immediately.
• ▶ The mounting bolts of the hydraulic lines (for example: hoses, pipes, flanges…) must be replaced after each
removal.
• ▶ When you replace a hydraulic line, also replace the rubber insert of the related hydraulic flanges.
• ▶ When you replace a hydraulic flange, also replace its rubber insert.
• ▶ Install new hoses in such a way that torsion loading is avoided.
• ▶ Ensure that the hydraulic hose is not twisted when mounting.

• ▶ Tighten the mounting screws of the SAE fittings with the following tightening torques and respecting the progressive criss-cross
tightening procedure described further in this chapter:

Table 1. Tightening torques for SAE flanges

M8 1,25 1/2 1/2 25 1

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Size of the screw (quality class 10.9) Thread pitch (mm) Valid for flange size CODE 61(in) Valid for flange size CODE 62(in) Screw w
(Nm) (l
M10 1,5 3/4, 1, 1-1/4 3/4 55 4
M12 1,75 1-1/2, 2, 2-1/2 1 100 7
M14 2 1-1/4 140 1
M16 2 3, 3-1/2, 4, 5 1-1/2 230 1
M20 2,5 2

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

Figure 2. Sealing flange 1 and hydraulic block 2

SAE half flanges installation

CAUTION!
SAE half flanges must not touch hose bearing surface.

To install half flanges:

• ▶ Pre-install first half flange (screw in only by a few threads).

• ▶ Install seal in hose.

• ▶ Install hose into bottom of mounted half flange without touching the bearing sur­face.

• ▶ Put the hose onto the bearing surface.

• ▶ Install the second half flange.

• ▶ Tighten mounting screws to the prescribed torque value and by following the progressive criss-cross tightening procedure described
further in this chapter.

From: Operator's manual R 9200 - 410 > Maintenance > Hydraulic system

6.13.17 | Progressive criss-cross tightening procedure

NOTE!
Always use this procedure to install the following flanges types:

• half flanges,
• single-part flanges,
• conical flanges,
• monobloc flanges (welded).

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Figure 1. Criss-cross tightening

• ▶ Make sure that all mounting surfaces have no damage, grease or contamination.

• ▶ Install the O-ring in the groove of the hose fitting.You can use grease to hold the O-ring in position into the groove.Be careful not to
apply too much grease because it could look like a leak during operation.

• ▶ Put the hose in position onto the mounting surface (be careful that you do not cause damage to the O-ring or remove the O-ring).

• ▶ Pre-install the flange and pre-tighten the mounting screws by hand.

• ▶ Tighten the screws progressively in a criss-cross pattern:

• first to 50% of the prescribed torque value,

• then to 100% of the prescribed torque value,

• do it again until the flange is tightened equally: the screw heads must not turn when you apply 100% of the prescribed torque value.

From: Operator's manual R 9200 - 410 > Maintenance > Hydraulic system

6.14 | Oil changes on components

From: Operator's manual R 9200 - 410 > Maintenance

6.14.1 | General information

▢ The machine must be standing level.

• ▶ Switch off the engine.

• ▶ Wait briefly until the oil has collected in the oil sump.

• ▶ Drain off the oil (preferably when oil is at operating temperature)

• ▶ Add the oil.

• ▶ Check the oil level.

Oil quality and quantity: see lubricant chart.

Change intervals: see lubrication and maintenance chart.

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From: Operator's manual R 9200 - 410 > Maintenance > Oil changes on components

6.14.2 | Swing gear – Oil change

Figure 1. Oil change on the swing gear

1 Oil filling couplings 4 Filling connection

2 Oil drain couplings 5 Ventilation connection
3 Drain plug

Figure 2. Expansion tank

6 Sealing cap 9 Sight gauge - Minimum level

7 Filler tube 10 Chamber connected to the front swing gear
8 Sight gauge - Maximum level 11 Chamber connected to the back swing gear

• ▶ For oil specifications and oil quantity, refer to the lubrication chart.

• ▶ For oil change intervals, refer to the control and maintenance chart.

Check the oil level

• ▶ Make sure that the oil is at operating temperature.

• ▶ Do a check of the oil level through the sight gauges 8 and 9 of the expansion tank.

If the oil level is less than the minimum value:

• ▶ Add oil.

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Drain the oil

• ▶ Make sure that the oil is at operating temperature.

• ▶ Remove the sealing cap 6 of the expansion tank located behind the cab.

Each chamber of the expansion tank is connected to the upper section of a swing gear through filling and ventilation connections 4 and 5.
The lower oil drain plug 3 of each swing gear is directly connected to an oil drain coupling 2 of the service trap: no oil drain is possible at
the lower section of the gears.

• ▶ Connect a vacuum pump to the oil drain coupling 2 of the service trap.

• ▶ Drain the oil.

• ▶ Install the sealing cap 6 of the expansion tank back.

Fill the oil

• ▶ Use the oil filling coupling 1 of the service trap.

• ▶ For small quantities, you can fill the oil through the filler tubes 7 on the top on the expansion tank.

CAUTION!
When you fill the oil through the expansion tank, make sure that you fill the correct chambers dedicated to the swing
gears.
From: Operator's manual R 9200 - 410 > Maintenance > Oil changes on components

6.14.3 | Travel gear and Lifetime travel gear (optional) – Oil change

CAUTION!
The components that follow are filled with protective oil on delivery:

• the travel brakes (one for each travel gear)

• if installed, the optional Lifetime sealing interspaces (one for each travel gear)

Before the first start of the excavator:

• ▶ Drain the travel brakes and the Lifetime sealing interspaces (if installed) and fill it with the same oil as used to fill the
hydraulic tank.
• ▶ If installed, fill the travel gear elements that follow with the same oil as used to fill the hydraulic tank:
• the chamber of the special Lifetime expansion tank
• the hydraulic lines between the Lifetime sealing interspaces and the special ex­pansion tank

DANGER!
When the oil is hot, the travel gear elements can be under pressure.

• ▶ Before you drain the oil, carefully loosen the oil filling plugs to release the inter­nal pressure.

• ▶ For oil specifications and quantity, refer to the lubrication chart.

• ▶ For oil change intervals, refer to the control and maintenance chart.

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Change the travel gear oil

Figure 1. Oil change on travel gear

1 Filling plugs and oil level

2 Drain plug

Each travel gear has:

• two filling plugs 1 to do a check of the oil level and add oil

• one drain plug 2

Before you drain or fill the oil

• ▶ Move the excavator until the drain plug 2 is in vertical position below the gear axle.

Drain the oil

• ▶ Make sure that the oil is at operating temperature.

• ▶ Carefully loosen the filling plugs 1 to release the internal pressure.

• ▶ Remove the filling plugs 1.

• ▶ Remove the drain plug 2.

• ▶ Drain the oil into an applicable container.

• ▶ Install all the plugs 1 and 2 back.

Fill the oil

• ▶ Make sure that the drain plug 2 is installed.

• ▶ Remove the filling plugs 1.

• ▶ Fill the oil through one of the filling plugs 1 until you get the level of the second one.

• ▶ Install all the plugs 1 back.

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Change the oil of the Lifetime interspace (optional)

Figure 2. Special expansion tank of the Lifetime interspace

1 Cab elevation 4 Oil filler neck

2 Special expansion tank of Lifetime interspace 5 Sight gauges

3 Sealing cap 6 Standard expansion tank of swing gears

Figure 3. Oil change on the Lifetime interspace

7 Filling plug
8 Drain plug

The filling plug 7 is closed with a screw plug. The drain plug 8 is connected to a hy­draulic hose.

Drain the oil

• ▶ Make sure that you have an used oil container.

• ▶ Remove the sealing cap 3.

• ▶ Remove the hydraulic hose from the drain plug 8 and put a plug on the open end of the hose.

• ▶ Drain the used oil into the used oil container.

• ▶ Install the sealing cap 3 again.

• ▶ Connect the hydraulic hose to the drain plug 8 again.

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Flush the Lifetime interspace

• ▶ Make sure that you have an used oil container.

• ▶ Make sure that you have a hand pump.

• ▶ Make sure that you have a flushing device.Liebherr recommends that you use the Lifetime Interspace Flushing Device (contact the
Customer service).

CAUTION!
Use of an incorrect tool!
Risk of damage to the travel gear.
The flushing device must have a safety valve which must be set to 3 bar.
The flushing device must have a 10 µm filter for the filling with new oil.

• ▶ Remove the filling plug 7.

• ▶ Put the used oil container under the drain plug 8.

• ▶ Remove the hydraulic hose from the drain plug 8 and put a plug on the open end of the hose.

• ▶ Attach a drain hose on the drain plug 8.

• ▶ Drain the used oil into the used oil container.

• ▶ If the Lifetime interspace is clogged:

CAUTION!
Incorrect use of the hand pump!
Risk of damage to the travel gear.

• ▶ Operate the hand pump for a short time.

The maximum permitted pressure is 3 bar with a pressure peak of 12 bar.

• Connect the hand pump to the filling plug 7.

• Operate the hand pump to remove the material that causes the blockage.

• Remove the hand pump.

• ▶ Connect the flushing device to the filling plug 7.

• ▶ Flush the Lifetime interspace with new hydraulic oil until clean oil flows out from the drain plug 8.Refer to section "Lubricants and
operating fluids" for oil quantity and specifica­tions.

• ▶ Remove the drain hose from the drain plug 8.

• ▶ Remove the flushing device from the filling plug 7. Let the filling plug 7 open.

• ▶ Connect the flushing device to the drain plug 8.

• ▶ Fill with new oil with the flushing device through the drain plug 8 until the oil level is at the filling plug 7.

• ▶ Remove the flushing device from the drain plug 8.

• ▶ Install the filling plug 7 again.

• ▶ Connect the hydraulic hose to the drain plug 8 again.

• ▶ Measure the oil level through the sight gauge 5 on the expansion tank 2.

• ▶ If necessary, add oil through the expansion tank 2 as described below.

• ▶ If the Lifetime interspace was clogged, flush it again after 20 to 30 translation hours.

• ▶ If the Lifetime interspace stays clogged, contact the Customer service.

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Fill the oil

• ▶ Make sure that you use the same oil as used to fill the hydraulic tank.

• ▶ Make sure that the filling plug 7 is closed.

• ▶ Make sure that the hydraulic hose is installed on the drain plug 8.

• ▶ Remove the sealing cap 3.

• ▶ Add oil through the filler neck 4. Make sure that you do not add oil under pressure (more than 3 bar).

• ▶ Do a check of the oil level through the sight gauge 5 on the expansion tank 2.

• ▶ When you get the correct oil level, install the sealing cap 3 again.

Change the oil of the external travel brake

Figure 4. Oil change on external travel brake

1 Hydraulic motor 4 Pressure port

2 External travel brake 5 Oil level plug
3 Filling plug 6 Drain plug

Drain the oil

• ▶ Remove filling plug 3, which is installed on the upper side of external travel brake 2.

• ▶ Remove drain plug 6, which is installed on the lower side of external travel brake 2.

• ▶ Drain the oil into an applicable container.

• ▶ Install plugs 3 and 6 again.

Fill the oil

• ▶ Make sure that you use the same oil as used to fill the hydraulic tank.

• ▶ Make sure that plugs 5 and 6 are installed.

• ▶ Remove filling plug 3, which is installed on the upper side of external travel brake 2.

• ▶ Apply a pressure of 19 bar on pressure port 4 to release the brake.

• ▶ Fill the oil through filling plug 3 until oil free of air flows out.

• ▶ Adjust to the correct level with oil level plug 5. Add oil or let oil flows out as nec­essary.

• ▶ Install plugs 3 and 5 again.

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From: Operator's manual R 9200 - 410 > Maintenance > Oil changes on components

6.14.4 | Swing gears and travel gears flushing

CAUTION!
Gears flushing is necessary when switching from mineral oil to synthetic oil.

• ▶ Use new oil to flush the gear when switching from mineral oil to synthetic oil.

Flushing with cleaning fluid or Diesel fuel is not permitted.

To flush the swing gears:

• ▶ Fill up the swing gear (it is not necessary to fill the line to the expansion tank).

• ▶ Turn the uppercarriage for 1 minute.

• ▶ Drain the oil.

• ▶ Fill the swing gear again and the expansion tank to correct level.

To flush the travel gears:

• ▶ Fill half the travel gear (i.e. with half the total quantity of oil).

• ▶ Lift one track off the ground.

• ▶ Turn the track chain for 1 minute.

• ▶ Put the track back down.

• ▶ Follow the procedure again for the second track chain.

• ▶ Drain the oil.

• ▶ Fill the travel gear again to correct level.

From: Operator's manual R 9200 - 410 > Maintenance > Oil changes on components

6.14.5 | Splitterbox – Oil change

Figure 1. Oil change on the splitterbox

1 Service trap coupling 4 Oil inlet

2 Dipstick 5 Service trap plug
3 Drain valve

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Check the splitterbox oil level

• ▶ Stop the engine.

• ▶ Wait a minimum of 15 minutes to let the oil collect at the bottom of the oil pan.

• ▶ Check of the oil level with dipstick 2.

Change the splitterbox oil

• ▶ Make sure that the splitterbox oil is at operating temperature.

• ▶ Change the splitterbox oil with the service trap coupling 1.

• ▶ Use a vacuum pump connected to the quick-change coupling 1 to drain the oil.

• ▶ Add oil up to the mark on the dipstick 2. Do not overfill.

• ▶ Let the engine run for a few minutes and stop the engine.

• ▶ Wait a minimum of 15 minutes and check the oil level with the dipstick 2 again.

• ▶ For oil specification and oil quantity, refer to the lubrication chart.

• ▶ For oil-changing intervals, refer to the control and maintenance chart.

As a help way, the oil can also be changed via the drain valve 3 and the oil inlet 4 located on the splitterbox.

Drain oil this way

• ▶ Remove cap on the drain valve 3.

• ▶ Screw on drain hose.

• ▶ Drain oil into a suitable container.

• ▶ Remove hose and reinstall cap on drain valve 3.

Fill oil this way

• ▶ Remove cap on the oil inlet 4.

• ▶ Add oil via the oil inlet 4 up to the mark on the dipstick 2.

• ▶ After each oil change, let the engine run for a few minutes, stop the engine then wait 15 minutes and check the oil level with the
dipstick 2 again.

From: Operator's manual R 9200 - 410 > Maintenance > Oil changes on components

6.15 | Track components

The track components are maintenance-free until the track needs to be recondi­tioned or has to be replaced.

The design of the carrier rollers, track rollers and idlers increases track components lifetime and metal sealing make them insensitive to
dirt.

From: Operator's manual R 9200 - 410 > Maintenance

6.15.1 | Check the track components mounting

• ▶ Regularly check the tightening of the track components mounting screws.

• ▶ For torque values, refer to the applicable fastening subsection for your machine undercarriage configuration.

• ▶ For maintenance intervals, refer to the control and maintenance chart.

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Figure 1. Undercarriage components

1 Track chain 7 Cover

2 Rotary connection 8 Track guide
3 Central part 9 Track roller
4 Idler with tensioning unit 10 Travel gear
5 Side frame 11 Sprocket
6 Carrier roller

Track components fastening

Travel gear fastening

Figure 2. Travel gear fastening (right and left sides)

Torque
2 Sprocket -
3 Travel gear -
10 Hydraulic motor -
20 External travel brake -
21 Screw M30x2x200 x quantity 30 for each side 2085 Nm
31 Screw M36x3x250 x quantity 24 for each side 3495 Nm
101 Screw M24x65 x quantity 4 for each side 965 Nm

• ▶ Apply black grease (ID. 8503279) to screws 21 and 31 after a part replacement

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Track pad fastening

Figure 3. Track pad fastening

Fastening
1 Track link -
2 Track pad -
3 Screw M36x150-12.9 x quantity 4 for each track pad Do a check:

• 3780 Nm

Install a new screw:

• first 1000 ± 50 Nm
• then 160° + 10°

• ▶ When you install a track pad or a track link, the related screws and pins must be clean and greased with black grease (ID.
8503279).

Carrier roller fastening

Figure 4. Carrier roller fastening

Torque
5 Carrier roller -
51 Screw M24x150 x quantity 4 for each carrier roller 965 Nm

Track roller fastening

Figure 5. Track roller fastening

Torque
8 Track roller -

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81 Screw M30x200 x quantity 4 for each track roller 1920 Nm

Idler fastening

Figure 6. Fastening of idler and tension unit

Torque
9 Idler -
10 Grease tensioner -
11 Grease nipple 140 - 180 Nm
20 Hydraulic cylinder -
30 Hydraulic block -
101 Screw M30x290 x quantity 2 for each idler 1920 Nm
111 Screw M30x300 x quantity 2 for each idler 1920 Nm
301 Screw M16x100 x quantity 6 for each idler 270 Nm

Track guide fastening

Figure 7. Track guide fastening

Depending on the machines, the quantity of the screws 61 can be different.

Torque
6 Track guide -
61 Screw M30x200 x quantity 16/24 for each side 1920 Nm

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Fastening of travel motor protection

Figure 8. Fastening of travel motor protection

Torque
12 Support of travel motor protection 15 -
13 Protection plate -
14 Support of travel motor protection 16 -
15 Travel motor protection -
16 Travel motor protection -
121 Screw M30x130 x quantity 2 for each side 1920 Nm
122 Screw M20x80 x quantity 2 for each side 560 Nm
123 Screw M20x80 x quantity 2 for each side 560 Nm
131 Screw M16x40 x quantity 3 for each side 270 Nm
141 Screw M30x130 x quantity 3 for each side 1920 Nm
151 Screw M16x40 x quantity 11 for each side 270 Nm
161 Screw M16x35 x quantity 5 for each side 270 Nm
From: Operator's manual R 9200 - 410 > Maintenance > Track components

6.15.2 | Check the track tension

With normal wear on the sprocket and on the track chain, it is necessary to check the track tension regularly and to tension the track
again if necessary.

Figure 1. Track correctly tensioned

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Check the track tension

Figure 2. Check of the track tension

• ▶ Release the tracks by driving the machine forward and rearward. Stop the ma­chine after a forward movement.

• ▶ Place the measuring rod 1 between the carrier rollers.

• ▶ Measure distance A between the measuring rod and the track.

The distance A must be, under operating conditions, approximately 30 mm be­tween the carrier rollers.

• ▶ If necessary, tighten the track chains again.

From: Operator's manual R 9200 - 410 > Maintenance > Track components

6.15.3 | Increase the track tension

DANGER!
Risk of injury because of sudden falling of the track chain or a spray of grease under high pressure.

• ▶ When adjusting the tension of the track chain, keep your head away from the opening 1 in the track side frame.
• ▶ Grease is under high pressure and might squirt out. Also make sure that the track tension cylinder is out!

Figure 1. Tightening the track

1 Access cover
2 Grease nipple

• ▶ Remove the cover 1 on the side frame of the undercarriage.

• ▶ Through this access, connect to the grease nipple 2 of the grease tensioner the high pressure hose with manual grease gun.

• ▶ Put grease until the track is sufficiently tensioned.

• ▶ Check the track tension as described above.

• ▶ Remove the pressure hose and reinstall the cover 1.

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From: Operator's manual R 9200 - 410 > Maintenance > Track components

6.15.4 | Decrease the track tension

DANGER!
Risk of injury because of sudden falling of the track chain or a spray of grease under high pressure.

• ▶ Because of the risk of grease spray, always wear protective gloves and glasses when releasing the track tension.
• ▶ When releasing the tension of the track chain, keep your head away from the opening 1 in the track side frame.
Never touch the grease nipple 2 with your hand but always use an applicable tool to loosen or tighten it.
• ▶ To tighten or loosen the grease nipple 2, always catch it at its rear part and never at its front part.

• ▶ Before trying to release the track chain tension, loosen and remove every item which can be blocked in the track chain while driving
forward and rearward or do­ing as described in the section "Clean the travel gear" that follows.

• ▶ Carefully loosen the grease nipple 2 until the grease goes out of the nipple.

• ▶ Tighten grease nipple 2 as soon as you get the correct track tension.

• ▶ After the adjustment, drive the machine forward and rearward and check the track tension again.

Figure 1. Cylinder shutoff valves CVTL and CVTR

Cylinder shutoff valves CVT are installed in the undercarriage central part. The two sides left L and right R are symmetrical.

• ▶ Turn on the lever CVTL (left side) or CVTR (right side) to release the track tension pressure on the side you are working on.

• ▶ Turn off the lever CVTL or CVTR to tighten the track back.

From: Operator's manual R 9200 - 410 > Maintenance > Track components

6.15.5 | Clean the travel gear

Do not start the machine if large stones, pieces of wood or metal, wires or cables are blocked in the travel gear.

Dried or frozen mud and stones or other unwanted materials in the travel gear parts can cause important damages to the machine if it is
operated or if you try to unblock it using the power of the machine.

From: Operator's manual R 9200 - 410 > Maintenance > Track components

6.16 | Electrical system

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From: Operator's manual R 9200 - 410 > Maintenance

6.16.1 | Notes on the electrical system

DANGER!
Risk of injury due to formation of sparks.

• ▶ Avoid sparks and naked flame when charging batteries or working on the batter­ies.
• ▶ Always wear protective goggles and gloves.

• ▶ Check that the machine’s electrical system is functioning correctly at regular in­tervals.

• ▶ Burnt-out fuses and bulbs should be replaced immediately once the cause of the defect has been rectified.

• ▶ Rectify defects such as loose connections, abraded cables or badly fastened clamps immediately.

• ▶ Before starting any work on the electrical system, including welding work on the machine, disconnect all the batteries.When carrying
out electric arc welding on the machine, also disconnect the connectors from the engine ECM (Electronic Control Module)
system.Refer to the section below.

DANGER!
Risk of injury due to formation of sparks.

• ▶ Disconnect the negative terminal (-) first and connect it last.

From: Operator's manual R 9200 - 410 > Maintenance > Electrical system

6.16.2 | Batteries switches and ECM connectors

For the location of the batteries switches, you can refer to chapter 3 of this manual.

Figure 1. Connectors on engine

1 ECM connectors
2 Connectors
3 Datalink connector

• ▶ Before starting any work on the electrical system, including welding work on the machine, switch all the batteries switches to
position "OPEN" (principal and ad­ditional/optional batteries).

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CAUTION!
Risk of damage.
Be careful if an optional coolant heater is installed.

• ▶ Do not disconnect the related batteries if the fan and/or the pump of the coolant heater are on.

Refer to chapter 3 of this manual.

• ▶ For welding work on the machine, also disconnect:

• the connectors 1 from each engine ECM (there are two ECM on the engine)

• the connectors 2 on the engine

• the datalink connector 3 on the engine

• ▶ When washing the machine, cover the electrical units (particularly the alternator, generator, cabling, electronic components and
measured value sensor) to pre­vent water penetrating.

• ▶ When cleaning the engine with a water / steam jet, do not subject electrical measured value sensors such as oil pressure switches
to any direct jets.

◦ ▷ If this happens, moisture could penetrate and lead to contact corrosion and the failure of the measuring function.

◦ ▷ Oil pressure switches are not watertight due to the necessary presence of membrane ventilation.

NOTE!
Risk of batteries discharge if the machine is out of service for longer periods.

• ▶ Before laying up the machine for longer periods, disconnect the batteries.Be careful if an optional coolant heater is
installed, its current time and the recorded data will be erased if the related electrical system is opened. Refer to
chapter 3 of this manual.

From: Operator's manual R 9200 - 410 > Maintenance > Electrical system

6.16.3 | Battery care

The batteries must always be kept clean to ensure that it is able to function perfectly.

• ▶ Particular care should be taken to clean the pole ends and cable terminals 1 regularly and to then cover them with a thick layer of
acid proof grease.

DANGER!
Bent rubber hoses on the central gas outlet increase the risk of explosion!
The hydrogen contained in the batteries should not be allowed to build up in the accumulator box and must be able to
escape via the rubber hoses. The central gas outlet hoses must be routed without kinks.

• ▶ Check the condition of the hoses regularly, particularly after installing a battery.

The fluid level in the cells should be 10 to 15 mm above the top of the plate. Only distilled water is to be used for any refilling.

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Figure 1. Battery care

1 Cable terminals
2Acid tester

• ▶ From time to time, measure the acid concentration using an acid tester 2.

When the battery is fully charged, the unit weight is 1,28 kg/L (31,5° Bé).

• ▶ If the acid tester shows a lower value, the batteries is virtually flat and should be charged if necessary.

From: Operator's manual R 9200 - 410 > Maintenance > Electrical system

6.16.4 | Electrical components location

Figure 1. Electrical components location

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A2 Radio E1022 Control box of the access lad­der

A15 Greasing module E1043 Grease control box on the service trap
A161 Electrical plate E1086 Electrical box on engine com­partment
A168 Powerpack keypad G1 - Batteries
G4
A169 Standard functions keypad 1 H15 Horn of travel alarm
A170 Standard functions keypad 2 H16 Horn of ladder alarm
A171 Optional functions keypad H109 Grease warning light
A1002 Electrical plate P5 Hour meter
A1004 Electrical plate S1 Ignition key
A1014 Electrical plate S7 Safety lever
C1 Camera 1 / Opposite side of the cab S9_1/2 Principal battery circuit break­ers
C2 Camera 2 / Counterweight S100_1 Cab emergency stop
D Display S100_2 E1086 emergency stop
E1 Front working light / Uppercarriage (cab S100_3 Emergency stop of engine compartment
elevation)
E18_1/2 Rear working lights / Counter­weight S100_4 Counterweight emergency stop
E22 Light of travel alarm S125 External push-button / exter­nal cab lighting
E58_1/2 Front working lights / Top of cab U21 Left joystick
E59_1/2 Rear working lights / Top of cab U22 Right joystick
E59_3 Ladder lighting U23 Right travel pedal
E60_1/2 Front working lights / Fuel tank U24 Left travel pedal
E61_1 Camera lighting / Fuel tank U103_1 Air-conditioning module
E61_2 Camera lighting / Counter­weight U103_2 Module for optional second air-conditioning system (if in­‐
stalled)
E1003 Power electrical box X60 Auxiliary start receptacle
E1005 Cab connection box
From: Operator's manual R 9200 - 410 > Maintenance > Electrical system

6.16.5 | Cab pressurization

Figure 1. Aeration device

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

The air filters for the cab pressurization must be cleaned regularly.

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Clean the air filters

• ▶ Press to open the dust discharge valve 5.

• ▶ Regularly replace the main element and the safety element of the air filter system of this device.

• ▶ For maintenance interval, refer to the control and maintenance chart.

From: Operator's manual R 9200 - 410 > Maintenance > Electrical system

6.17 | Heating and air-conditioning system

From: Operator's manual R 9200 - 410 > Maintenance

6.17.1 | Possible configurations

Heating system
The machine has a standard heating system. It operates with a heater, which is in­stalled under the cab floor.

Air-conditioning system
The machine has a standard air-conditioning system.

Depending on the machines, the compressor for the standard air-conditioning sys­tem can be belt driven or hydraulically driven.

Air-conditioning system with belt driven compressor

The standard air-conditioning system has:

• An evaporator, which is integrated in the cab roof

• A condenser, which is installed on the oil cooler

• A dryer/receiver unit, which is installed on the oil cooler box

• A compressor, which is installed on the Diesel engine.

The machine can have an optional double air-conditioning system that replaces the standard air-conditioning system.

• ▶ Refer to the air-conditioning system with hydraulically driven compressor that has an optional second air-conditioning system.

Air-conditioning system with hydraulically driven compressor

The standard air-conditioning system has:

• An evaporator, which is integrated in the cab roof

• A condenser unit, which is installed on the outer side of the cab elevation. The condenser unit has:

◦ A condenser battery

◦ A dryer/receiver unit

◦ A compressor

• A special hydraulic pump that supplies the condenser unit. This pump is installed on the splitterbox.

The machine can have an optional second air-conditioning system. In this case:

• A second evaporator is installed in the cab roof

• A second condenser unit is installed adjacent to the standard condenser unit

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The two condenser units are the same and they are supplied by the same special hydraulic pump.

From: Operator's manual R 9200 - 410 > Maintenance > Heating and air-conditioning system

6.17.2 | Heating system

• ▶ For maintenance intervals, refer to the control and maintenance chart.

Figure 1. Location of the coolant shutoff valves on the Diesel engine

1 Coolant shutoff valve

2 Coolant shutoff valve

Figure 2. Heater

3 Fresh air filter

4 Heat exchanger
5 Air flap (if installed)

The heater is installed under the cab floor. Depending on the machines, the heater can have an air flap 5.

If filters are dirty, the airflow in the heating and in the air-conditioning systems is reduced. A reduced airflow causes frost and system
shutoff.

• ▶ Remove and clean the heat exchanger 4 and the fresh air filter 3 at intervals spec­ified in the control and maintenance chart.

• ▶ Do not operate the machine, even momentarily, without the air filter. It can quickly cause the blockage of the heat exchanger 4.

Independently from weather conditions:

• ▶ Make sure that the coolant shutoff valves 1 and 2 located on the Diesel engine are always open.

• ▶ Close the shutoff valves 1 and 2 when you change the coolant.

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Clean and replace the fresh air filter

• ▶ Remove the fresh air filter 3.

• ▶ Never wash the filter elements with hot water or a steam jet.

• ▶ Never wash the filter elements with acids or aggressive solvents.

• ▶ If damaged or in a bad condition, replace the filter elements.

• ▶ Clean the filter elements.

From: Operator's manual R 9200 - 410 > Maintenance > Heating and air-conditioning system

6.17.3 | Air-conditioning system

General procedures
This section gives general maintenance instructions for the air-conditioning system.

• ▶ Obey these maintenance procedures for all the air-conditioning system configu­rations.

• ▶ Operate the air-conditioning system at the intervals specified in the control and maintenance chart independently of the season.

• ▶ During the warm season, do the checks or maintenance works that follow.

• ▶ For maintenance intervals, refer to the control and maintenance chart.

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

Check the evaporator filter

Figure 1. Location of the evaporator(s)

1 Evaporator of standard air-conditioning system

2 Evaporator of optional second air-conditioning system (if installed)
3 Evaporator filter (recirculated air filter)

The evaporators 1 and 2 (if installed) are integrated in the cab roof.

• ▶ Check and clean the evaporator filter 3 (recirculated air filter), which is installed in the evaporator.

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Check the dryer/receiver unit

The maintenance works below must be done:

• At least once a year

• By a specialist in refrigeration engineering.

Figure 2. Dryer/receiver unit

1 Dryer/receiver unit 3 Float

2 Sight glass 4 Indicator

The location of the dryer/receiver unit 1 depending on the air-conditioning system configuration is given in the related section.

• ▶ Start the Diesel engine.

• ▶ Start the air-conditioning system.

• ▶ Do the check of the refrigerant level of the dryer/receiver unit 1 through the sight glass 2 and the float 3 (white colour):

• If the float 3 is at the bottom of the sight glass 2, the level is not sufficient.

• If the float 3 is at the middle of the sight glass 2, the level is correct.

• If the float 3 is at the top of the sight glass 2, there is too much refrigerant.

• ▶ If necessary, fill the system again.

• ▶ Do the check of the moisture degree of the dryer/receiver unit 1 through the sight glass 2 and indicator 4:

• If the indicator 4 has orange color, the moisture degree in the coolant circuit is cor­rect.

• If the indicator 4 has no color, the dryer/receiver unit 1 is soaked with moisture.

• ▶ If necessary, replace the dryer/receiver unit 1 immediately: empty, check for leaks and abrasion and fill the coolant circuit again.

• ▶ Do a visual check of the conditions of the dryer/receiver unit 1 (e.g. hoses connections, damages, rust, mounting bolts, ...). Replace
if necessary.

Check the condenser

The location of the condenser depending on the air-conditioning system configura­tion is given in the related section.

• ▶ Check the condenser.

• ▶ If necessary, blow it out with pressurised air or steam from the inner (fan side) to outside.

Air-conditioning system with belt driven compressor

Check the evaporator filter

• ▶ Obey the maintenance instructions given in the section "General procedures".

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Check the condenser

Figure 3. Location of the condenser

1 Condenser
2 Oil cooler box
3 Oil cooler

The condenser 1 is installed on the oil cooler 3.

• ▶ Obey the maintenance instructions given in the section "General procedures".

Check the dryer/receiver unit

Figure 4. Location of the dryer/receiver unit

1 Dryer/receiver unit
2 Oil cooler box

The dryer/receiver unit 1 is installed on the oil cooler box 2.

• ▶ Obey the maintenance instructions given in the section "General procedures".

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Check the compressor

Figure 5. Location of the air-conditioning compressor

1 Air-conditioning compressor
2 Compressor belt

The compressor 1 is installed on the Diesel engine.

• ▶ Examine the compressor 1 for possible damages.

• ▶ Do a check of compressor fastening.

• ▶ Do a check of condition, alignment and tension of the compressor belt 2.

Air-conditioning system with hydraulically driven compres­sor

Figure 6. Location of the condenser units

1 Condenser unit of standard air-conditioning system

2 Condenser unit of optional second air-conditioning system (if installed)
3 Cab elevation

The condenser unit 1 is installed on the outer side of the cab elevation 3.

If the machine has an optional second air-conditioning system, the same condenser unit 2 is installed adjacent to the condenser unit 1. A
second evaporator is also in­stalled in the cab roof.

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Figure 7. Components of the condenser unit

1 Condenser unit 4 Compressor (with hydraulic motor)

2 Fans 5 Condenser battery
3 Dryer/receiver unit

• ▶ Obey the maintenance procedures that follow.If the machine has an optional second air-conditioning system, do it for the two
condenser units and for the two evaporators.

Check the evaporator filter

• ▶ Obey the maintenance instructions given in the section "General procedures".

Check the condenser battery

• ▶ Obey the maintenance instructions given in the section "General procedures".

Check the dryer/receiver unit

• ▶ Obey the maintenance instructions given in the section "General procedures".

Check the fans

The fans 2 must be free of dirt and damages.

• ▶ Do a check of the fans 2. Replace if necessary.

Check the compressor

• ▶ Examine the compressor for possible damages.

• ▶ Check for missing, broken or loosen mounting screws of the compressor. If necessary, torque the screws (M8) to 14 Nm again. Also
do a visual check of the mounts of the related bracket.

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From: Operator's manual R 9200 - 410 > Maintenance > Heating and air-conditioning system

6.17.4 | Additional maintenance work

• ▶ Do a check of the operation of evaporator blowers and condenser fans. All blowers must operate correctly to prevent air short
circuit.

• ▶ Do a check of the electric installation.

• ▶ Do a check of all hose fittings and couplings for leakage.

• ▶ Do a check of the adjustment and function of defrosting thermostat at the evapo­rator coil.

• ▶ Do a check of the pressure switch on the dryer/receiver unit.

From: Operator's manual R 9200 - 410 > Maintenance > Heating and air-conditioning system

6.17.5 | Additional cab heater (optional equipment)

• ▶ If the additional cab heater is installed, refer to section "Starting aids" in chapter 5 for the maintenance to do.

From: Operator's manual R 9200 - 410 > Maintenance > Heating and air-conditioning system

6.18 | Greasing the machine

From: Operator's manual R 9200 - 410 > Maintenance

6.18.1 | Lubrication of attachment bearing points

Automatic lubrication
The lubrication points of the working attachment, with those in the grab tool area, are connected to the centralized lubrication system of
the machine. Thus, they are lubri­cated automatically with grease at regular intervals during the operation.

• ▶ For grease specifications, refer to the lubricant chart.

Manual lubrication
If the lubrication points that follow are installed on the machine, you must lubricate them manually.

• ▶ For maintenance intervals, refer to the control and maintenance chart.

• ▶ For grease specifications, refer to the lubricant chart.

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Lubricate the piston rod protections for bucket cylinders (if installed)

Figure 1. Protection device for bucket cylinders

1 Piston rod protection for bucket cylinder

2 Grease nipple M14x1,5

• ▶ Use the grease nipples 2.

• ▶ Because the nipples configurations X (internal sides) and Y (external sides) are not the same, make sure that you use all the grease
nipples 2.

From: Operator's manual R 9200 - 410 > Maintenance > Greasing the machine

6.18.2 | Lubricate the service trap

Manual lubrication
• ▶ For maintenance intervals, refer to the control and maintenance chart.

• ▶ For grease specifications, refer to the lubricant chart.

Figure 1. Grease nipples for the service trap

1 Service trap

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2 Grease nipple M10x1,0 (3x)

• ▶ Use the grease nipples 2. Make sure that you use all the grease nipples.

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From: Operator's manual R 9200 - 410 > Maintenance > Greasing the machine

6.19 | Check mounting bolts for tightness

The mounting bolts listed below must be regularly checked and retighten if necessary. Refer to the control and maintenance chart for
checks intervals.

NOTE!
When installing bolts of size bigger than M40 the thread of the screw must be slightly coated with a MoS2 based grease.
Also grease the bolt head supporting surface, unless hereafter otherwise specified.

DANGER!
Due to their size, most of the below listed mounting bolts require, to be tensioned to the prescribed torque, the use of a
special, hydraulic or electric actuated tension­ing device.
These high torque tensioning devices are power tools, which must be operated by trained mechanics, knowing the safety
precautions edicted by the tool manufacturer and that must be observed to avoid accidents or personal injury.
In particular, pay attention to chose a solid and secure reaction point for the tool and position the reaction arm during
operation. Keep clear of the reaction arm during operation; if it must be held or steaded during operation, use alternative
means of securing the tool during operation.

CAUTION!
The mounting bolts of the main components (especially the bolts listed below), of the hydraulic hoses and of the
counterweight must be replaced after every removal.
From: Operator's manual R 9200 - 410 > Maintenance

6.19.1 | Counterweight mounting bolts

Figure 1. Counterweight bolts

Torque Quantity
1 Counterweight - -
2 Screw M42x320 5001 Nm 8

• ▶ Apply special grease ID. 8503279 on the head and thread of the screw.

From: Operator's manual R 9200 - 410 > Maintenance > Check mounting bolts for tightness

6.19.2 | Mounting bolts of the swing ring

The swing ring is installed on the uppercarriage and on the undercarriage with an an­gular tightening method.

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Swing ring installation on uppercarriage

Figure 1. Swing ring bolts on uppercarriage

Quantity
1 Swing ring -
2 Uppercarriage -
3 Screw 96
11 Outer ring -
12 Inner ring -

Check the screws tightening

• ▶ Apply a torque of 1600 Nm.

• ▶ If a screw 3 is loosened, replace it.

Install a new screw

Till SN 40002:
• The height of the outer ring 11 is 225 mm.

• The screws 3 are M30x280.

• ▶ Torque the new screw 3 to 600 Nm.

• ▶ Apply a angle of rotation of 103°.

From SN 40003:
• The height of the outer ring 11 is 205 mm.

• The screws 3 are M30x260.

• ▶ Torque the new screw 3 to 600 Nm.

• ▶ Apply a angle of rotation of 90°.

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Swing ring installation on undercarriage

Figure 2. Swing ring bolts on undercarriage

Quantity
1 Swing ring -
4 Undercarriage -
5 Screw M30x240 96

Check the screws tightening

• ▶ Apply a torque of 1600 Nm.

• ▶ If a screw 5 is loosened, replace it.

Install a new screw

• ▶ Torque the new screw 5 to 800 Nm.

• ▶ Apply an angle of rotation of 90°.

From: Operator's manual R 9200 - 410 > Maintenance > Check mounting bolts for tightness

6.19.3 | Mounting bolts of the fuel tank

Figure 1. Fuel tank bolts

Torque Quantity
1 Fuel tank - -
2 Screw M30x300 1920 Nm 6

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From: Operator's manual R 9200 - 410 > Maintenance > Check mounting bolts for tightness

6.19.4 | Mounting bolts of the hydraulic tank

Figure 1. Hydraulic tank bolts

Torque Quantity
1 Hydraulic tank - -
2 Screw M30x230 1920 Nm 4
From: Operator's manual R 9200 - 410 > Maintenance > Check mounting bolts for tightness

6.19.5 | Mounting bolts of the engine cooler box

Figure 1. Bolts of engine cooler box

Torque Quantity
1 Engine cooler box - -
2 Screw M24x240 965 Nm 4

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From: Operator's manual R 9200 - 410 > Maintenance > Check mounting bolts for tightness

6.19.6 | Mounting bolts of the oil cooler box

Figure 1. Bolts of the oil cooler box

Torque Quantity
1 Oil cooler box
2 Screw M24x240 965 Nm 4
From: Operator's manual R 9200 - 410 > Maintenance > Check mounting bolts for tightness

6.19.7 | Mounting bolts of the pumps box

Figure 1. Pumps box bolts

Torque Quantity
1 Screw M30x250 1920 Nm 2
2 Screw M30x230 1920 Nm 4
3 Pumps box - -

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From: Operator's manual R 9200 - 410 > Maintenance > Check mounting bolts for tightness

6.19.8 | Mounting bolts of swing gear and swing motor

Figure 1. Bolts of swing gear and swing motor

Torque Quantity
1 Screw M24x320 965 Nm 32 (2x16)
2 Screw M24x70 965 Nm 4 (2x2)
3 Swing gear - -
From: Operator's manual R 9200 - 410 > Maintenance > Check mounting bolts for tightness

6.19.9 | Mounting bolts of the cab elevation

Figure 1. Cab elevation bolts

Torque Quantity
1 Cab elevation - -
2 Screw M30x300 1920 Nm 6

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From: Operator's manual R 9200 - 410 > Maintenance > Check mounting bolts for tightness

6.19.10 | Mounting bolts of the cab

Figure 1. Screws and mounts of the cab

Torque Quantity
1 Screw M16x65 270 Nm 12 (4x3)
2 Screw M16x65 270 Nm 12 (4x3)
3 Cab mount - 4
A Test distance - -

• ▶ Also measure distance A, that is the total height of cab mounts 3.

If distance A is smaller than the minimum permitted distance of 134,5 mm:

• ▶ Replace the mount.

The tool you use must have a minimum precision of ± 0,25 mm.

• ▶ For maintenance intervals, see control and maintenance chart.

From: Operator's manual R 9200 - 410 > Maintenance > Check mounting bolts for tightness

6.19.11 | Mounting bolts of the service trap

Figure 1. Service trap bolts

Torque Quantity

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1 Support of the service trap - -

2 Screw M16x65 270 Nm 4
From: Operator's manual R 9200 - 410 > Maintenance > Check mounting bolts for tightness

6.19.12 | Mounting bolts of hydraulic pumps

Figure 1. Hydraulic pumps bolts

An intermediate flange can be located between the pumps.

• ▶ Check and obey the tightening torque values that follow for the mounting bolts of the pumps Px and the flanges Fx.

Torque Quantity
F1 Screw M20x50 560 Nm 4
F2 Screw M20x50 560 Nm 4
F3 Screw M16x40 270 Nm 4
F4 Screw M20x40 560 Nm 4
F5 Screw M20x40 560 Nm 4
P1 Screw M20x70 560 Nm 4
P2 Screw M20x55 395 Nm 4
P3 Screw M20x55 395 Nm 4
P4 Screw M20x70 560 Nm 4
P5 Screw M20x55 395 Nm 4
P6.2 Screw M16x50 270 Nm 4
P10 Screw M12x35 110 Nm 2
P70 Screw M12x30 110 Nm 2

• ▶ Apply Loctite nr. 243 on the mounting screws of P2, P3 and P5.

• ▶ Also do a regularly check of the four nuts of the splitterbox cooling pump.

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From: Operator's manual R 9200 - 410 > Maintenance > Check mounting bolts for tightness

6.19.13 | Mounting bolts of side frames

Figure 1. Side frames bolts

Torque Quantity
1 Screw M39x260 4280 Nm 24 (2x12)
2 Screw M42x320 4810 Nm 12 (2x6)

• ▶ After a part replacement, grease bolts 1 and 2 with teeth grease.

From: Operator's manual R 9200 - 410 > Maintenance > Check mounting bolts for tightness

6.20 | Drive unit brakes and swing gear brakes

Both the drive unit brakes and the swing gear brakes are spring-applied, pressure-released multi-plate brakes. They are ventilated
hydraulically and are fully sealed and integrated in the travel gear or swing gear transmission.

Their usage purely as parking brakes makes them wear-free and therefore mainte­nance free.

From: Operator's manual R 9200 - 410 > Maintenance

6.21 | Starting aids (optional equipment)

If starting aids are installed, also obey the instructions given in the manual of the cool­ant heater manufacturer.

From: Operator's manual R 9200 - 410 > Maintenance

6.21.1 | Fuel system of the coolant heater

Figure 1. Fuel system of the coolant heater

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1 Special fuel tank of the coolant heater (35 l capacity)

2 Sight gauge
3 Filler neck

Fuel system of the coolant heater: check the fuel level

Make sure that the following preconditions are met:

▢ The machine is safely parked on firm and level ground.

▢ The Diesel engine is stopped.

▢ The coolant heater is stopped.

• ▶ Measure the fuel level with the sight gauge 2.

Fuel system of the coolant heater: refuel

DANGER!
Explosive and flammable fuel!
Risk of death.

• ▶ Stop the Diesel engine.

• ▶ Stop the coolant heater.
• ▶ Turn off cell phones.
• ▶ Do not smoke.
• ▶ Do not let an open flame or another source of ignition come near the machine.
• ▶ Use the applicable Personal Protective Equipment (PPE).

Make sure that the following preconditions are met:

▢ The machine is safely parked on firm and level ground in an area that is open to the air.

▢ The Diesel engine is stopped.

▢ The coolant heater is stopped.

▢ The new fuel is approved.

• ▶ Remove the cap from the filler neck 3.

• ▶ Refuel through the filler neck 3.

• ▶ When you get the correct fuel level, clean the cap and install it on the filler neck 3 again.

NOTE!
If the fuel supply of the coolant heater comes directly from the machine fuel tank, there is no special fuel tank. Thus, in
this case, you must obey the machine refuel procedure.

Fuel system of the coolant heater: replace the fuel filter

CAUTION!
Unwanted material in the fuel system!
Risk of damage to the fuel injection system.

• ▶ Keep all parts clean during this procedure.

Make sure that the following preconditions are met:

▢ The machine is safely parked on firm and level ground.

▢ The Diesel engine is stopped.

▢ The coolant heater is stopped.

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Make sure that the following tools are available:

▢ Used fuel container

Fuel system of the 30 kW coolant heater: replace the fuel filter

The fuel filter is installed on the 30 kW coolant heater.

Figure 2. Fuel system of the 30 kW coolant heater: replace the fuel filter

1 Fuel filter

• ▶ Put the used fuel container below the fuel filter 1.

• ▶ Remove the used fuel filter 1 and discard it.

• ▶ Install the new fuel filter 1.

Fuel system of the 35 kW coolant heater: replace the fuel filter

The fuel filter is integrated in the 35 kW coolant heater.

• ▶ Obey the instructions given in the manual of the coolant heater manufacturer.

From: Operator's manual R 9200 - 410 > Maintenance > Starting aids (optional equipment)

6.21.2 | Coolant circuit of the starting aids

The coolant circuit of the starting aids must be bled in the following situations:

• After maintenance on the coolant heater system

• After maintenance on the cooling system of the Diesel engine

• After maintenance on the additional cab heater

• If the coolant heater is not operated for a long time

Coolant circuit of the starting aids: bleed the coolant heater

Make sure that the following preconditions are met:

▢ The machine is safely parked on firm and level ground.

▢ The Diesel engine is stopped and cold.

▢ The coolant heater is stopped and cold.

▢ The coolant level is correct.

▢ All the valves are open.

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Coolant circuit of the starting aids: bleed the 30 kW coolant heater

• ▶ Remove the cap from the coolant expansion tank.

• ▶ Loosen the bleed screw.

• ▶ When clean coolant flows out without air from the bleed connection, tighten the bleed screw again.

• ▶ Start the coolant heater pump: push the button S258.

• ▶ Let the pump operate.

◦ ▷ The pump stops automatically after the preset time.

• ▶ Loosen the bleed screw.

• ▶ Check that clean coolant flows out without air from the bleed connection, tighten the bleed screw again.

• ▶ Install the cap on the expansion tank again.

Coolant circuit of the starting aids: bleed the 35 kW coolant heater

• ▶ Remove the cap from the coolant expansion tank.

• ▶ Loosen the bleed screw.

• ▶ When clean coolant flows out without air from the bleed connection, tighten the bleed screw again.

• ▶ Start and operate the coolant heater pump: push and hold the button S258.

• ▶ Stop the coolant heater pump: release the button S258.

• ▶ Loosen the bleed screw.

• ▶ Check that clean coolant flows out without air from the bleed connection, tighten the bleed screw again.

• ▶ Install the cap on the expansion tank again.

Coolant circuit of the starting aids: bleed the additional cab heater (if installed)

Figure 1. Coolant circuit of the starting aids: bleed the additional cab heater

1 Bleed screw

Make sure that the following preconditions are met:

▢ The machine is safely parked on firm and level ground.

▢ The coolant level is correct.

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▢ All the valves are open.

• ▶ Operate the heating system at maximum temperature.

• ▶ Loosen the bleed screw 1.

• ▶ When clean coolant flows out without air from the bleed connection, tighten the bleed screw 1 again.

NOTE!
Depending on the machines, a coolant shutoff valve can be installed on the Diesel engine.
If it is necessary to isolate the additional cab heater from the coolant supply:

• ▶ Use the coolant shutoff valve.

From: Operator's manual R 9200 - 410 > Maintenance > Starting aids (optional equipment)

6.22 | General maintenance points

From: Operator's manual R 9200 - 410 > Maintenance

6.22.1 | Replacing working parts

In addition to the normal maintenance and repair work that is to be carried out at the given intervals, the machine operator and
maintenance personnel can also carry out the repairs referred to below:

• Replacing defective sealing material on the pipe and hose system and on the hydraulic unit connections (not, however, on pressure
relief valves which are lead sealed at the works).

• In addition, high pressure hoses, hydraulic lines and bolt connections on the hy­draulic system can be replaced.

It should be noted that only original Liebherr replacement parts are to be used.

This is particularly relevant for hoses and hydraulic lines, which must be preassembled at the works. For all other repairs, particularly
when dismounting the counter­weight, works and dealership fitters are to be consulted.

From: Operator's manual R 9200 - 410 > Maintenance > General maintenance points

6.22.2 | Welding work on the machine

Welding work on all main components serving the power transmission (such as the chassis frame, rotating platform, attachment parts
etc.) may only be carried out by the manufacturer or by an authorized workshop.

• ▶ Disconnect the batteries before starting any electric arc welding work on the ma­chine.

• ▶ Disconnect the connectors of the engine control unit.

• ▶ Always disconnect the negative terminal (-) first and reconnect it last.

• ▶ Switch off the main battery switch!

Nevertheless if welding repair should be done on components which may contain inflammable gases (welded counterweight, hydraulic
tank, fuel tank, ...) these components must be previously and sufficiently ventilated with pressurized air to avoid all fire or explosion
hazard.

CAUTION!
If high currents flow through the bearings or sealing elements, these could be burnt.

• ▶ Move the earthing cable of the welding tool as close as possible to the welding surface so that the welding current
cannot flow over parts like the swing ring, rotary connection, gears, bushings, bearings, hinges, joints, hydraulic hoses,
sockets, rubber parts or seals.

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From: Operator's manual R 9200 - 410 > Maintenance > General maintenance points

6.23 | Control and maintenance chart

CAUTION!
Careful maintenance can only be carried out when the machine is clean. Visual checks such as crack testing are only
applicable on a clean machine.

• ▶ Clean the machine before you start maintenance work (see also the chapter “Servicing the machine safely”, sections
“Cleaning" and "Crack testing”).

CAUTION!
You must do the weekly additional maintenance tasks. Liebherr recommends that you schedule this maintenance interval
carefully.

NOTE!
IF YOU FIND DAMAGE(S) ON STRUCTURAL COMPONENTS (BOOM, STICK, BUCKET, CENTRAL PART, SIDE
FRAMES, ROTATING DECK, HYDRAULIC TANK, FUEL TANK OR CABIN) PLEASE FILL OUT THE "STRUCTURAL
INSPECTION" FORM IN SERVICE MANUAL - CHAPTER 4.
In addition:
- a visual inspection is required every 500 hours,
- a detailed inspection is required every year or at least every 7500 hours.
From: Operator's manual R 9200 - 410 > Maintenance

6.23.1 | General information

The following maintenance chart will help you to do the adequate maintenance on your excavator.

It is mandatory to follow these maintenance charts, to keep your excavator into best and safe condition.

The pre-requisite to any claim to Liebherr for operation issues or warranty, is that these maintenance charts are strictly followed and
recorded.

It is mandatory to follow these requirements in order to keep your excavator safe, efficient and also for warranty reason. Liebherr is not
responsible in case of damage if the maintenance requirements are not correctly followed. Moreover, your machine may not be running
as efficiently and productively as it could be.

For lubricants and operating fluids, refer to the related section of this manual.

Two types of inspection

Visual Check
• A visual examination of an interior or exterior area, installation or assembly to detect obvious damage, failure or irregularity. This level
of inspection is made from within touching distance unless otherwise specified. A mirror may be necessary to ensure visual access to
all surfaces in the inspection area. This level of inspection is made under normally available lighting conditions such as daylight,
hangar lighting, flashlight or drop-light and may require removal or opening of access panels or doors. Stands, ladders or platforms
may be required to have safe ac­cess to the area being checked.

Detailed Check
• An intensive examination of a specific item, installation or assembly to detect damage, failure or irregularity. This examination may
require the use of special­ized inspection techniques and/or equipment. Surface cleaning and elaborate ac­cess may also be required.

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From: Operator's manual R 9200 - 410 > Maintenance > Control and maintenance chart

6.23.2 | How to use the maintenance chart

The following maintenance chart is split in 5 individual check lists:

• a daily,

• a 250 hours,

• a 500 hours,

• a 1000 hours,

• and a 2000 hours.

Intervals:
• daily,

• 250 hours, 750 hours, 1250 hours, 1750 hours, ...

• 500 hours, 1500 hours, 2500 hours, 3500 hours, ...

• 1000 hours, 3000 hours, 5000 hours, 7000 hours, ...

• 2000 hours, 4000 hours, 6000 hours, 8000 hours, ...

Examples:
At 750 hours you must follow the 250 hours maintenance chart.

At 2500 hours you must follow the 500 hours maintenance chart.

At 3000 hours, you must follow the 1000 hours maintenance chart.

At 6000 hours, you must follow the 2000 hours maintenance chart.

Figure 1. How to use the check lists (in addition to the daily maintenance)
From: Operator's manual R 9200 - 410 > Maintenance > Control and maintenance chart

6.23.3 | Daily Maintenance Schedule - R9200

Serial Number: Completed by :

Fleet Number: Date and Signature :
SMU HOURS:
Travel Hours:

WORK TO BE PERFORMED DAILY Check Initials Comments

Check ▢ for first and only interval or Check ○ for repeat interval
GENERAL HYDRAULIC SYSTEM

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WORK TO BE PERFORMED DAILY Check Initials Comments

Check ▢ for first and only interval or Check ○ for repeat interval
Do a visual check of all hoses, pipes and fittings for any external damage or leakage ○
Do a visual check of the hydraulic components for leaks and/or damages ○
Do a visual check of the hydraulic cylinder rods for leaks and good condi­tion ○
GENERAL FASTENING
General hydraulic: Do a visual check for missing, broken or loosen mounting screws of all ○
hoses, pipes, fittings and clamps, tighten if neces­sary
Track components: Do a visual check for missing, broken or loosen mounting screws of ○
the sprockets, rollers, idlers, track guides and track pads, protection covers and final
drives, tighten if necessary
Undercarriage: Do a visual check for missing, broken or loosen mounting screws of the ○
side frames, tighten if necessary
Undercarriage: Do a visual check for missing, broken or loosen mounting screws of all ○
parts, tighten if necessary
Attachment: Do a visual check for missing, broken or loosen mounting screws of the ○
handrails, pin covers fastening and greases connections, tighten if necessary
Uppercarriage: Do a visual check for missing, broken or loosen mounting screws of the ○
counterweight, tanks, Powerpack, control valve console, cab, cab elevation, catwalks,
handrails, grease box, ladder, tighten if nec­essary
Swing gear: Do a visual check for missing, broken or loosen mounting bolts of the swing ○
gear and hydraulic motors, tighten if necessary
Diesel engine: Do a visual check for missing, broken or loosen mounting screws of the ○
thermic protection on exhaust manifold fastening, tighten if necessary
Diesel engine: Do a visual check for missing, broken or loosen mounting bolts of the ○
starter motors, alternator and AC compressor, tighten if nec­essary
TRACK COMPONENTS
Clean track chains (after the end of each shift) ○
Do a visual check of the tensioning cylinders, idler, carrier and track rollers for leaks ○
Do a visual check of the track chains tension ○
TRAVEL GEAR
Do a visual check of the gear for leaks, if there are leaks, check oil level ○
UNDERCARRIAGE
Do a visual check of all parts for damages and cracks ○
If necessary fill out the "Structural Inspection" form in Service Manual - Chapter 4
ATTACHMENT
Do a visual check of the bucket teeth and wear kit for wear ○
Do a visual check of the grease supply at each lube point ○
Do a visual check of cable harness and sensors for damage ○
UPPERCARRIAGE
Do a visual check of the service trap for leaks or damage ○
Do a visual check of oil, grease or fuel for leaks ○
Do a visual check of mirrors and cameras, clean and adjust if necessary ○
Do all the maintenance tasks which are scheduled for this interval in the manual of the ○
coolant heater manufacturer (optional equipment)
SWING GEAR
Do a visual check of the swing gears for leaks and oil level in expansion tanks ○
CENTRALIZED LUBRICATION SYSTEM
Do a check of the grease tank level ○
Perform a complete daily maintenance given in the SKF / Lincoln Operating Instructions ○
Manual
DIESEL ENGINE AND SPLITTERBOX
Do a visual check in and around the engine compartment for leaks, contaminations and ○
damage
Check engine oil level ○
Check coolant level ○

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WORK TO BE PERFORMED DAILY Check Initials Comments

Check ▢ for first and only interval or Check ○ for repeat interval
Do a visual check of the engine and external pipework for leaks ○
Do a visual check of the exhaust gas system connections for leaks ○
Do a visual check of the oil supply / return pipework for leaks ○
Do a visual check of the water separator on fuel filters, drain if necessary ○
Replace all preliminary filters and fuel filters as soon as fuel level reaches the red mark on ○
the bell of the preliminary filters (replace the filters at least every 500 hours)
Do a visual check of the vacuum indicators for air filters clogging, replace if necessary and ○
reset the indicator
Do a visual check of the coupling for cracks, chips and missing parts ○
Check oil level in the splitterbox ○
Do a visual check of the splitterbox input shaft seal or engine main rear seal for leaks ○
Do a visual check of the starter motors, alternator and AC compressor for cables, and ○
brackets
Do a visual check of the coolers for clogging and damage, clean or replace if necessary ○
Perform the complete "Daily" Maintenance Echelon given in the CUMMINS Operating and ○
Maintenance Manual
HYDRAULIC SYSTEM
Check oil level in hydraulic tank ○
Clean magnetic rods of the leak oil filter (daily during the first 250 hours) ▢
ELECTRICAL SYSTEM
Press to open dust discharge valve on aeration devices for cabin and elec­trical boxes ○
FIRE FIGHTING SYSTEM
Do a visual check of the fire fighting system condition (optional equipment, refer to the fire ○
fighting system documentation)
- If any issue contact fire fighting local dealer
Follow the inspection intervals recommended by the specific Health and Safety rules ○
existing in country and/or on mine site
START THE ENGINE TO CHECK THE FOLLOWING ACTIONS
General: Maintenance work must include the check of the correct functions of hydraulic ○
and electric systems before starting operation
Attachment: Check function of the working attachment lubrication system during operation ○
Attachment: Check if the damping system on equipment is working cor­rectly ○
Uppercarriage: Check position of the hydraulic shut-off valve ○
Uppercarriage: Check that the swing movement of the uppercarriage and the travel ○
movement are locked when the access ladder is lowered
Swing Gear: Check function and operation of the swing brake ○
Swing Ring: Check function of the swing ring bearing lubrication system during operation ○
Swing Ring: Check function of the swing ring teeth lubrication system during operation ○
Diesel engine: Check speed on RPM gauge ○
Diesel engine: Check running noises ○
Diesel engine: Check exhaust gas colour ○
Diesel engine: Check oil pressure and coolant temperature during oper­ation ○
Diesel engine: Check if the prelub system is working properly ○
Electrical system: Clean and check LCD screen of the display for proper function when ○
starting
Electrical system: Check indicator lights and gauges on the control panel when starting ○
Electrical system: Check for warning and fault messages on display (monitoring, grease, ○
air conditioning, ...). If necessary refer to chapter 4 in the Operating Manual to identify and
rectify faults and errors.
Cabin: Check if the safety lever is working properly ○
Cabin: Check the horn ○
Cabin: Check for green flash light on control module if fire fighting system is installed ○
WEEKLY CHECK THESE STEPS IN ADDITION TO THE DAILY REQUIREMENTS

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WORK TO BE PERFORMED DAILY Check Initials Comments

Check ▢ for first and only interval or Check ○ for repeat interval
UPPERCARRIAGE
Check level in reservoir for windshield washer, refill if necessary ○
CENTRALIZED LUBRICATION SYSTEM
Perform the complete weekly maintenance given in the SKF / Lincoln Operating ○
Instructions Manual
Tighten all the fittings again 6 weeks after the initial start-up as stated in Beka Operating ▢
manual
Do a visual check of all the components for any damage or leakage as stated in Beka ○
Operating manual
DIESEL ENGINE AND SPLITTERBOX
Do a visual check of the precleaner ○
Do a visual check of the air intake hose for condition and leaks ○
Do a visual check and clean the radiator core and fan ○
Do a visual check of the radiator cap for leaks, replace if necessary ○
Drain off water and sediment at fuel tank ○
HYDRAULIC SYSTEM
Clean magnetic rods of all return filters (weekly during the first 250 hours) ▢
Do a visual check of the hydraulic tank breather filter, clean if necessary ○
ELECTRICAL SYSTEM
Do a visual check of the head and floodlights, clean and adjust if neces­sary ○
Do a visual check of the wiring system for damage ○
CABIN, CABIN ELEVATION AND HEATER/AIR CONDITIONER
Operate air conditioner every week for 10 minutes ○
Visual check condenser unit and evaporator filter ○
Check refrigerant level, if necessary refill circuit ○
Do a detailed check of the V-belt tension for air conditioner ○

WORK TO BE PERFORMED DAILY Check Initials Comments

Check ▢ for first and only interval or Check ○ for repeat interval
General comments:

Daily maintenance schedule - R9200

From: Operator's manual R 9200 - 410 > Maintenance > Control and maintenance chart

6.23.4 | 250 Hours Maintenance Schedule - R9200

Serial Number: Completed by :

Fleet Number: Date and Signature :
SMU HOURS:
Travel Hours:

WORK TO BE PERFORMED AT 250, 750, 1250 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
GENERAL HYDRAULIC SYSTEM
Do a visual check of all hoses, pipes and fittings for any external damage or leak­age ○
Do a detailed check for good condition of pipes, hoses, clamps and fittings for damage ○
and leakage
Do a visual check of the hydraulic components for leaks and/or damages ○
Do a visual check of the hydraulic cylinder rods for leaks and good condition ○
GENERAL FASTENING
General hydraulic: Do a visual check for missing, broken or loosen mounting screws of all ○
hoses, pipes, fittings and clamps, tighten if necessary

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WORK TO BE PERFORMED AT 250, 750, 1250 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
Track components: Do a visual check for missing, broken or loosen mounting screws of ○
the sprockets, rollers, idlers, track guides, track pads, protection covers and final drives,
tighten if necessary
Undercarriage: Do a visual check for missing, broken or loosen mounting screws of the ○
side frames, tighten if necessary
Undercarriage: Do a visual check for missing, broken or loosen mounting screws of all ○
parts, tighten if necessary
Attachment: Do a visual check for missing, broken or loosen mounting screws of the ○
handrails, pin covers fastening and greases connections, tighten if neces­sary
Uppercarriage: Do a visual check for missing, broken or loosen mounting screws of the ○
counterweight, tanks, Powerpack, control valve console, cab, cab elevation, catwalks,
handrails, grease box, ladder, tighten if necessary
Swing gear: Do a visual check for missing, broken or loosen mounting bolts of the swing ○
gear and hydraulic motors, tighten if necessary
Diesel engine: Do a visual check for missing, broken or loosen mounting screws of the ○
thermic protection on exhaust manifold fastening, tighten if necessary
Diesel engine: Do a visual check for missing, broken or loosen mounting bolts of the ○
starter motors, alternator and AC compressor, tighten if necessary
TRACK COMPONENTS
Clean track chains (after the end of each shift) ○
Do a visual check of the tensioning cylinders, idler, carrier and track rollers for leaks ○
Do a visual check of the track chains tension ○
TRAVEL GEAR
Do a visual check of the gear for leaks, if there are leaks, check oil level ○
UNDERCARRIAGE
Do a visual check of all parts for damages and cracks ○
If necessary fill out the "Structural Inspection" form in Service Manual - Chapter 4
ATTACHMENT
Do a visual check of the bucket teeth and wear kit for wear ○
Do a visual check of the grease supply at each lube point ○
If installed, grease the piston rod protection ○
Do a visual check of cable harness and sensors for damage ○
Do a visual check of all parts for damages and cracks ○
If necessary fill out the "Structural Inspection" form in Service Manual - Chapter 4
Do a visual check of the fastening of pin covers ○
UPPERCARRIAGE
Do a visual check of the service trap for leaks or damage ○
Do a visual check of oil, grease or fuel for leaks ○
Do a visual check of mirrors and cameras, clean and adjust if necessary ○
Do all the maintenance tasks which are scheduled for this interval in the manual of the ○
coolant heater manufacturer (optional equipment)
Do a visual check of the non-slip surfaces for wear and damage ○
SWING GEAR
Do a visual check of the swing gears for leaks and oil level in expansion tanks ○
CENTRALIZED LUBRICATION SYSTEM
Do a check of the grease tank level ○
Perform a complete daily maintenance given in the SKF / Lincoln Operating Instructions ○
Manual
DIESEL ENGINE AND SPLITTERBOX
Do a visual check in and around the engine compartment for leaks, contamination and ○
damage
Check engine oil level ○
Sample and analyse engine oil ○
Change oil in Diesel engine ○

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WORK TO BE PERFORMED AT 250, 750, 1250 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
Replace engine oil filters ○
Check coolant level ○
Do a visual check of the engine and external pipework for leaks ○
Do a visual check of the exhaust gas system connections for leaks ○
Do a visual check of the oil supply / return pipework for leaks ○
Drain off water and sediment at fuel tank ○
Do a visual check of the water separator on fuel filters, drain if necessary ○
Do a visual check of the vacuum indicators for air filters clogging, replace if necessary and ○
reset the indicator
Do a visual check of the precleaner ○
Replace primary element of the air filter (if necessary or at least once a year) ○
Replace safety element of the air filter if indicated (if necessary or at least once a year) ○
Do a visual check of the coupling for cracks, chips and missing parts ○
Check oil level in the splitterbox ○
Change oil in splitterbox ▢
Do a visual check of the splitterbox input shaft seal or engine main rear seal for leaks ○
Do a visual check of the starter motors, alternator and AC compressor for cables, and ○
brackets
Do a visual check of the air intake hose for condition and leaks ○
Do a visual check of the coolers for clogging and damage, clean or replace if nec­essary ○
Do a visual check of the radiator core and fan, clean if necessary ○
Do a visual check of the radiator cap for leaks, replace if necessary ○
Perform the complete "Daily" Maintenance Echelon given in the CUMMINS Operating and ○
Maintenance Manual
Every 250hours or 6 months, perform a complete Maintenance Echelon given in the ○
CUMMINS Operating and Maintenance Manual
See CUMMINS Operation and Maintenance Manual for other maintenance (Eliminator, ○
Centinel, Fleetguard, valves and injectors adjustment)
HYDRAULIC SYSTEM
Check oil level in hydraulic tank ○
Sample and analyse hydraulic oil and change oil if necessary (if filled with HEES ○
biodegradable oil)
Clean magnetic rods of the leak oil filter ○
Clean magnetic rods of all return filters ○
ELECTRICAL SYSTEM
Do a visual check of the head and floodlights, clean and adjust if necessary ○
Press to open dust discharge valve on aeration devices for cabin and electrical boxes ○
Do a visual check of electric harness, sensors for damage and/or rubbing zone ○
Do a detailed check of fuses and circuit breakers ○
CABIN
If installed, do a detailed check of the V-belt tension for air conditioner ○
Do a visual check of the cabin for oil/fluids leaks ○
FIRE FIGHTING SYSTEM
Do a visual check of the fire fighting system condition (optional equipment, refer to the fire ○
fighting system documentation)
- If any issue contact fire fighting local dealer
Follow the inspection intervals recommended by the specific Health and Safety rules ○
existing in country and/or on mine site
START THE ENGINE TO CHECK THE FOLLOWING ACTIONS
General: Maintenance work must include the check of the correct functions of hydraulic ○
and electric systems before starting operation
Attachment: Check function of the working attachment lubrication system dur­ing operation ○
Attachment: Check if the damping system on equipment is working correctly ○

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WORK TO BE PERFORMED AT 250, 750, 1250 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
Uppercarriage: Check position of the hydraulic shut-off valve ○
Uppercarriage: Check that the swing movement of the uppercarriage and the travel ○
movement are locked when the access ladder is lowered
Swing Gear: Check function and operation of the swing brake ○
Swing Ring: Check function of the swing ring bearing lubrication system during operation ○
Swing Ring: Check function of the swing ring teeth lubrication system during op­eration ○
Diesel engine: Check speed on RPM gauge ○
Diesel engine: Check running noises ○
Diesel engine: Check exhaust gas colour ○
Diesel engine: Check oil pressure and coolant temperature during operation ○
Diesel engine: Check if the prelub system is working properly ○
Electrical system: Clean and check LCD screen of the display for proper function when ○
starting
Electrical system: Check indicator lights and gauges on the control panel when starting ○
Electrical system: Check for warning and fault messages on display (monitoring, grease, ○
air conditioning, ...). If necessary refer to chapter 4 in the Operating Manual to identify and
rectify faults and errors.
Cabin: Check if the safety lever is working properly ○
Cabin: Check the horn ○
Cabin: Check for green flash light on control module if fire fighting system is in­stalled ○

250 Hours maintenance schedule - R9200

From: Operator's manual R 9200 - 410 > Maintenance > Control and maintenance chart

6.23.5 | 500 Hours Maintenance Schedule - R9200

Serial Number: Completed by :

Fleet Number: Date and Signature :
SMU HOURS:
Travel Hours:

WORK TO BE PERFORMED AT 500, 1500, 2500 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
GENERAL HYDRAULIC SYSTEM
Do a visual check of all hoses, pipes and fittings for any external damage or leak­age ○
Do a detailed check for good condition of pipes, hoses, clamps and fittings for damage ○
and leakage
Do a visual check of the hydraulic components for leaks and/or damages ○
Do a visual check of the hydraulic cylinder rods for leaks and good condition ○
GENERAL FASTENING
General hydraulic: Do a visual check for missing, broken or loosen mounting screws of all ○
hoses, pipes, fittings and clamps, tighten if necessary
Track components: Do a visual check for missing, broken or loosen mounting screws of ○
the sprockets, rollers, idlers, track guides, track pads, protection covers and final drives,
tighten if necessary
Undercarriage: Do a visual check for missing, broken or loosen mounting screws of the ○
side frames, tighten if necessary
Undercarriage: Do a visual check for missing, broken or loosen mounting screws of all ○
parts, tighten if necessary
Attachment: Do a visual check for missing, broken or loosen mounting screws of the ○
handrails, pin covers fastening and greases connections, tighten if neces­sary
Uppercarriage: Do a visual check for missing, broken or loosen mounting screws of the ○
counterweight, tanks, Powerpack, control valve console, cab, cab elevation, catwalks,
handrails, grease box, ladder, tighten if necessary

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WORK TO BE PERFORMED AT 500, 1500, 2500 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
Swing gear: Do a visual check for missing, broken or loosen mounting bolts of the swing ○
gear and hydraulic motors, tighten if necessary
Diesel engine: Do a visual check for missing, broken or loosen mounting screws of the ○
thermic protection on exhaust manifold fastening, tighten if necessary
Diesel engine: Do a visual check for missing, broken or loosen mounting bolts of the ○
starter motors, alternator and AC compressor, tighten if necessary
Hydraulic: Do a detailed check for missing, broken or loosen mounting screws of pumps, ▢
motors, clamps, ..., tighten the screws
TRACK COMPONENTS
Clean track chains (after the end of each shift) ○
Do a visual check of the tensioning cylinders, idler, carrier and track rollers for leaks ○
Do a visual check of the track chains tension ○
TRAVEL GEAR
Do a visual check of the gear for leaks, if there are leaks, check oil level ○
Sample and analyse gear oil, change oil if necessary ○
Change gear oil (if filled with OIL-1 gear oil) ▢
Change gear oil (if filled with OIL-2 or OIL-3 gear oil) ▢
Sample and analyse lifetime sealing interspace oil, change oil if necessary (optional ○
equipment)
Change lifetime sealing interspace oil (optional equipment) ▢
UNDERCARRIAGE
Do a visual check of all parts for damages and cracks ○
If necessary fill out the "Structural Inspection" form in Service Manual - Chapter 4
ATTACHMENT
Do a visual check of the bucket teeth and wear kit for wear ○
Do a visual check of the grease supply at each lube point ○
If installed, grease the piston rod protection ○
Do a visual check of cable harness and sensors for damage ○
Do a visual check of all parts for damages and cracks ○
If necessary fill out the "Structural Inspection" form in Service Manual - Chapter 4
Do a visual check of the fastening of pin covers ○
UPPERCARRIAGE
Do a visual check of the service trap for leaks or damage ○
Do a visual check of oil, grease or fuel for leaks ○
Do a visual check of mirrors and cameras, clean and adjust if necessary ○
Do a detailed check of all structural parts for damages and cracks ○
If necessary fill out the "Structural Inspection" form in Service Manual - Chapter 4
Do a detailed check and lubricate covers, doors hinges, locks as well as service trap, ○
access ladder cylinders bushings and swivel pins
Do a visual check if the fan guards are in place and secured ○
Do all the maintenance tasks which are scheduled for this interval in the manual of the ○
coolant heater manufacturer (optional equipment)
Do a visual check of the non-slip surfaces for wear and damage ○
SWING GEAR
Do a visual check of the swing gears for leaks and oil level in expansion tanks ○
Sample and analyse gear oil, change oil if necessary ○
Change gear oil (if filled with OIL-1 gear oil) ▢
Change gear oil (if filled with OIL-2 or OIL-3 gear oil) ▢
SWING RING
Do a detailed check of the grease supply (outlet of new grease around the swing ring) ○
CENTRALIZED LUBRICATION SYSTEM
Do a check of the grease tank level ○

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Operator's Manual R9200 - 410

WORK TO BE PERFORMED AT 500, 1500, 2500 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
Perform a complete daily maintenance given in the SKF / Lincoln Operating Instructions ○
Manual
DIESEL ENGINE AND SPLITTERBOX
Do a visual check in and around the engine compartment for leaks, contaminations and ○
damage
Check engine oil level ○
Sample and analyse engine oil ○
Change oil in Diesel engine ○
Replace engine oil filters ○
Check coolant level ○
Do a visual check of the engine and external pipework for leaks ○
Do a visual check of the exhaust gas system connections for leaks ○
Do a visual check of the oil supply / return pipework for leaks ○
Drain off water and sediment at fuel tank ○
Do a visual check of the water separator on fuel filters, drain if necessary ○
Replace all preliminary filters and fuel filters as soon as fuel level reaches the red mark on ○
the bell of the preliminary filters (replace the filters at least every 500 hours)
Do a visual check of the vacuum indicators for air filters clogging, replace if necessary and ○
reset the indicator
Do a visual check of the precleaner ○
Replace primary element of the air filter (if necessary or at least once a year) ○
Replace safety element of the air filter if indicated (if necessary or at least once a year) ○
Do a visual check of the coupling for cracks, chips and missing parts ○
Check oil level in the splitterbox ○
Sample and analyse splitterbox oil ○
Do a visual check of the splitterbox breather for clogging, replace if necessary ○
Do a visual check of the splitterbox input shaft seal or engine main rear seal for leaks ○
Do a visual check of the starter motors, alternator and AC compressor for cables, and ○
brackets
Do a visual check of the air intake hose for condition and leaks ○
Do a visual check of the coolers for clogging and damage, clean or replace if nec­essary ○
Do a visual check of the radiator core and fan, clean if necessary ○
Do a visual check of the radiator cap for leaks, replace if necessary ○
Perform the complete "Daily" Maintenance Echelon given in the CUMMINS Operating and ○
Maintenance Manual
Every 250 hours or 6 months, perform a complete Maintenance Echelon given in the ○
CUMMINS Operating and Maintenance Manual
Every 1500 hours or 1 year, perform a complete Maintenance Echelon given in the ○
CUMMINS Operating and Maintenance Manual
See CUMMINS Operation and Maintenance Manual for other maintenance (Eliminator, ○
Centinel, Fleetguard, valves and injectors adjustment)
HYDRAULIC SYSTEM
Drain water sediment from hydraulic tank ○
Check oil level in hydraulic tank ○
Sample and analyse hydraulic oil and change oil if necessary ○
Clean magnetic rods of all return filters ○
Clean magnetic rods of the leak oil filter ○
Replace filter element of the return filters ▢
Replace filter element of the return filters (if hydraulic hammer is used) ○
Replace filter element of the leak oil filter ▢
Replace the hydraulic tank breather filter (if hydraulic hammer is used) ○
Replace control oil filter element ▢
Replace swing pumps replenishing oil filter elements ▢

Confidential - This document is uncontrolled when printed.

Page 311 of 358
Copyright © Liebherr-Mining Equipment SAS
 Printed by: Zevallos Romulo (LPE) ([email protected])
Operator's Manual R9200 - 410

WORK TO BE PERFORMED AT 500, 1500, 2500 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
Do a visual check of the oil cooler protection filters, clean or replace if necessary (optional ▢
equipment)
ELECTRICAL SYSTEM
Do a visual check of the head and floodlights, clean and adjust if necessary ○
Press to open dust discharge valve on aeration devices for cabin and electrical boxes ○
Replace main element on aeration devices for cabin and electrical boxes (at least once a ○
year)
Replace safety element on aeration devices for cabin and electrical boxes, after 3 services ○
of main element
Do a visual check of electric harness, sensors for damage and/or rubbing zone ○
Do a detailed check of fuses and circuit breakers ○
Do a visual check of wiring system damage ○
Check battery electrolyte level (refill if necessary) and clean battery terminals ○
CABIN
If installed, do a detailed check of the V-belt tension for air conditioner ○
Do a visual check of the cabin for oil/fluids leaks ○
Operate air conditioner every week for 10 minutes ○
Do a visual check of the fresh air filter and the recirculated air filter ○
Check the condition of the condenser, blow it out if necessary ○
Do a visual check of the dryer / accumulator unit for moisture degree, coolant level and ○
good condition, replace if necessary (at least once a year)
The function of the air flaps and the defrosting thermostat must be checked yearly by a ○
refrigeration specialist
Perform maintenance for the second air-conditioning system (optional equip­ment) ○
Lubricate all doors seals with silicone or talc (before cold season) ○
Do a visual check of the AC for leaks or rubbing hoses or pipes ○
FIRE FIGHTING SYSTEM
Do a visual check of the fire fighting system condition (optional equipment, refer to the fire ○
fighting system documentation)
- If any issue contact fire fighting local dealer
Follow the inspection intervals recommended by the specific Health and Safety rules ○
existing in country and/or on mine site
START THE ENGINE TO CHECK THE FOLLOWING ACTIONS
General: Maintenance work must include the check of the correct functions of hydraulic ○
and electric systems before starting operation
Attachment: Check function of the working attachment lubrication system during operation ○
Attachment: Check if the damping system on equipment is working correctly ○
Uppercarriage: Check position of the hydraulic shut-off valve ○
Uppercarriage: Check movement and locking of the access ladder ○
Uppercarriage: Check that the swing movement of the uppercarriage and the travel ○
movement are locked when the access ladder is lowered
Swing Gear: Check function and operation of the swing brake ○
Swing Ring: Check function of the swing ring bearing lubrication system during operation ○
Swing Ring: Check function of the swing ring teeth lubrication system during op­eration ○
Diesel engine: Check speed on RPM gauge ○
Diesel engine: Check running noises ○
Diesel engine: Check exhaust gas colour ○
Diesel engine: Check oil pressure and coolant temperature during operation ○
Diesel engine: Check if the prelub system is working properly ○
Electrical system: Clean and check LCD screen of the display for proper function when ○
starting
Electrical system: Check indicator lights and gauges on the control panel when starting ○

Confidential - This document is uncontrolled when printed.

Page 312 of 358
Copyright © Liebherr-Mining Equipment SAS
 Printed by: Zevallos Romulo (LPE) ([email protected])
Operator's Manual R9200 - 410

WORK TO BE PERFORMED AT 500, 1500, 2500 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
Electrical system: Check for warning and fault messages on display (monitoring, grease, ○
air conditioning, ...). If necessary refer to chapter 4 in the Operating Manual to identify and
rectify faults and errors.
Cabin: Check if the safety lever is working properly ○
Cabin: Check the horn ○
Cabin: Check for green flash light on control module if fire fighting system is in­stalled ○

WORK TO BE PERFORMED AT 500, 1500, 2500 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
General comments:

500 Hours maintenance schedule - R9200

From: Operator's manual R 9200 - 410 > Maintenance > Control and maintenance chart

6.23.6 | 1000 Hours Maintenance Schedule - R9200

Serial Number: Completed by :

Fleet Number: Date and Signature :
SMU HOURS:
Travel Hours:

WORK TO BE PERFORMED AT 1000, 3000, 5000 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
GENERAL HYDRAULIC SYSTEM
Do a visual check of all hoses, pipes and fittings for any external damage or leak­age ○
Do a detailed check for good condition of pipes, hoses, clamps and fittings for damage ○
and leakage
Do a visual check of the hydraulic components for leaks and/or damages ○
Do a visual check of the hydraulic cylinder rods for leaks and good condition ○
GENERAL FASTENING
General hydraulic: Do a visual check for missing, broken or loosen mounting screws of all ○
hoses, pipes, fittings and clamps, tighten if necessary
Track components: Do a visual check for missing, broken or loosen mounting screws of ○
the sprockets, rollers, idlers, track guides, track pads, protection covers and final drives,
tighten if necessary
Track components: Do a detailed check for missing, broken or loosen mounting screws of ▢
the rollers, pins locking and track guides, tighten the screws
Track components: Do a detailed check for missing, broken or loosen mounting screws of ▢
the idler axis locking keys, tighten the screws
Track components: Do a detailed check for missing, broken or loosen mounting screws of ▢
the track pads, tighten the screws
Travel gear: Do a detailed check for missing, broken or loosen mounting screws of the ▢
gears, sprocket wheels and hydraulic motors, tighten the screws
Undercarriage: Do a visual check for missing, broken or loosen mounting screws of the ○
side frames, tighten if necessary
Undercarriage: Do a detailed check for missing, broken or loosen mounting screws of the ▢
side frames, tighten the screws
Undercarriage: Do a visual check for missing, broken or loosen mounting screws of all ○
parts, tighten if necessary
Attachment: Do a visual check for missing, broken or loosen mounting screws of the ○
handrails, pin covers fastening and greases connections, tighten if neces­sary
Uppercarriage: Do a visual check for missing, broken or loosen mounting screws of the ○
counterweight, tanks, Powerpack, control valve console, cab, cab elevation, catwalks,
handrails, grease box, ladder, tighten if necessary

Confidential - This document is uncontrolled when printed.

Page 313 of 358
Copyright © Liebherr-Mining Equipment SAS
 Printed by: Zevallos Romulo (LPE) ([email protected])
Operator's Manual R9200 - 410

WORK TO BE PERFORMED AT 1000, 3000, 5000 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
Swing gear: Do a visual check for missing, broken or loosen mounting bolts of the swing ○
gear and hydraulic motors, tighten if necessary
Swing ring: Do a detailed check for missing, broken or loosen mounting screws and ▢
protective nuts of swing ring, tighten the bolts
Diesel engine: Do a visual check for missing, broken or loosen mounting screws of the ○
thermic protection on exhaust manifold fastening, tighten if necessary
Diesel engine: Do a visual check for missing, broken or loosen mounting bolts of the ○
starter motors, alternator and AC compressor, tighten if necessary
Diesel engine: Do a detailed check for missing, broken or loosen mounting screws of the ○
splitterbox, tighten the screws
Hydraulic: Do a detailed check for missing, broken or loosen mounting screws of pumps, ○
motors, clamps, ..., tighten the screws
Cabin: Do a visual check for missing, broken or loosen mounting screws of the AC ○
compressor, tighten if necessary
TRACK COMPONENTS
Clean track chains (after the end of each shift) ○
Do a visual check of the tensioning cylinders, idler, carrier and track rollers for leaks ○
Do a visual check of the track chains tension ○
TRAVEL GEAR
Do a visual check of the gear for leaks, if there are leaks, check oil level ○
Sample and analyse gear oil, change oil if necessary ○
Change gear oil (if filled with OIL-2 or OIL-3 gear oil) ○
Sample and analyse lifetime sealing interspace oil, change oil if necessary (optional ○
equipment)
Change lifetime sealing interspace oil (optional equipment) ○
UNDERCARRIAGE
Do a visual check of all parts for damages and cracks ○
- If necessary fill out the "Structural Inspection" form in Service Manual - Chapter 4
ATTACHMENT
Do a visual check of the bucket teeth and wear kit for wear ○
Do a visual check of the grease supply at each lube point ○
If installed, grease the piston rod protection ○
Do a visual check of cable harness and sensors for damage ○
Do a visual check of all parts for cracks ○
- If necessary fill out the "Structural Inspection" form in Service Manual - Chapter 4
Do a visual check of the fastening of pin covers ○
UPPERCARRIAGE
Do a visual check of the service trap for leaks or damage ○
Do a visual check of oil, grease or fuel for leaks ○
Do a visual check of mirrors and cameras, clean and adjust if necessary ○
Do a detailed check of all structural parts for cracks ○
- If necessary fill out the "Structural Inspection" form in Service Manual - Chapter 4
Do a detailed check and lubricate covers, doors hinges, locks as well as service trap, ○
access ladder cylinders bushings and swivel pins
Do a visual check if the fan guards are in place and secured ○
Do all the maintenance tasks which are scheduled for this interval in the manual of the ○
coolant heater manufacturer (optional equipment)
Do a visual check of the non-slip surfaces for wear and damage ○
SWING GEAR
Do a visual check of the swing gears for leaks and oil level in expansion tanks ○
Sample and analyse gear oil, change oil if necessary ○
Change gear oil (if filled with OIL-2 or OIL-3 gear oil) ○
SWING RING

Confidential - This document is uncontrolled when printed.

Page 314 of 358
Copyright © Liebherr-Mining Equipment SAS
 Printed by: Zevallos Romulo (LPE) ([email protected])
Operator's Manual R9200 - 410

WORK TO BE PERFORMED AT 1000, 3000, 5000 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
Do a detailed check of the grease supply (outlet of new grease around the swing ring) ○
CENTRALIZED LUBRICATION SYSTEM
Do a check of the grease tank level ○
Perform a complete daily maintenance given in the SKF / Lincoln Operating Instructions ○
Manual
Every 1000 hours, perform a complete 1000 hours Maintenance Echelon given in the SKF ○
/ Lincoln Operating Instructions
Replace filter element of the grease filters as stated in Beka Operating manual ○
Yearly, replace filter element of the filling filter as stated in Beka Operating man­ual ○
DIESEL ENGINE AND SPLITTERBOX
Do a visual check in and around the engine compartment for leaks, contamination and ○
damage
Check engine oil level ○
Sample and analyse engine oil ○
Change oil in Diesel engine ○
Replace engine oil filters ○
Check coolant level ○
Do a visual check of the engine and external pipework for leaks ○
Do a visual check of the exhaust gas system connections for leaks ○
Do a visual check of the thermic protection on the exhaust manifold fastening ○
Do a visual check of the oil supply / return pipework for leaks ○
Drain off water and sediment at fuel tank ○
Do a visual check of the water separator on fuel filters, drain if necessary ○
Replace all preliminary filters and fuel filters as soon as fuel level reaches the red mark on ○
the bell of the preliminary filters (replace the filters at least every 500 hours)
Do a visual check of the vacuum indicators for air filters clogging, replace if necessary and ○
reset the indicator
Do a visual check of the precleaner ○
Do a detailed check of the precleaner, clean ○
Replace primary element of the air filter (if necessary or at least once a year) ○
Replace safety element of the air filter if indicated (if necessary or at least once a year) ○
Do a visual check of the coupling for cracks, chips and missing parts ○
Do a detailed check of the coupling rubber rollers ○
Check oil level in the splitterbox ○
Sample and analyse splitterbox oil ○
Change oil in splitterbox ○
Do a visual check of the splitterbox breather for clogging, replace if necessary ○
Replace filter in splitterbox breather ○
Do a visual check of the splitterbox input shaft seal or engine main rear seal for leaks ○
Do a detailed check of the engine and the splitterbox rubber buffers (replace if necessary ▢
and at least every 10000 hours)
Do a visual check of the starter motors, alternator and AC compressor for cables, and ○
brackets
Do a visual check of the air intake hose for condition and leaks ○
Do a visual check of the coolers for clogging and damage, clean or replace if nec­essary ○
Do a visual check of the radiator core and fan, clean if necessary ○
Do a visual check of the radiator cap for leaks, replace if necessary ○
Perform the complete "Daily" Maintenance Echelon given in the CUMMINS Operating and ○
Maintenance Manual
Every 250 hours or 6 months, perform a complete Maintenance Echelon given in the ○
CUMMINS Operating and Maintenance Manual
Every 1500 hours or 1 year, perform a complete Maintenance Echelon given in the ○
CUMMINS Operating and Maintenance Manual

Confidential - This document is uncontrolled when printed.

Page 315 of 358
Copyright © Liebherr-Mining Equipment SAS
 Printed by: Zevallos Romulo (LPE) ([email protected])
Operator's Manual R9200 - 410

WORK TO BE PERFORMED AT 1000, 3000, 5000 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
See CUMMINS Operation and Maintenance Manual for other maintenance (Eliminator, ○
Centinel, Fleetguard, valves and injectors adjustment)
HYDRAULIC SYSTEM
Drain water sediment from hydraulic tank ○
Check oil level in hydraulic tank ○
Sample and analyse hydraulic oil and change oil if necessary ○
Clean magnetic rods of all return filters ○
Clean magnetic rods of the leak oil filter ○
Replace filter element of the return filters ○
Replace filter element of the return filters (if hydraulic hammer is used) ○
Replace filter element of the leak oil filter ○
Replace the hydraulic tank breather filter ○
Replace the hydraulic tank breather filter (if hydraulic hammer is used) ○
Replace control oil filter element ○
Replace swing pumps replenishing oil filter elements ○
Do a visual check of the oil cooler protection filters, clean or replace if necessary (optional ○
equipment)
Check and adjust primary and secondary pressure relief valves ○
ELECTRICAL SYSTEM
Do a visual check of the head and floodlights, clean and adjust if necessary ○
Press to open dust discharge valve on aeration devices for cabin and electrical boxes ○
Replace main element on aeration devices for cabin and electrical boxes (at least once a ○
year)
Replace safety element on aeration devices for cabin and electrical boxes, after 3 services ○
of main element
Do a visual check of electric harness, sensors for damage and/or rubbing zone ○
Do a detailed check of fuses and circuit breakers ○
Do a visual check of wiring system damage ○
Check battery electrolyte level (refill if necessary) and clean battery terminals ○
CABIN
If installed, do a detailed check of the V-belt tension for air conditioner ○
Do a visual check of the cabin for oil/fluids leaks ○
Operate air conditioner every week for 10 minutes ○
Check the condition of the condenser, blow it out if necessary ○
Do a visual check of the fresh air filter and the recirculated air filter ○
Do a visual check of the dryer / accumulator unit for moisture degree, coolant level and ○
good condition, replace if necessary (at least once a year)
The function of the air flaps and the defrosting thermostat must be checked yearly by a ○
refrigeration specialist
Perform maintenance for the second air-conditioning system (optional equip­ment) ○
Lubricate all doors seals with silicone or talc (before cold season) ○
Do a visual check of the AC for leaks or rubbing hoses or pipes ○
Do a visual check of the locks and hinges on doors and windows (lubricate if nec­essary) ○
Do a detailed check of the cabin rubber mounts ○
FIRE FIGHTING SYSTEM
Do a visual check of the fire fighting system condition (optional equipment, refer to the fire ○
fighting system documentation)
- If any issue contact fire fighting local dealer
Follow the inspection intervals recommended by the specific Health and Safety rules ○
existing in country and/or on mine site
START THE ENGINE TO CHECK THE FOLLOWING ACTIONS
General: Maintenance work must include the check of the correct functions of hydraulic ○
and electric systems before starting operation

Confidential - This document is uncontrolled when printed.

Page 316 of 358
Copyright © Liebherr-Mining Equipment SAS
 Printed by: Zevallos Romulo (LPE) ([email protected])
Operator's Manual R9200 - 410

WORK TO BE PERFORMED AT 1000, 3000, 5000 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
Attachment: Check function of the working attachment lubrication system during operation ○
Attachment: Check if the damping system on equipment is working correctly ○
Uppercarriage: Check position of the hydraulic shut-off valve ○
Uppercarriage: Check movement and locking of the access ladder ○
Uppercarriage: Check that the swing movement of the uppercarriage and the travel ○
movement are locked when the access ladder is lowered
Swing Gear: Check function and operation of the swing brake ○
Swing Ring: Check function of the swing ring bearing lubrication system during operation ○
Swing Ring: Check function of the swing ring teeth lubrication system during op­eration ○
Diesel engine: Check speed on RPM gauge ○
Diesel engine: Check running noises ○
Diesel engine: Check exhaust gas colour ○
Diesel engine: Check oil pressure and coolant temperature during operation ○
Diesel engine: Check if the prelub system is working properly ○
Electrical system: Clean and check LCD screen of the display for proper function when ○
starting
Electrical system: Check indicator lights and gauges on the control panel when starting ○
Electrical system: Check for warning and fault messages on display (monitoring, grease, ○
air conditioning, ...). If necessary refer to chapter 4 in the Operating Manual to identify and
rectify faults and errors.
Cabin: Check if the safety lever is working properly ○
Cabin: Check the horn ○
Cabin: Check for green flash light on control module if fire fighting system is in­stalled ○
Cabin: Check the heater function (before the cold season) ○

WORK TO BE PERFORMED AT 1000, 3000, 5000 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
General comments:

1000 hours maintenance schedule - R9200

From: Operator's manual R 9200 - 410 > Maintenance > Control and maintenance chart

6.23.7 | 2000 Hours Maintenance Schedule - R9200

Serial Number: Completed by :

Fleet Number: Date and Signature :
SMU HOURS:
Travel Hours:

WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
GENERAL HYDRAULIC SYSTEM
Do a visual check of all hoses, pipes and fittings for any external damage or leak­age ○
Do a detailed check for good condition of pipes, hoses, clamps and fittings for damage ○
and leakage
Do a visual check of the hydraulic components for leaks and/or damages ○
Do a visual check of the hydraulic cylinder rods for leaks and good condition ○
GENERAL FASTENING
General hydraulic: Do a visual check for missing, broken or loosen mounting screws of all ○
hoses, pipes, fittings and clamps, tighten if necessary
Track components: Do a visual check for missing, broken or loosen mounting screws of ○
the sprockets, rollers, idlers, track guides, track pads, protection covers and final drives,
tighten if necessary

Confidential - This document is uncontrolled when printed.

Page 317 of 358
Copyright © Liebherr-Mining Equipment SAS
 Printed by: Zevallos Romulo (LPE) ([email protected])
Operator's Manual R9200 - 410

WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
Track components: Do a detailed check for missing, broken or loosen mounting screws of ○
the rollers, pins locking and track guides, tighten the screws
Track components: Do a detailed check for missing, broken or loosen mounting screws of ○
the idler axis locking keys, tighten the screws
Track components: Do a detailed check for missing, broken or loosen mounting screws of ○
the track pads, tighten the screws
Travel gear: Do a detailed check for missing, broken or loosen mounting screws of the ○
gears, sprocket wheels and hydraulic motors, tighten the screws
Undercarriage: Do a detailed check for missing, broken or loosen mounting screws of the ○
side frames, tighten the screws
Undercarriage: Do a visual check for missing, broken or loosen mounting screws of all ○
parts, tighten if necessary
Attachment: Do a visual check for missing, broken or loosen mounting screws of the ○
handrails, pin covers fastening and greases connections, tighten if neces­sary
Attachment: Do a detailed check for missing, broken or loosen mounting screws of the ○
handrails, pin covers fastening and greases connections, tighten the screws
Uppercarriage: Do a visual check for missing, broken or loosen mounting screws of the ○
counterweight, tanks, Powerpack, control valve console, cab, cab elevation, catwalks,
handrails, grease box, ladder, tighten if necessary
Uppercarriage: Do a detailed check for missing, broken or loosen mounting screws of the ○
counterweight, tanks, Powerpack, control valve console, cab, cab elevation, catwalks,
handrails, grease box, ladder, tighten the screws
Swing gear: Do a visual check for missing, broken or loosen mounting bolts of the swing ○
gear and hydraulic motors, tighten if necessary
Swing gear: Do a detailed check for missing, broken or loosen mounting bolts of the swing ○
gear and hydraulic motors, tighten the bolts
Swing ring: Do a detailed check for missing, broken or loosen mounting screws and ○
protective nuts of swing ring, tighten the bolts
Diesel engine: Do a visual check for missing, broken or loosen mounting screws of the ○
thermic protection on exhaust manifold fastening, tighten if necessary
Diesel engine: Do a visual check for missing, broken or loosen mounting bolts of the ○
starter motors, alternator and AC compressor, tighten if necessary
Diesel engine: Do a detailed check for missing, broken or loosen mounting screws of the ○
splitterbox, tighten the screws
Diesel engine: Do a detailed check for missing, broken or loosen mounting screws of the ○
engine, tighten the screws
Hydraulic: Do a detailed check for missing, broken or loosen mounting screws of pumps, ○
motors, clamps, ..., tighten the screws
Cabin: Do a visual check for missing, broken or loosen mounting screws of the AC ○
compressor, tighten if necessary
TRACK COMPONENTS
Clean track chains (after the end of each shift) ○
Do a visual check of the tensioning cylinders, idler, carrier and track rollers for leaks ○
Do a visual check of the track chains tension ○
Liebherr recommends to measure the track chains with TCM software ○
TRAVEL GEAR
Do a visual check of the gear for leaks, if there are leaks, check oil level ○
Sample and analyse gear oil, change oil if necessary ○
Change gear oil (if filled with OIL-1 gear oil) ○
Change gear oil (if filled with OIL-2 or OIL-3 gear oil) ○
Sample and analyse lifetime sealing interspace oil, change oil if necessary (optional ○
equipment)
Change lifetime sealing interspace oil (optional equipment) ○
Change the oil of the external travel brake ○
UNDERCARRIAGE
Confidential - This document is uncontrolled when printed.
Page 318 of 358
Copyright © Liebherr-Mining Equipment SAS
 Printed by: Zevallos Romulo (LPE) ([email protected])
Operator's Manual R9200 - 410

WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
Do a visual check of all parts for damages and cracks ○
- If necessary fill out the "Structural Inspection" form in Service Manual - Chapter 4
ATTACHMENT
Do a visual check of the bucket teeth and wear kit for wear ○
Do a visual check of the grease supply at each lube point ○
If installed, grease the piston rod protection ○
Do a visual check of cable harness and sensors for damage ○
Do a visual check of all parts for cracks ○
- If necessary fill out the "Structural Inspection" form in Service Manual - Chapter 4
Do a visual check of the fastening of pin covers ○
UPPERCARRIAGE
Do a visual check of the service trap for leaks or damage ○
Do a visual check of oil, grease or fuel for leaks ○
Do a visual check of mirrors and cameras, clean and adjust if necessary ○
Do a detailed check of all structural parts for cracks ○
- If necessary fill out the "Structural Inspection" form in Service Manual - Chapter 4
Do a detailed check and lubricate covers, doors hinges, locks as well as service trap, ○
access ladder cylinders bushings and swivel pins
Do a visual check if the fan guards are in place and secured ○
Do all the maintenance tasks which are scheduled for this interval in the manual of the ○
coolant heater manufacturer (optional equipment)
Do a functional test of the camera system and global view around machine (including ○
mirrors)
Do a visual check of the non-slip surfaces for wear and damage ○
Do a detailed check of all the anchor points and the tightening of the handrails mounting ○
screws, only by authorized specialist personnel (at least once a year)
Every 6000 hours (or at least once a year), check the emergency ladder for damage and ○
correct operation. Replace if necessary. Replace the emergency rope ladder every eight
years (if installed)
SWING GEAR
Do a visual check of the swing gears for leaks and oil level in expansion tanks ○
Sample and analyse gear oil, change oil if necessary ○
Change gear oil (if filled with OIL-1 gear oil) ○
Change gear oil (if filled with OIL-2 or OIL-3 gear oil) ○
Measure the axial play of the output shaft bearing, replace if necessary ○
SWING RING
Do a detailed check of the grease supply (outlet of new grease around the swing ring) ○
Do a detailed check of the meshing of the swing gears with the swing ring ○
Do a detailed check of the swing ring teeth for damage ○
Do a detailed check of the swing ring axial play ○
CENTRALIZED LUBRICATION SYSTEM
Do a check of the grease tank level ○
Perform a complete daily maintenance given in the SKF / Lincoln Operating Instructions ○
Manual
Every 1000 hours, perform a complete 1000 hours Maintenance Echelon given in the SKF ○
/ Lincoln Operating Instructions
Every 2000 hours, perform a complete 2000 hours Maintenance Echelon given in the SKF ○
/ Lincoln Operating Instructions
Replace filter element of the grease filters as stated in Beka Operating manual ○
Yearly, replace filter element of the filling filter as stated in Beka Operating man­ual ○
DIESEL ENGINE AND SPLITTERBOX
Do a visual check in and around the engine compartment for leaks, contaminations and ○
damage

Confidential - This document is uncontrolled when printed.

Page 319 of 358
Copyright © Liebherr-Mining Equipment SAS
 Printed by: Zevallos Romulo (LPE) ([email protected])
Operator's Manual R9200 - 410

WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
Check engine oil level ○
Sample and analyse engine oil ○
Change oil in Diesel engine ○
Replace engine oil filters ○
Check coolant level ○
Do a visual check of the engine and external pipework for leaks ○
Do a visual check of the exhaust gas system connections for leaks ○
Do a visual check of the thermic protection on the exhaust manifold fastening ○
Do a visual check of the oil supply / return pipework for leaks ○
Drain off water and sediment at fuel tank ○
Do a visual check of the water separator on fuel filters, drain if necessary ○
Replace all preliminary filters and fuel filters as soon as fuel level reaches the red mark on ○
the bell of the preliminary filters (replace the filters at least every 500 hours)
Replace the filter element of the dust filter for the vent valve ○
Do a visual check of the vacuum indicators for air filters clogging, replace if necessary and ○
reset the indicator
Do a visual check of the precleaner ○
Do a detailed check of the precleaner, clean ○
Replace primary element of the air filter (if necessary or at least once a year) ○
Replace safety element of the air filter if indicated (if necessary or at least once a year) ○
Do a sealing control of the air intake system: use the Liebherr special tool which is ○
dedicated for this purpose
Do a visual check of the coupling for cracks, chips and missing parts (coupling) ○
Do a detailed check of the coupling rubber rollers ○
Every 10000 hours, replace the coupling rubber rollers ○
Check oil level in the splitterbox ○
Sample and analyse splitterbox oil ○
Change oil in splitterbox ○
Do a visual check of the splitterbox breather for clogging, replace if necessary ○
Replace filter in splitterbox breather ○
Do a visual check of the splitterbox input shaft seal or engine main rear seal for leaks ○
Do a detailed check of the engine and the splitterbox rubber buffers (replace if necessary ○
and at least every 10000 hours)
Do a visual check of the starter motors, alternator and AC compressor for cables, and ○
brackets
Do a visual check of the air intake hose for condition and leaks ○
Do a visual check of the coolers for clogging and damage, clean or replace if nec­essary ○
Do a visual check of the radiator core and fan, clean if necessary ○
Do a visual check of the radiator cap for leaks, replace if necessary ○
Perform the complete "Daily" Maintenance Echelon given in the CUMMINS Operating and ○
Maintenance Manual
Every 250 hours or 6 months, perform a complete Maintenance Echelon given in the ○
CUMMINS Operating and Maintenance Manual
Every 6000 hours or 2 years, perform a complete Maintenance Echelon given in the ○
CUMMINS Operating and Maintenance Manual
See CUMMINS Operation and Maintenance Manual for other maintenance (Eliminator, ○
Centinel, Fleetguard, valves and injectors adjustment)
HYDRAULIC SYSTEM
Drain water sediment from hydraulic tank ○
Check oil level in hydraulic tank ○
Sample and analyse hydraulic oil and change oil if necessary ○
Change hydraulic oil ○
Clean magnetic rods of all return filters ○

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WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
Clean magnetic rods of the leak oil filter ○
Replace filter element of the return filters ○
Replace filter element of the return filters (if hydraulic hammer is used) ○
Replace filter element of the leak oil filter ○
Replace the hydraulic tank breather filter ○
Replace the hydraulic tank breather filter (if hydraulic hammer is used) ○
Replace control oil filter element ○
Replace swing pumps replenishing oil filter elements ○
Replace the control valves high pressure filters, replace filter elements after each ○
replacement or repair of a working pump and check the internal surface of the filter
housing
Do a visual check of the oil cooler protection filters, clean or replace if necessary (optional ○
equipment)
Do a detailed check of the oil coolers, clean if necessary ○
Do a visual check of the cooling fan blades, replace if necessary ○
Check and adjust primary and secondary pressure relief valves ○
Do a detailed check of mounting of components (pumps, motors, ...) ○
Every 4000 hours (or at least once a year), all hydraulic pumps must be checked and ○
adjusted by trained and qualified Liebherr personnel
Every 4000 hours (or at least once a year), check the pressure of the hydraulic ○
accumulators and fill if necessary: use the special tool which is dedicated for this purpose
Every 10000 hours, replace following high pressure (HP) hoses: ○

• all HP hoses between work pumps and valve banks,

• all HP hoses of the swing circuit:
◦ all HP hoses between swing pumps and swing motors,
◦ all pressure equalizing hoses between swing pump / swing motors circuits,
◦ all HP pilot hoses of the swing pumps regulation,
• all HP hoses of the oil cooler fan drive circuit, including HP pilot hoses,
• all HP hoses of the water cooler fan drive circuit, including HP pilot hoses.

ELECTRICAL SYSTEM
Do a visual check of the head and floodlights, clean and adjust if necessary ○
Press to open dust discharge valve on aeration devices for cabin and electrical boxes ○
Replace main element on aeration devices for cabin and electrical boxes (at least once a ○
year)
Replace safety element on aeration devices for cabin and electrical boxes, after 3 services ○
of main element
Do a visual check of electric harness, sensors for damage and/or rubbing zone ○
Do a detailed check of fuses and circuit breakers ○
Do a visual check of wiring system damage ○
Check battery electrolyte level (refill if necessary) and clean battery terminals ○
Do a test of all emergency stops (engine stop only) ○
Make sure that the display goes off after each test
CABIN
If installed, do a detailed check of the V-belt tension for air conditioner ○
Do a visual check of the cabin for oil/fluids leaks ○
Operate air conditioner every week for 10 minutes ○
Check the condition of the condenser, blow it out if necessary ○
Do a visual check of the fresh air filter and the recirculated air filter ○
Do a visual check of the dryer / accumulator unit for moisture degree, coolant level and ○
good condition, replace if necessary (at least once a year)
The function of the air flaps and the defrosting thermostat must be checked yearly by a ○
refrigeration specialist
Perform maintenance for the second air-conditioning system (optional equip­ment) ○
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WORK TO BE PERFORMED AT 2000, 4000, 6000 HOURS, ... Check Initials Comments
Check ▢ for first and only interval or Check ○ for repeat interval
Lubricate all doors seals with silicone or talc (before cold season) ○
Do a visual check of the AC for leaks or rubbing hoses or pipes ○
Do a visual check of the locks and hinges on doors and windows (lubricate if nec­essary) ○
Do a detailed check of the cabin rubber mounts ○
Do a detailed check of the heater exchanger and filter for leaks ○
Do a detailed check of the warm water solenoid valve for function and chocking, clean it if ○
necessary
Check the condition of the evaporator, clean it if necessary ○
FIRE FIGHTING SYSTEM
Do a visual check of the fire fighting system condition (optional equipment, refer to the fire ○
fighting system documentation)
- If any issue contact fire fighting local dealer
Follow the inspection intervals recommended by the specific Health and Safety rules ○
existing in country and/or on mine site
START THE ENGINE TO CHECK THE FOLLOWING ACTIONS
General: Maintenance work must include the check of the correct functions of hydraulic ○
and electric systems before starting operation
Attachment: Check function of the working attachment lubrication system during operation ○
Attachment: Check if the damping system on equipment is working correctly ○
Uppercarriage: Check position of the hydraulic shut-off valve ○
Uppercarriage: Check movement and locking of the access ladder ○
Uppercarriage: Check that the swing movement of the uppercarriage and the travel ○
movement are locked when the access ladder is lowered
Swing Gear: Check function and operation of the swing brake ○
Swing Ring: Check function of the swing ring bearing lubrication system during operation ○
Swing Ring: Check function of the swing ring teeth lubrication system during op­eration ○
Diesel engine: Check speed on RPM gauge ○
Diesel engine: Check running noises ○
Diesel engine: Check exhaust gas colour ○
Diesel engine: Check oil pressure and coolant temperature during operation ○
Diesel engine: Check if the prelub system is working properly ○
Electrical system: Clean and check LCD screen of the display for proper function when ○
starting
Electrical system: Check indicator lights and gauges on the control panel when starting ○
Electrical system: Check for warning and fault messages on display (monitoring, grease, ○
air conditioning, ...). If necessary refer to chapter 4 in the Operating Manual to identify and
rectify faults and errors.
Cabin: Check if the safety lever is working properly ○
Cabin: Check the horn ○
Cabin: Check for green flash light on control module if fire fighting system is in­stalled ○
Cabin: Check the heater function (before the cold season) ○
Cabin: Check the pressure switch function on the dryer / accumulator unit ○

2000 hours maintenance schedule - R9200

From: Operator's manual R 9200 - 410 > Maintenance > Control and maintenance chart

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7 | Appendix

From: Operator's manual R 9200 - 410

7.1 | Fluids and lubricants specification

From: Operator's manual R 9200 - 410 > Appendix

7.2 | Visual check of the hydraulic hoses

From: Operator's manual R 9200 - 410 > Appendix

7.2.1 | Preface

This section describes the procedure for the visual check of the hydraulic hoses.

NOTE!
These instructions have been written for the maintenance personnel of the ma­chine.
The activities described in this section may only be carried out by specially trained personnel.

The instructions are to be read and used carefully by all persons who carry out work with or on the machine before putting the
machine into service for the first time and later, at regular intervals.

The instructions must be completed by information on current national regulations for accident prevention and protection. In addition,
authorized specialist rules for safe and correct working procedures are also to be observed.

However, should you require any further explanations or information, LIEBHERR technical documentation, sales school and customer
service departments are avail­able for your convenience.

DANGER!
Fluid injection injuries have to be treated immediately!

• Fluid under pressure can cause serious injury. It can be almost invisible when it escapes from a pinhole and it can go
through the skin and contaminate the blood.
• Do not touch a pressurized hydraulic hose assembly with any part of your body.
• If a fluid-injection accident occurs, medical treatment is necessary immediately.
• Stay out of hazardous areas while testing hose assemblies under pressure. Use available safety protection.
• Refer to "Isolate machine for hydraulic repair" safe work procedure in the Ser­vice Manual.

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From: Operator's manual R 9200 - 410 > Appendix > Visual check of the hydraulic hoses

7.2.2 | General information

Components description

Figure 1. Hydraulic tube and hose assembly

1 Rubber cover 5 Nipple

2 Reinforcement layer 6 Nipple wire trap area
3 Inside rubber tube 7 Sealing zone
4 Crimp fitting 8 Damping zone

For this document, the terms that follow are available:

• A hose is a hydraulic tube. It is made by:

◦ the rubber cover 1

◦ the reinforcement layer 2

◦ the inside rubber tube 3

• A hose assembly is a hose with fittings attached at the two ends. The fittings are made by:

◦ the crimp fitting 4

◦ the nipple 5

Marking of the components

The hose and the hose assembly are marked with the general data given below.

Hose marking
The hose is marked on the rubber cover with:

• the nominal diameter (DN)

• the manufacturer identification

• the date of production "xQxx" of the hose (i.e. 2Q13 = second quarter of 2013)

• the hose type and quality

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Figure 2. Marking of hose

Hose assembly marking

The hose assembly is marked on the fittings with:

• the manufacturer identification

• the date when the hose assembly has been made

• the hose identification number

• the service pressure

Figure 3. Marking of hose assembly

Normal conditions of use

DANGER!
It is necessary to replace the hydraulic hoses at specified intervals to maintain their maximum operating performance and
to reduce the risk of personal injury and/or machine damage.

• ▶ Obey the replacement intervals given below.

Natural ageing
Hydraulic hoses and hose assemblies undergo a process of natural ageing. Thus, their service life has a limit:

• When you make a hose assembly, the hose must not be more than four years old.

• The service life of a hose assembly must obey the requirements given in the section "Replacement of the hydraulic hoses" of this
manual.

• ▶ When you check a hose assembly or you install a new one, refer to the date of assembly marked on the hose assembly fittings.

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Operating stress
The hydraulic hoses must also be regularly replaced because of the operating stress.

• ▶ For the replacement intervals given in working hours of the hydraulic hoses, refer to the section "Control and maintenance chart" of
this manual.

Mounting instructions
• ▶ Refer to the Operating Manual.

From: Operator's manual R 9200 - 410 > Appendix > Visual check of the hydraulic hoses

7.2.3 | Components functions

This section gives the function of the different main components of a hydraulic hose assembly.

Inside rubber tube

The inside rubber tube keeps the conveyed fluid in the hose. It is resistant against the fluid and the temperature of the fluid. Internal
damages to this tube can be caused by contamination of the hydraulic circuit.

The inside rubber seals the hose but it has no pressure stability.

Reinforcement layer
The reinforcement layer, made up of some steel layers with rubber in between, holds the internal pressure.

The reinforcement layer is the only component of the hose which gives the hose the pressure stability. The hose has a minimum burst
pressure (static) and a maximum operating pressure (dynamic). The maximum operating pressure is usually at least four times lower
than the minimum burst pressure because dynamic pressures fa­tigue the reinforcement layer more quickly than static pressures.

The value of the burst pressure and the operating pressure will be lower if the rein­forcement layer has one of the damages that follow:

• Corrosion of the reinforcement layer.

• Rub between the steel layers.

• Damaged rubber in between the steel layers.

The inside rubber can also be damaged if the reinforcement layer moves.

Rubber cover
The rubber cover protects the reinforcement layer from the ambient conditions (UV, ozone, different liquids) and from mechanical effects
(scrubbing, corrosion).

Any rub, cut or rib in the rubber cover means that the protection is no longer satisfactory and the reinforcement layer is subject to a
potential destruction.

Nipple
The nipple is necessary to connect a hydraulic hose to another component. The nipple is resistant to all the mechanical forces and
bending stress caused by the pressure pulsations in the hose. Thus, it is important to have a good contact between the nipple and the
hose.

Cracks on the nipple cause its fast failure.

Crimp fitting
To make sure that the assembly is correctly sealed, the crimp fitting presses the inside rubber tube onto the nipple. In addition, if the hose
has a wire trap area, the crimp fitting clamps the reinforcement layer in between the nipple and the crimp fit­ting.

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If the hose assembly starts to leak at the end of the crimp fitting, the causes that fol­low are possible:

• The sealing function between rubber hose and nipple is not satisfactory.

• The crimp fitting has not been done 100% correctly.

• The pressure range of the crimp fitting is lower.

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From: Operator's manual R 9200 - 410 > Appendix > Visual check of the hydraulic hoses

7.2.4 | Recommendations for hose assembly maintenance

Severity levels
Hose assembly damages can be divided into three severity levels:

• minor damage

• serious damage

• major damage

For each severity level, there are special actions to do at specific intervals.

Checks and recommendations

The sections that follow give:

• the visual checks which are necessary to make an estimate of the damage sever­ity level

• the recommendations for the related actions and intervals

Minor damage
If you find a minor damage:

Daily • ▶ Examine the hose assembly. Monitor if the deterioration increases.

• ▶ In case of rubbing, move the hose assembly to make sure there is no more con­tact.
• ▶ Check all necessary conditions for the possible replacement of the defective part(s) (e.g. part in stock,
time of delivery).

Rubber cover is rubbed - Reinforcement layer is not corroded or not rubbed - No sign of oil

Rubber cover has a cut or a crack - Reinforcement layer is not corroded or not cut - No sign of oil

Hose is visually wet near the crimp fitting - Oil does not propagate
There is a small surface of remaining oil which is visually wet but does not result in the formation of drop.

Dry dust collection which does not propagate

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Serious damage
If you find a serious damage:

Immediately • ▶ Inform formally the responsible Maintenance Manager about the condition of the hose
assembly.
• ▶ Make sure that you have the correct replacement part in stock.

Daily • ▶ Examine the hose assembly. Monitor if the deterioration increases.

• ▶ If the deterioration of the hose assembly increases in a small number of days, refer to next
section "Major damage" for the actions to do.

One of the next services, • ▶ Replace the hose assembly.

but not later than 250 hours

Rubber cover has many cuts or cracks - Reinforcement layer is not corroded or not cut - No sign of oil

Rubber cover is rubbed - Reinforcement layer is uncovered but not corroded - No sign of oil

Hoses and fittings are visually wet - Oil propagates

There is a surface of remaining oil which is visually wet and results in the formation of non-falling or falling drop.

Major damage
If you find a major damage:

DANGER!
In this case, the hose assembly must be replaced immediately because it can burst at any time.

• ▶ Obey all safety instructions given in the Operating Manual to avoid accidents and fires.

Immediately • ▶ Stop the machine immediately (no exception).

• ▶ Inform formally the responsible Maintenance Manager, or his superior, that the machine is stopped
and about the condition of the hose assembly.

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Before restart the • ▶ Replace the hose assembly.

ma­chine

Oil leakage
The frequency of the drops makes a measurable flow.

Reinforcement layer is cracked, rubbed or corroded

Nipple or crimp fittings are Blisters have formed on the rubber Oil comes out of the cut or
cracked cover cracked rubber cover

From: Operator's manual R 9200 - 410 > Appendix > Visual check of the hydraulic hoses

7.3 | Cleaning procedure for hydraulic circuits

This section gives the procedures to drain and clean the different hydraulic circuits of the machine after a repair and before you put the
machine back in operation.

From: Operator's manual R 9200 - 410 > Appendix

7.3.1 | Preface

NOTE!
These instructions have been written for the maintenance personnel of the ma­chine.
The activities described in this section may only be carried out by specially trained personnel.

The instructions are to be read and used carefully by all persons who carry out work with or on the machine before putting the
machine into service for the first time and later, at regular intervals or after a repair.

The instructions must be completed by information on current national regulations for accident prevention and protection. In addition,
authorized specialist rules for safe and correct working procedures are also to be observed.

However, should you require any further explanations or information, LIEBHERR technical documentation, sales school and customer
service departments are avail­able for your convenience.

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DANGER!
Fluid injection injuries have to be treated immediately!

• Fluid under pressure can cause serious injury. It can be almost invisible when it escapes from a pinhole and it can go
through the skin and contaminate the blood.
• Do not touch a pressurized hydraulic hose assembly with any part of your body.
• If a fluid-injection accident occurs, medical treatment is necessary immediately.
• Stay out of hazardous areas while testing hose assemblies under pressure. Use available safety protection.
• Refer to "Isolate machine for hydraulic repair" safe work procedure in the Ser­vice Manual.

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From: Operator's manual R 9200 - 410 > Appendix > Cleaning procedure for hydraulic circuits

7.3.2 | General information about hydraulic oil contamination

Hydraulic oil contamination

Hydraulic oil contamination is unwanted liquid or solid material and/or particles in the hydraulic circuit. It can be caused by:

• The failure of components like pumps, hydraulic motors or cylinders

• Too much wear of a component

• Material/particles introduced during:

◦ The general maintenance

◦ A repair work

• Hydraulic circuit not cleaned on previous maintenance work (too much remaining contamination in the hoses and pipes).

Hydraulic oil contamination has a lot of unwanted effects, for example:

• Corrosion

• Internal leaks

• Overheating

• Wear of the moving part

• Damages to other components

• Degradation of rubber and elastomer compounds.

Metallic contamination of the hydraulic circuit

You can see metallic contamination of the hydraulic circuit through:

• Special error codes on the display for working pumps and swing pumps

• The condition of the magnetic rods of return filters and leak oil filters, which are installed on the hydraulic tank:

Figure 1. Clean magnetic rod

• In normal operation, the magnetic rods are clean.

Figure 2. Magnetic rod with metal collection

• In case of contamination of the hydraulic circuit by metal particles, there is an important metal collection on the magnetic rods.

• Because of the set-up of the components, a metal collection on the magnetic rods is also possible during the initial operation time of
the machine.

• Because of the normal wear of pumps and motors, a thin layer of metal on the magnetic rods is always possible.

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When you remove the filters, you can also find particles of fibre support bands, O-ring material or sealant material in the filter element or
in the filter housing.

Thus, to prevent damages to the components because of particles contamination in the hydraulic circuit, you must monitor the hydraulic
circuit condition and, when nec­essary, do all the applicable maintenance tasks.

From: Operator's manual R 9200 - 410 > Appendix > Cleaning procedure for hydraulic circuits

7.3.3 | General cleaning procedure

• ▶ Refer to chapter "Safe work procedures" of the Service manual for all the instruc­tions about the works to do.

• ▶ Obey the sequence that follows.

Disassemble the hydraulic circuits of the component to re­place

• ▶ Lay down the attachment on the ground.

• ▶ Stop the Diesel engine.

• ▶ Release hydraulic pressure as given in the dedicated section of this manual.

• ▶ Close the shutoff valve(s) of the hydraulic tank.

• ▶ With applicable tools, disconnect, drain and clean all of the hydraulic circuits of the component to replace, as given in the following
detailed sections.

During these tasks and depending on the different assemblies, it is possible that you must disassemble some components.

• ▶ Clean the hydraulic tank as given in the dedicated following section.

Assemble the hydraulic circuits

• ▶ Assemble all of the hydraulic circuits again. For more information about general installation procedures, refer to the dedicated
section of this manual.

• ▶ Replace all the filter elements of the hydraulic tank filters, as given in the dedicat­ed section of this manual.

• ▶ Open the shutoff valve(s) of the hydraulic tank.

• ▶ Before you put the machine in operation again, do the procedure "Restart the ma­chine" that is given in this section.

From: Operator's manual R 9200 - 410 > Appendix > Cleaning procedure for hydraulic circuits

7.3.4 | Working pumps circuit

This section gives the different hydraulic circuits of the working pumps, to which the disassembly and assembly instructions of the
general cleaning procedure refer.

• ▶ Obey the sequence that follows.

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Leak oil circuit

Figure 1. Leak oil circuit of working pumps

3 Hydraulic tank 12 Drain plug

6 Hydraulic pipe 13 Hydraulic block (if installed)
7 Hydraulic hose CP3 Collecting pipe
8 Hydraulic hose P1 Working pump 1
9 Hydraulic hose P2 Working pump 2
10 Hydraulic hose P3 Working pump 3
11 Hydraulic hose P4 Working pump 4

• ▶ Open drain plug 12 and drain the leak oil circuit. The location of drain plug 12 de­pends on the machines.

• ▶ Disconnect, drain and clean all the hydraulic hoses and pipes.

• ▶ Open, drain and clean the collecting pipe CP3.

• ▶ Move to next section about the high pressure circuit.

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High pressure circuit

Figure 2. High pressure hoses between valves blocks and working pumps

6 Hydraulic hose HPF4P4 High pressure filter

7Hydraulic hose P1Working pump 1
8Hydraulic hose P2Working pump 2
9Hydraulic hose P3Working pump 3
HPF1P1 high pressure filter P4Working pump 4
HPF2P2 high pressure filter VB1Valve block 1
HPF3P3 High pressure filter VB2Valve block 2

• ▶ According to the defective pump, remove the related high pressure filter HPFx.

• ▶ Disconnect, drain and clean the related high pressure hose.

• ▶ Install a new high pressure filter.

• ▶ Move to next section about the oil intake circuit.

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Oil intake circuit

Figure 3. Intake lines of working pumps

3 Hydraulic tank P1 Working pump 1

6 Shutoff valve P2 Working pump 2
7 Compensators (4x) P3 Working pump 3
8 Suction pipes (4x) P4 Working pump 4
SP1 Intake pipe

• ▶ Disconnect, drain and clean all the compensators and the intake pipe SP1.

• ▶ Clean the shutoff valve 6.

• ▶ Move to next section about the return oil circuit.

Return oil circuit

Figure 4. Return lines

3 Hydraulic tank 12 Hydraulic hose

4 Oil cooler box 13 Hydraulic hose
5 Oil cooler 14 Hydraulic hose
6 Hydraulic hose 15 Hydraulic hose
7 Hydraulic hose 16 Oil cooler protection filters (optional)

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8 Hydraulic hose CP2 Control valve collecting pipe

9 Hydraulic hose VB1 Valve block 1
10 Hydraulic hose VB2 Valve block 2
11 Hydraulic hose

• ▶ Disconnect, drain and clean all the hydraulic hoses.

• ▶ Open, drain and clean the collecting pipe CP2.

• ▶ Clean the hydraulic tank as given in the dedicated following section.

• ▶ Complete the general cleaning procedure and do the procedure "Restart the ma­chine" before you put the machine in operation.

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From: Operator's manual R 9200 - 410 > Appendix > Cleaning procedure for hydraulic circuits

7.3.5 | Swing circuit

This section gives the different hydraulic circuits of the swing pump, to which the disassembly and assembly instructions of the general
cleaning procedure refer.

• ▶ Obey the sequence that follows.

Leak oil circuit

Figure 1. Leak oil hoses of swing pump

6 Hydraulic hose CP3 Collecting pipe

7 Hydraulic hose P5 Swing pump
a Refer to section "Leak oil circuit of working pumps"

• ▶ Refer to section "Leak oil circuit of working pumps" to drain the leak oil circuit.

• ▶ Disconnect, drain and clean all the hydraulic hoses.

• ▶ Open, drain and clean the collecting pipe CP3.

Figure 2. Leak oil hoses of swing motors

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3 Hydraulic tank 12 Hydraulic hose

8 Hydraulic hose 13 Hydraulic pipe
9 Hydraulic hose MSB Rear right swing motor
10 Hydraulic pipe MSF Front right swing motor
11 Hydraulic hose RC Rotary connection

• ▶ Disconnect, drain and clean all the hydraulic hoses, blocks and pipes.

• ▶ Move to next section about the working pressure circuit.

Working pressure circuit

Figure 3. Working pressure lines

6 Hydraulic hose 12Hydraulic pipe/hose (depend­ing on the machines)

7Hydraulic hose 13Hydraulic hose
8Hydraulic pipe/hose (depend­ing on the machines) MSBRear right swing motor
9Hydraulic hose MSFFront right swing motor
10Hydraulic hose P5Swing pump
11Hydraulic hose

• ▶ Disconnect, drain and clean all the hydraulic hoses and pipes.

• ▶ Disconnect, drain and clean all the distribution blocks.

• ▶ Move to next section about the oil intake and oil replenishing circuit.

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Oil intake and oil replenishing circuit

Figure 4. Intake and replenishing lines

6 Hydraulic hose P5Swing pump

7Hydraulic hose P10Replenishing oil pump
8Hydraulic hose SP1Intake pipe
dRefer to section "Oil intake cir­cuit" of the working pumps

• ▶ Disconnect, drain and clean all the hydraulic hoses.

• ▶ Clean the hydraulic tank as given in the dedicated following section.

• ▶ Complete the general cleaning procedure and do the procedure "Restart the ma­chine" before you put the machine in operation.

From: Operator's manual R 9200 - 410 > Appendix > Cleaning procedure for hydraulic circuits

7.3.6 | Cooling pumps circuit

This section gives the different hydraulic circuits of the cooling pumps, to which the disassembly and assembly instructions of the general
cleaning procedure refer.

• ▶ Obey the sequence that follows.

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Leak oil circuit

Figure 1. Leak oil lines of fan motors

3 Hydraulic tank 10 Hydraulic hose

4 Oil cooler box 11 Hydraulic hose
6 Hydraulic pipe 12 Hydraulic hose
7 Hydraulic hose MF1 Water fan motor
8 Hydraulic hose MF2 Oil fan motor
9 Hydraulic pipe

Figure 2. Leak oil hose of cooling pumps

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13 Hydraulic hose P6.1Engine cooling pump

dRefer to section "Leak oil circuit of working pumps" P6.2Oil cooling pump
CP3Collecting pipe

• ▶ Refer to section "Leak oil circuit of working pumps" to drain the leak oil circuit.

• ▶ Disconnect, drain and clean all the hydraulic hoses.

• ▶ Open, drain and clean the collecting pipe CP3.

• ▶ Move to next section about the working pressure circuit.

Working pressure circuit

Figure 3. Working pressure lines of fan motors

6 Hydraulic hose 12 Hydraulic hose

7 Hydraulic pipe MF1 Water fan motor
8 Hydraulic hose MF2 Oil fan motor
9 Hydraulic pipe P6.1 Engine cooling pump
10 Hydraulic pipe P6.2 Oil cooling pump
11 Hydraulic hose

• ▶ Disconnect, drain and clean all the hydraulic hoses and pipes.

• ▶ Move to next section about the oil intake circuit.

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Oil intake circuit

Figure 4. Intake line of cooling pumps

6 Hydraulic hose P6.1 Engine cooling pump

a Refer to section "Oil intake circuit" of the working pumps P6.2 Oil cooling pump
SP1Intake pipe

• ▶ Disconnect, drain and clean the hydraulic hose 6 and the intake pipe SP1.

• ▶ Move to next section about the return oil circuit.

Return oil circuit

Figure 5. Return oil lines of fans motors

3 Hydraulic tank 10 Hydraulic hose

4 Oil cooler box 11 Hydraulic hose
6 Hydraulic hose 12 Hydraulic hose
7 Hydraulic hose CP2 Control valve collecting pipe
8 Hydraulic pipe MF1 Water fan motor
9 Hydraulic hose MF2 Oil fan motor

• ▶ Disconnect, drain and clean all the hydraulic hoses and pipes.

• ▶ Open, drain and clean the collecting pipe CP2.

• ▶ Clean the hydraulic tank as given in the dedicated following section.

• ▶ Complete the general cleaning procedure and do the procedure "Restart the ma­chine" before you put the machine in operation.

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From: Operator's manual R 9200 - 410 > Appendix > Cleaning procedure for hydraulic circuits

7.3.7 | Travel motors circuit

This section gives the different hydraulic circuits of the travel motors, to which the disassembly and assembly instructions of the general
cleaning procedure refer.

• ▶ Obey the sequence that follows.

Leak oil circuit

Figure 1. Leak oil circuit of travel motors

6 Hydraulic hose GTL Left travel gear

7 Hydraulic hose GTR Right travel gear
8 Hydraulic hose MTL Left travel motor
9 Hydraulic hose MTR Right travel motor
a Refer to section "Leak oil hoses of swing motors" RC Rotary connection
UBV Overspeed shutoff valve

• ▶ Refer to section "Leak oil hoses of swing motors" to drain the leak oil circuit.

• ▶ Disconnect, drain and clean all the hydraulic hoses.

• ▶ Move to next section about the working pressure circuit.

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Working pressure circuit

Figure 2. Working pressure circuit on the undercarriage

6 Hydraulic hose 19Hydraulic hose

7Hydraulic hose 20Hydraulic hose
8Hydraulic hose 21Hydraulic hose
9Hydraulic hose 22Hydraulic hose
10Hydraulic hose 23Hydraulic hose
11Hydraulic hose FBVLLeft travel brake valve
12Hydraulic hose FBVRRight travel brake valve
13Hydraulic hose GTLLeft travel gear
14Hydraulic hose GTRRight travel gear
15Hydraulic hose MTLLeft travel motor
16Hydraulic hose MTRRight travel motor
17Hydraulic hose RCRotary connection
18Hydraulic hose

• ▶ Disconnect, drain and clean all the hydraulic hoses.

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Figure 3. Working pressure circuit on the uppercarriage

24 Hydraulic hose 28Hydraulic hose

25Hydraulic hose RCRotary connection
26Hydraulic hose VB1Valve block 1
27Hydraulic hose VB2Valve block 2

• ▶ Disconnect, drain and clean all the hydraulic hoses.

• ▶ Move to next section about the overspeed pressure circuit.

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Overspeed pressure circuit

Figure 4. Overspeed pressure circuit on the undercarriage

6 Hydraulic hose GTL Left travel gear

7 Hydraulic hose GTR Right travel gear
8 Hydraulic hose MTL Left travel motor
9 Hydraulic hose MTR Right travel motor
10 Hydraulic hose RC Rotary connection
UBVOverspeed shutoff valve

• ▶ Disconnect, drain and clean all the hydraulic hoses.

Figure 5. Overspeed pressure circuit on the uppercarriage

11 Hydraulic hose PRV1 Pressure reducing valve

12 Hydraulic hose to collecting pipe CP3 , refer to section "Leak oil circuit of working pumps" RC Rotary connection
13 Hydraulic hose RC-ADD Additional rotary connection
SU1 Servo oil unit

• ▶ Disconnect, drain and clean all the hydraulic hoses.

• ▶ Clean the hydraulic tank as given in the dedicated following section.

• ▶ Complete the general cleaning procedure and do the procedure "Restart the ma­chine" before you put the machine in operation.

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From: Operator's manual R 9200 - 410 > Appendix > Cleaning procedure for hydraulic circuits

7.3.8 | Backhoe cylinders lines

This section gives the different hydraulic circuits of the backhoe cylinders lines, to which the disassembly and assembly instructions of
the general cleaning procedure refer.

• ▶ Obey the sequence that follows.

Circuit of bucket tilt cylinders

Figure 1. Hydraulic lines on the uppercarriage

1 Hydraulic hose 7 Hydraulic pipe

2 Hydraulic hose 8 Hydraulic pipe
3 Hydraulic hose 9 Hydraulic hose
4 Hydraulic hose 10 Hydraulic hose
5 Hydraulic pipe VB1 Valve block 1
6 Hydraulic pipe VB2 Valve block 2

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Figure 2. Hydraulic lines on the attachment

11 Hydraulic lines installed on the boom

12 Hydraulic lines installed on the stick and on the bucket cylinders

• ▶ Disconnect, drain and clean all the hydraulic hoses, pipes and distribution blocks.

• ▶ Complete the general cleaning procedure and do the procedure "Restart the ma­chine" before you put the machine in operation.

Stick cylinders circuit

Figure 3. Hydraulic lines on the uppercarriage

1 Hydraulic hose 8 Hydraulic hose

2 Hydraulic hose 9 Hydraulic hose
3 Hydraulic hose 10 Hydraulic pipe
4 Hydraulic hose 11 Hydraulic hose
5 Hydraulic pipe VB1 Valve block 1
6 Hydraulic pipe VB2 Valve block 2
7 Hydraulic hose

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Figure 4. Hydraulic lines on the boom

12 Hydraulic lines installed on the boom

13 Hydraulic pipe installed on the stick cylinders

• ▶ Disconnect, drain and clean all the hydraulic hoses, pipes and distribution blocks.

• ▶ Complete the general cleaning procedure and do the procedure "Restart the ma­chine" before you put the machine in operation.

Boom cylinders circuit

Figure 5. Hydraulic lines on the uppercarriage

1 Hydraulic hose 8 Hydraulic pipe

2 Hydraulic hose 9 Hydraulic hose
3 Hydraulic hose 10 Hydraulic pipe
4 Hydraulic hose 11 Hydraulic pipe
5 Hydraulic pipe 12 Hydraulic pipe
6 Hydraulic pipe VB1 Valve block 1
7 Hydraulic pipe VB2 Valve block 2

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Figure 6. Hydraulic lines on the boom

13 Hydraulic lines installed on the boom

14 Hydraulic pipe installed on the boom cylinders

• ▶ Disconnect, drain and clean all the hydraulic hoses, pipes and distribution blocks.

• ▶ Complete the general cleaning procedure and do the procedure "Restart the ma­chine" before you put the machine in operation.

From: Operator's manual R 9200 - 410 > Appendix > Cleaning procedure for hydraulic circuits

7.3.9 | Shovel cylinders lines

This section gives the different hydraulic circuits of the shovel cylinders lines, to which the disassembly and assembly instructions of the
general cleaning procedure refer.

• ▶ Obey the sequence that follows.

Circuit of shovel flap cylinders

Figure 1. Hydraulic lines on the uppercarriage

1 Hydraulic hose 4Hydraulic pipe

2Hydraulic hose VB1Valve block 1
3Hydraulic pipe VB2Valve block 2

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Figure 2. Hydraulic lines on the attachment

5 Hydraulic lines installed on the boom

6 Hydraulic lines installed on the crowd

Figure 3. Hydraulic lines on the bucket

7 Hydraulic lines installed on the shovel flap cylinders 10Hydraulic hose

8Hydraulic hose 11Hydraulic hose
9Hydraulic hose DBFDistribution block for flap cylin­ders

• ▶ Disconnect, drain and clean all the hydraulic hoses, pipes and the distribution block.

• ▶ Complete the general cleaning procedure and do the procedure "Restart the ma­chine" before you put the machine in operation.

Circuit of shovel tilt cylinders

For the hydraulic lines on the uppercarriage:

• ▶ Refer to the section "Circuit of bucket tilt cylinders" of the machine with backhoe attachment.

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Figure 4. Hydraulic lines on the attachment

1 Hydraulic lines installed on the boom

2 Hydraulic lines installed on the crowd and on the shovel tilt cylinders

• ▶ Disconnect, drain and clean all the hydraulic hoses, pipes and distribution blocks.

• ▶ Complete the general cleaning procedure and do the procedure "Restart the ma­chine" before you put the machine in operation.

Crowd cylinder circuit

For the hydraulic lines on the uppercarriage:

• ▶ Refer to the section "Stick cylinders circuit" of the machine with backhoe attach­ment.

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Figure 5. Hydraulic lines on the boom

1 Hydraulic lines installed on the boom

• ▶ Disconnect, drain and clean all the hydraulic hoses and pipes.

• ▶ Complete the general cleaning procedure and do the procedure "Restart the ma­chine" before you put the machine in operation.

Boom cylinders circuit

For the hydraulic lines on the uppercarriage:

• ▶ Refer to the section "Boom cylinders circuit" of the machine with backhoe attach­ment.

Figure 6. Hydraulic lines on the boom

1 Hydraulic lines installed on the boom

2 Hydraulic pipe installed on the boom cylinders

• ▶ Disconnect, drain and clean all the hydraulic hoses, pipes and distribution blocks.

• ▶ Complete the general cleaning procedure and do the procedure "Restart the ma­chine" before you put the machine in operation.

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From: Operator's manual R 9200 - 410 > Appendix > Cleaning procedure for hydraulic circuits

7.3.10 | Clean the hydraulic tank

NOTE!
Depending on the machines, the hydraulic tank can be different!
The oil inlet compartments of the hydraulic tank can have lateral drain plugs.

• ▶ Refer to the section "Hydraulic system" of this manual to check the configuration of your hydraulic tank and obey the
following procedure that is applicable to.

Clean the hydraulic tank with lateral drain plugs

• ▶ Make sure that you have an applicable container to let the used oil flow into.

• ▶ Remove the drain plug of the leak oil circuit as given in the dedicated section of this cleaning procedure for the hydraulic circuits.

• ▶ Remove the lateral drain plugs.

• ▶ Clean the top surface of the hydraulic tank.

• ▶ Remove the covers of the hydraulic tank filters.

CAUTION!
Contamination!
Risk of damage to the hydraulic system.

• ▶ To prevent that contaminated oil goes into the hydraulic tank, do not remove the filter elements and the filter
housings at this step.

• ▶ Remove the magnetic rods as given in the dedicated section of this manual, but do not remove the filter elements.

• ▶ Flush the oil inlet compartments with an applicable tool. We recommend that you use hydraulic oil to do this task.

CAUTION!
Contamination!
Risk of damage to the hydraulic system.

• ▶ Make sure that dirt or unwanted material, which possibly stays in the oil inlet compartments, does not go into the
hydraulic tank.
• ▶ If you use cleaning cloths, make sure that there is no lint.

• ▶ Remove the filter elements as given in the dedicated section of this manual.

• ▶ Remove the filters housings.

• ▶ Put an applicable protection on the openings.

• ▶ Carefully clean the inner surfaces of the oil inlet compartments.

• ▶ Carefully clean the filters housings and the magnetic rods.

• ▶ Install the filter housings again.

• ▶ Install the lateral drain plugs and the drain plug of the leak oil circuit again.

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Clean the hydraulic tank without lateral drain plugs

• ▶ Make sure that you have an applicable container to let the used oil flow into.

• ▶ Remove the drain plug of the leak oil circuit as given in the dedicated section of this cleaning procedure for the hydraulic circuits.

• ▶ Clean the top surface of the hydraulic tank.

• ▶ Drain the hydraulic tank, as given in the dedicated section of this manual.

• ▶ Remove the covers of the hydraulic tank filters.

CAUTION!
Contamination!
Risk of damage to the hydraulic system.

• ▶ To prevent that contaminated oil goes into the hydraulic tank, do not remove the filter elements and the filter
housings at this step.

• ▶ Remove the magnetic rods as given in the dedicated section of this manual, but do not remove the filter elements.

• ▶ Remove the oil from the oil inlet compartments.

• ▶ Flush the oil inlet compartments with an applicable tool. We recommend that you use hydraulic oil to do this task.

CAUTION!
Contamination!
Risk of damage to the hydraulic system.

• ▶ Make sure that dirt or unwanted material, which possibly stays in the oil inlet compartments, does not go into the
hydraulic tank.
• ▶ If you use cleaning cloths, make sure that there is no lint.

• ▶ Remove the filter elements as given in the dedicated section of this manual.

• ▶ Remove the filters housings.

• ▶ Put an applicable protection on the openings.

• ▶ Carefully clean the inner surfaces of the oil inlet compartments.

• ▶ Carefully clean the inner surfaces of the hydraulic tank trough the lateral access covers.

• ▶ If necessary, flush the hydraulic tank with an applicable tool. We recommend that you use hydraulic oil to do this task.

• ▶ Install the lateral access covers again.

• ▶ Carefully clean the filters housings and the magnetic rods.

• ▶ Install the filter housings again.

• ▶ Install the drain plug of the leak oil circuit again.

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From: Operator's manual R 9200 - 410 > Appendix > Cleaning procedure for hydraulic circuits

7.3.11 | Restart the machine

You must do the procedures that follow before you restart the machine.

• ▶ Make sure that:

• All defective components are replaced or repaired.

• All unwanted material and/or particles are removed from the circuit parts.

• The hydraulic oil filters are replaced.

• All the parts you disconnected, drained and cleaned as given above are connect­ed back.

• ▶ Fill the hydraulic system again, as given in the dedicated section of this manual.

• ▶ Bleed the hydraulic pumps, as given in the dedicated section of this manual.

• ▶ Let the engine operate at the minimum speed during approximately 10 minutes. Do not operate attachment movements.

• ▶ Make sure that the monitoring display does not show errors symbols, as given in this manual.

• ▶ Operate the engine at nominal speed.

• ▶ Set the auto idle function to off as given in the dedicated section of this manual.

Figure 1. Solenoid valves on servo oil unit

SU1 Servo oil unit SU1.2Additional servo oil unit (if installed)
SU1.1Additional servo oil unit (if installed) YR3_xSolenoid valves

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Servo oil unit SU1 is installed in the pumps box. Depending on the machines, there can be also additional servo oil units SU1.1 and
SU1.2.

• ▶ Disconnect the solenoid valves YR3_x.

• ▶ Do not move the operating and control elements (joystick and pedals) during ap­proximately 5 minutes.

• ▶ Connect the solenoid valves YR3_x again.

• ▶ Set the auto idle function to on again.

• ▶ Slowly operate all movements that follow. Do not reach the end position of the piston rods (be careful with the Diesel effect, you can
also refer to the Operating Manual)

• Lift up the attachment.

• Operate each cylinder of the attachment in order below and repeat 10 times be­fore moving to next cylinders:

◦ shovel flap cylinders (in case of shovel attachment)

◦ bucket tilt cylinders

◦ stick cylinders

◦ boom cylinders

• Swing clockwise and counterclockwise on approximately 1/2 turn. Repeat 4 times in each direction.

• ▶ Make sure again that no error symbols are shown on the monitoring display (refer to the Operating Manual).

• ▶ Only for crawler excavators: start the travel hydraulic circuits forward and back­ward on approximately 10 meters. Repeat 4 times.

• ▶ Stop the engine. The attachment must stay on the ground.

• ▶ Release the pressure from the hydraulic system (refer to the Operating Manual).

• ▶ Check the return and leak oil filters with related magnetic rods and the high pres­sure filters.

• ▶ Check the machine for leaks.

The machine can now be operated.

From: Operator's manual R 9200 - 410 > Appendix > Cleaning procedure for hydraulic circuits

7.3.12 | Monitor the restarted machine

After you restart the machine, you must monitor the condition of the hydraulic oil fil­ters as an initial set-up of the machine.

• ▶ Clean magnetic rods of the leak oil filter daily during the first 250 hours.

• ▶ Clean magnetic rods of all return filters weekly during the first 250 hours.

You can also refer to the Operating Manual.

From: Operator's manual R 9200 - 410 > Appendix > Cleaning procedure for hydraulic circuits

7.4 | Centralized lubrication system

From: Operator's manual R 9200 - 410 > Appendix

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