Liebherr Lh120 C-1103 Excavator Operators Operating Manual by www.heydownloads.com

Operating manual Machine for Industrial Applications LH 120 C-1103 From serial number 49287

Document ID Order number: Issued: Version: Author:

ORIGINAL OPERATING MANUAL 11110170 2011-07-21 02 LHB / Technical Documentation Department

Product ID Manufacturer: Type: Type no.: Serial no. from:

Liebherr-Hydraulikbagger GmbH LH 120 C 1103 49287

Conformity:

Contact Address:

Liebherr-Hydraulikbagger GmbH Liebherrstraße 12 D – 88457 Kirchdorf/Iller

Machine data: Enter the following information on taking delivery. *You will find the information on the type plate of the machine. This will also be useful when you order spares.

* Vehicle ID number: WLHZ ..........................................................

* Year of construction: ............................. CE

Commissioning date:

LHB/11110170/02/2011-07-21/en

.................. / ................. / .................

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Fig. 1: Example of an EC Declaration of Conformity Applicable for countries in the European Economic Area (EEA): An EC Declaration of Conformity is supplied with the machine. Keep the EC Declaration of Conformity in a safe place.

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en copyright by

LH 120 C-1103 / 49287

Preface

This operating manual is intended for you as the machine operator or as a member of the maintenance personnel. It contains warnings, important information and tips for working with the machine. It simplifies the process of familiarisation and getting to know the machine, and helps to avoid faults caused by incorrect operation. Compliance with the operating manual increases the reliability and service life of the machine. The operating manual must be kept with the machine. Make sure that a copy is always kept close to hand at the workplace. Read the operating manual before initial commissioning and subsequently at regular intervals. Everyone who carries out work with or on the machine must be familiar with and use this operating manual. Examples of this work: â&#x20AC;&#x201C; Operation including setup and fitting attachments, elimination of faults, care, disposal of service products and consumables â&#x20AC;&#x201C; Maintenance including servicing, inspection and repair â&#x20AC;&#x201C; Transporting or loading the machine The owner is responsible for supplementing the operating manual with instructions based on existing national regulations on accident prevention and environmental protection. In addition to this operating manual and the regulations on accident prevention applicable in the user's country and at the place of use, it is also necessary to comply with the recognised technical rules on safety and technically proficient working. Some sections of this operating manual do not apply to all machines. Some illustrations in this operating manual may show details and implements that are different from your machine. In some illustrations, protective devices and covers have been removed to provide a clearer representation. Our machines are subject to continuous development and improvement. This may have resulted in modifications to your machine which are possibly not referred to in this operating manual. LHB/11110170/02/2011-07-21/en

If you require further explanations or information, please contact Liebherr customer service.

Liability and warranty Due to the wide variety of products offered by other manufacturers (e.g. service products, lubricants, tool attachments and spare parts), Liebherr cannot examine the general suitability and absence of defects in third-party products which are used in or on Liebherr products. The same applies to possible interactions between third-party products and Liebherr products. Third-party products are used in or on Liebherr machines at the user's own discretion. Liebherr does not offer any warranty or accept any liability for losses of any

LH 120 C-1103 / 49287

Preface

Operating manual kind caused by failures of or damage to Liebherr machines attributable to the use of third-party products. Furthermore, Liebherr will not recognise any warranty claims attributable to incorrect operation, inadequate maintenance or the failure to follow safety instructions.

Modifications, conditions, copyright We reserve the right to make modifications in the course of technical development, without issuing prior notification. Information and illustrations in these instructions are not allowed to be duplicated, distributed or used for the purposes of competing with Liebherr. All rights under copyright legislation are expressly reserved.

LHB/11110170/02/2011-07-21/en

The aforementioned provisions do not extend the warranty and liability conditions in the general terms and conditions of business of Liebherr.

LH 120 C-1103 / 49287

Reply form

We need your help to continually improve our documentation. Please copy this page and fax it or e-mail it to us with your comments, ideas and suggestions for improvement. To:

Fax: E-mail:

Liebherr-Hydraulikbagger GmbH Liebherr StraĂ&#x;e 12 D-88457 Kirchdorf 0043 50809 6 7708 info.lhb@liebherr.com Ideas, comments (please state the page number):

Overall, how would you judge this document? Excellent Very good Good Satisfactory Poor Your data:

Machine / serial number: Company: Last name:

LHB/11110170/02/2011-07-21/en

Address: Telephone number: Dealer: Thank you for your help.

LH 120 C-1103 / 49287

Reply form

Operating manual

LHB/11110170/02/2011-07-21/en

Notes:

LH 120 C-1103 / 49287

Contents

Product description

1.1

Technical description

1.1.1

1.2

LHB/11110170/02/2011-07-21/en

General overview

Technical data

1.2.1

Vibration emission

1.2.1

Operator seat

1.2.1

Hand/arm vibrations

1.2.1

Whole-body vibrations

1.2.2

Sound emissions

1.2.3

Specifications

Safety warnings, signs

2.1

Identification of the warning instructions

2.1.1

Other indications

2.1.2

Additional rules and guidelines

2.2

Designated use

2.3

Safety warnings

2.3.1

General safety instructions

2.3.2

Avoid crushing and burning injuries

2.3.3

Avoid fire and explosions

2.3.4

Seeing and being seen

2.3.5

Protection against vibration

2.3.6

Before taking into operation

2.3.7

Getting in and out

2.3.8

Starting the machine

2.3.9

Working

2.3.10 Transfer loading

2.3.11 Shutting down the machine

2.3.12 Maintenance, repair

LH 120 C-1103 / 49287

Contents

Operating manual

2.3.14 Removal and installation of attachment pins

2.3.15 Rock protection (FOPS)

2.3.16 Checking for cracks

2.3.17 Regular checks

Control and operation

3.1

Control and operating elements

3.1.1

Overview of operator's platform

3.1.2

Control unit A

3.1.3

Control unit B

3.1.4

Control unit C

3.1.5

Control unit D

3.2

Control

3.2.1

Battery main switch

3.2.2

Entering and exiting the machine

3.2.3

Emergency exit

3.2.4

Fire extinguisher

3.2.5

Safety lever

3.2.6

Operator seat

3.2.7

Instructor seat

3.2.8

Safety belt

3.2.9

Cab lift (special equipment)

3.2.10 Sun visor / sun blind

3.2.11 Side windows

3.2.12 Lighting

3.2.13 Cab lighting system

3.2.14 Windscreen wiper

3.2.14 Indicating unit

3.2.15 Touch screen

3.2.16 Quick access via the menu bar

3.2.17 Quick access via user-programmable keys

3.2.18 Status symbols

3.2.19 Neutral position

3.2.20 Main menu

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

2.3.13 Modifications, add-ons and conversions

Operating manual

Contents

3.3

LHB/11110170/02/2011-07-21/en

3.4

3.2.21 Camera system menu

3.2.22 Air conditioning system

3.2.23 Operating status menu

3.2.24 General settings menu

3.2.25 Device-specific settings menu

3.2.26 Information menu

100

3.2.27 Messages menu

103

3.2.28 Radio system (special equipment)

103

Operation

105

3.3.1

Inspection tour before commissioning

105

3.3.2

Refuelling

106

3.3.3

Refuelling from a tanker (special equipment)

107

3.3.4

Starting the engine

108

3.3.5

Starting process at low ambient temperatures

109

3.3.6

Operating mode and engine speed

110

3.3.7

After starting

111

3.3.8

Sensor-controlled low idle automatic

112

3.3.9

Shutting down the engine

112

3.3.10 Driving operation

113

3.3.11 Observe the inclination angle

116

3.3.12 Operating the working attachment

117

3.3.13 Turning and braking the uppercarriage

118

3.3.14 AutoLift (special equipment)

119

3.3.15 Overload warning device (special equipment)

119

3.3.16 Turning and moving the tool attachment

121

3.3.17 Magnet system (special equipment)

122

3.3.18 Reversible fan drive (special equipment)

123

General working methods

124

3.4.1

Safety belt

124

3.4.2

Drugs and alcohol misuse

124

3.4.3

Working without damaging the machine

124

3.4.4

Preparatory work

126

3.4.5

Working position

127

3.4.6

Working with the grapple

127

3.4.7

Transferring loads

128

LH 120 C-1103 / 49287

Operating manual

3.4.8

Loading a transport vehicle

128

3.4.9

Load-lifting work

128

3.5

Parking and exiting the machine

130

3.6

Transport and assembly

131

3.7

Emergency operation

132

3.7.1

Lowering the working attachment with the engine shut down

132

3.7.2

Operator's cab emergency discharge

133

Malfunctions

135

4.1

Service code tables

136

4.1.1

Warning symbols

136

Fault â&#x20AC;&#x201C; Cause â&#x20AC;&#x201C; Remedy

140

4.2.1

Diesel engine and fuel system

140

4.2.2

Hydraulic system

142

4.2.3

Travel gear

142

4.2.4

Electrical system

143

4.2.5

Heating, ventilation, air conditioning system

143

4.2.6

Working attachment

143

4.2

4.3

Problem remedy

145

4.3.1

145

Fuses and relays

Maintenance

147

5.1

Maintenance and inspection schedule

147

5.2

Filling quantities and lubrication chart

152

5.2.1

Recommended lubricants

152

5.2.2

Recommended service materials

152

5.2.3

Lubricating chart

153

5.3

Fuels, lubricants and operating fluids

154

5.3.1

General information

154

5.3.2

Diesel fuels

154

5.3.3

Lubricants for the diesel engine

155

5.3.4

Coolant for the diesel engine

157

5.3.5

Hydraulic oil

159

5.3.6

Lubricating oils for axles and gearboxes

165

5.3.7

Grease

167

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Contents

Operating manual

Contents

5.4

5.5

5.6

5.7

5.8

5.9

5.3.8

Screenwash

167

5.3.9

Lubricant and care product for electrical and mechanical systems

168

Access points for maintenance work

169

5.4.1

Access points to the uppercarriage

169

5.4.2

Access points on the underside of the uppercarriage

169

5.4.3

Access points to tracked travel gear

170

Cleaning and care

171

5.5.1

Cleaning the machine

171

5.5.2

Clean the tracked travel gear, remove blocks

172

5.5.3

Door locks and hinges

172

5.5.4

Rubber seals

172

5.5.5

Applying corrosion protection to piston rods

172

Diesel engine

174

5.6.1

174

Checking the oil level

Cooling system

175

5.7.1

Checking the coolant level

175

5.7.2

Antifreeze and corrosion protection of the coolant

175

Fuel system

176

5.8.1

Draining water from the fuel pre-filter

176

5.8.2

Draining water and sediments in the fuel tank

177

Air filter

178

5.9.1

Renewing air filters

178

5.9.2

Emptying the dust collecting tank

179

5.9.3

Checking the clean-air line

180

LHB/11110170/02/2011-07-21/en

5.10 Hydraulic components

181

5.10.1 Checking the oil level in the hydraulic tank

181

5.10.2 Reducing the pressure in the hydraulic system

182

5.10.3 Renewing the breather filter

183

5.10.4 Renewing the control oil filter

183

5.10.5 Renewing the return filter

185

5.10.6 Renewing the return leakage oil filter

187

5.10.7 Changing / topping up hydraulic oil

188

5.10.8 Bleeding the hydraulic pumps

190

5.11 Crawler drive

192

5.11.1 Checking the mounting of the travel gear components

192

LH 120 C-1103 / 49287

Contents

Operating manual

5.11.2 Checking the track tension

193

5.11.3 Tightening the track

194

5.11.4 Slackening the track

195

5.11.5 Changing the oil

196

5.12 Electrical system

197

5.12.1 Battery care

197

5.13 Windscreen washer system

199

5.13.1 Screenwash container 5.14 Automatic lubrication system 5.14.1 Topping up the grease container 5.15 Working attachment and working tools 5.15.1 Renewing the teeth of the digging tools

199 200 200 201 201 203

5.16.1 Welding

203

LHB/11110170/02/2011-07-21/en

5.16 Overall machine

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

1 Product description

LH 120 C-1103 / 49287

Product description

Operating manual

Technical description

1.1 Technical description

Fig. 2: Overview LH120 1 2 3 4 5

Upper carriage Under carriage Travel drive Steps to upper carriage Steps to under carriage

6 7 8 9 10

Travel gear left Hoist cylinder Travel gear right Grapple Industrial stick

11 12 13

Stick cylinder Industrial boom Operator's cab

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

1.1.1 General overview

Operating manual

Product description Technical description

Fig. 3: Overview LH120 High Rise Upper carriage Under carriage Travel drive Steps to upper carriage Steps to under carriage

6 7 8 9 10

Tower superstructure Travel gear left Hoist cylinder Travel gear right Grapple

11 12 13 14

Industrial stick Stick cylinder Industrial boom Operator's cab

LHB/11110170/02/2011-07-21/en

1 2 3 4 5

LH 120 C-1103 / 49287

Product description

Operating manual

Technical description

1 2 3 4 5

Uppercarriage Undercarriage Travel drive Access to uppercarriage Column

6 7 8 9 10

Left travel gear Operator's cab with cab lift Right travel gear Grapple Industrial stick

11 12 13

Stick cylinder Industrial boom Hoist cylinder

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Fig. 4: General overview of LH120 Gantry

Operating manual

Product description Technical data

1.2 Technical data 1.2.1 Vibration emission 1.2.1 Operator seat The operator seat installed in this machine by the manufacturer complies with ISO 7096:2000, EM 6. If the operator seat is replaced, the new operator seat must also comply with this standard.

1.2.1 Hand/arm vibrations Given designated use of the machine, the weighted (frequency-weighted) rootmean-square value of the hand/arm vibrations acc. to ISO 5349- 1:2001 is less than 2.5 m/sÂ˛.

1.2.1 Whole-body vibrations If the machine is used as designated, weighted (frequency-weighted) root-meansquare values for specific sample applications of the machine can result according to the table below. These values correspond to the information contained in the technical report ISO/TR 25398:2006 "Earth-moving machinery â&#x20AC;&#x201C; Guidelines for assessment of exposure to whole-body vibration of ride-on machines â&#x20AC;&#x201C; Use of harmonised data measured by international institutes, organisations and manufacturers". The measurement procedure used in this case is in accordance with ISO 2631-1:1997. The listed root-mean-square values of representative machines are specified with deviations (standard deviation). These deviations are divided into light, normal and heavy-duty operating conditions. The subdivision of operating conditions must be undertaken by the user in accordance with the aspects of terrain conditions, construction site status, construction site organisation, material, machine equipment, working method and the training level of the operator. The specified values are individual root-mean-square values for certain typical application areas, therefore it is only possible to assess the load imposed on the operator by whole-body vibrations to a limited extent. In order to accurately assess the daily exposure of an operator in the course of an 8-hour working day, please refer to the Liebherr brochure concerning whole-body vibrations as well as the software that has been written for this purpose. Both these resources can be obtained from your Liebherr dealership or found on the documentation CD that is supplied with each new machine (Liebherr Parts). LHB/11110170/02/2011-07-21/en

The measuring inaccuracy is defined in the EN 12096:1997 standard.

LH 120 C-1103 / 49287

Product description

Operating manual

Technical data

Machine type

Crawler excavator

Wheeled excavator

Typical working cycles

Weighted root-mean-square values in m/sÂ˛ under light, normal and heavy-duty operating conditions X-axis

Y-axis

Z-axis

Light Normal Hea vy

Excavating

0.14

0.31

0.49 0.08

0.19

0.31 0.13

0.30

0.47

with hydraulic hammer

0.16

0.38

0.59 0.09

0.22

0.35 0.27

0.55

0.83

Use in extraction

0.31

0.46

0.61 0.19

0.30

0.41 0.29

0.61

0.93

Delivery drive

0.21

0.34

0.48 0.09

0.23

0.37 0.56

0.79

1.02

Excavating

0.19

0.37

0.56 0.09

0.25

0.41 0.16

0.29

0.42

Delivery drive

0.21

0.29

0.38 0.24

0.38

0.52 0.42

0.61

0.80

Tab. 1: Weighted root-mean-square values

1.2.2 Sound emissions The sound values of the machine are specified in the technical data. The sound pressure level (LWA) is measured according to Directive 2000/14/EC. The measuring inaccuracy of the value for the sound pressure level corresponds to the difference between the guaranteed and the measured values. The sound pressure level (LpA) is measured according to ISO 6396. The measuring inaccuracy is defined in this standard.

1.2.3 Specifications Machine without tower superstructure Total weight, depending on equipmentA)

130 - 140

Total lengthB)

9250

Total width, with track pads 750 mm or 1000 mm

6180 / 6430

Total heightB)

7290

Ground pressure

on request

Total weight, depending on equipmentA)

136 - 146

Total lengthB)

9250

Total width, with track pads 750 mm or 1000 mm

7310 / 7310

Total heightB)

9290

Ground pressure

on request degrees

2.5 / 5

Total weight, depending on equipmentA)

156 - 166

Total lengthB)

9250

Maximum slope angle (working / driving)C) Machine with gantry undercarriage (4.7 m passage height)

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Machine with tower superstructure 2 m

Operating manual

Product description Technical data

Total width, with track pads 750 mm or 1000 mm

7904 / 8154

Total heightB)

12401

Ground pressure

on request degrees

2.5 / 5

Total weight, depending on equipmentA)

159 - 169

Total lengthB)

9250

Total width, with track pads 750 mm or 1000 mm

7904 / 8154

Total heightB)

13201

Maximum slope angle (working / driving)C) Machine with gantry undercarriage (5.5 m passage height)

Ground pressure

on request degrees

Maximum slope angle (working / driving)C)

2.5 / 5

Diesel engine D 9508 Cylinders

Displacement

16.16

Power at rated speed acc. to DIN ISO 9249

kW (h.p.)

400 (543)

Rated speed

rpm-1

1800

Maximum torque

2400

Maximum operating pressure

bar

350

Maximum flow

l/min

4 x 309 l

Hydraulic system

Tab. 2: Specifications A) B) C)

Additional weight with track pads 1000 mm: 3.5 t Basic machine without working attachment, with rigid cab superstructure 2500 mm on weight-bearing ground

LHB/11110170/02/2011-07-21/en

See Maintenance chapter for capacities.

LH 120 C-1103 / 49287

Product description

Operating manual

LHB/11110170/02/2011-07-21/en

Technical data

LH 120 C-1103 / 49287

2 Safety warnings, signs

Working with the machine represents a risk of serious or fatal injury, which you as the owner, machine operator or a member of the maintenance personnel can counteract. You can avoid dangers and accidents by reading the various safety instructions attentively on a regular basis, and by following them at all times. This applies in particular to personnel who only work on the machine occasionally, e.g. for setup or maintenance work. The safety instructions are listed below. If you comply with these instructions conscientiously, you can be sure to safeguard your own safety and the safety of other people, and you will avoid causing damage to the machine. The descriptions of work in this publication describe the necessary safety precautions which must be taken to prevent people and the machine from being exposed to hazards.

2.1 Identification of the warning instructions This is the warning symbol. It warns you against a possible risk of injury. Follow all the measures that are identified by this warning symbol in order to avoid serious or fatal injuries. Tab. 3

LHB/11110170/02/2011-07-21/en

The warning symbol always appears in conjunction with the following signal words: DANGER WARNING CAUTION DANGER

This identifies a situation of immediate danger which will result in serious or fatal injury if the situation is not avoided.

WARNING

This identifies a dangerous situation which could result in serious or fatal injury if the situation is not avoided.

CAUTION

This identifies a dangerous situation which could result in slight or moderate injury if the situation is not avoided.

CAUTION

This identifies a dangerous situation which could result in damage to property if the situation is not avoided.

Tab. 4

LH 120 C-1103 / 49287

Safety warnings, signs

Operating manual

Safety warnings

2.1.1 Other indications Note

This identifies useful information and tips.

Tab. 5

2.1.2 Additional rules and guidelines Following these notes does not invalidate the requirement to comply with additional rules and guidelines! Additionally, it is necessary to comply with: – The safety rules applicable in the place of use – Statutory “rules of the road” – Directives issued by employers' professional liability insurers

2.2 Designated use The hydraulic excavator is a machine with a working implement (e.g. grapple) for loosening, picking up, transporting and dumping soil, stones and other materials in which the load is transported without displacement of the machine. Machines for load-lifting work are subjected to particular conditions and must be provided with the prescribed safety devices (see "Load-lifting work" section). Special applications such as demolition work or loading/unloading operations require special equipment and possibly special safety devices. This equipment is only allowed to be mounted and used with the approval of and in accordance with the conditions of the manufacturer of the basic machine. Any other use or use beyond what is defined here shall be regarded as not in accordance with the designated use. Use not in accordance with the designated use includes e.g. transporting people, moving the machine with a suspended load or working in a potentially explosive atmosphere or a contaminated area. Compliance with the operating manual as well as the inspection and maintenance manuals also forms part of the designated use. The manufacturer is not liable for damage attributable to use not in accordance with the designated use. The user bears sole responsibility.

LHB/11110170/02/2011-07-21/en

2.3 Safety warnings 2.3.1 General safety instructions Qualification of the operating personnel Only expressly authorised and trained people are allowed to operate, maintain or repair the machine. The statutory minimum age shall be complied with.

LH 120 C-1103 / 49287

Operating manual

Safety warnings, signs Safety warnings

Training of the personnel should include theoretical information about technology and safety as well as practical training on the machine. It is essential to ensure that the operating personnel have read and understood the operating manual and any other additional instructions for special equipment which may be provided. Personnel who are undergoing training or instruction or are taking part in a general apprenticeship are only allowed to work on the machine if permanently supervised by an experienced person. The owner must check regularly that the personnel are working safely, with awareness of the potential dangers and in accordance with the operating manual. The responsibility of the personnel for operation or setup, maintenance and repair must be clearly defined.

Personal protective equipment Wear safe working clothes when you are working on or with the machine. For certain work, it is mandatory to wear safety glasses, safety boots, a protective helmet, working gloves, a high-visibility tabard, ear defenders and additional protective equipment. Avoid wearing rings, wristwatches, ties, scarves, open jackets and loose-fitting clothing. Risk of injury, e.g. by getting snagged or pulled in.

Safety instructions at the place of use Find out from the construction site manager whether there are special safety instructions applicable on the construction site, and comply with them. Do not work in any way which represents a safety risk. Refuse to comply with instructions from third parties which contravene safety instructions. This also applies with regard to the rules of the road.

2.3.2 Avoid crushing and burning injuries Do not work under the machine unless it has been parked securely and is protected against rolling and driving away. During all work on access doors, insert the securing devices provided to prevent inadvertent closing. Do not use any damaged lifting tackle such as cables or chains, or lifting tackle that does not have an adequate load-carrying capacity. Wear working gloves when handling wire ropes. LHB/11110170/02/2011-07-21/en

When working on connecting parts, never use your fingers to line up the bores. Use a suitable pin in order to achieve alignment. Make sure not to put your hands or other objects within reach of the fan when the diesel engine is running. The fan can cause serious injuries. Objects can be flung out or irreparably damaged. The fan can be damaged by objects. Shut down the engine before you perform care jobs, maintenance or repairs on the machine. Work on the engine at operating temperature can result in scalds or burns due to hot coolant or oil. Avoid touching hot coolant, oil or parts that carry fluids. During operation, the engine and hydraulic oil will be hot and under pressure.

LH 120 C-1103 / 49287

Safety warnings, signs

Operating manual

Safety warnings

Do not check the coolant level until the sealing cap of the expansion tank has cooled down to such an extent that it is possible to touch it safely. Then turn the cap carefully in order to allow excess pressure to escape.

2.3.3 Avoid fire and explosions Fire extinguisher Familiarise yourself with the attachment points and operation of fire extinguishers on the machine as well as with the fire alarm and fire-fighting possibilities on site. The source of a fire can only be extinguished if it is accessible. Before starting, close all locks for the covers on the machine. In case of a fire, the covers can be opened immediately and the fire extinguished.

Electrical system Regularly check the electrical system and have all faults repaired without delay. Examples: – Loose connections – Blown fuses – Defective bulbs – Charred or chafed cables When charging batteries, do not smoke or use naked flames. Wear safety glasses and protective gloves when you are working on the battery.

Diesel engine Do not use any ether starting aids to start diesel engines with a pre-heat system or flame glow unit. Always start the diesel engine as described in the operating manual.

Refuelling Prior to refuelling, shut down the diesel engine and switch off the auxiliary heater (special equipment). When refuelling, do not smoke or use naked flames.

Refuelling with the wrong fuel will result in damage to the fuel system and engine. Do not start the engine if the wrong fuel has been filled by mistake. The tank and the fuel lines will then have to be drained. Notify a qualified specialist workshop. Have the tank and the fuel lines drained fully.

Flammable liquids Do not carry any flammable liquids on the machine, except for in the tanks intended for such. Oil spraying out of leaks can easily cause fires. Regularly check all lines, hoses and fittings for leaks and damage. Have all leaks repaired immediately, and renew the damaged components.

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Avoid contact with fuels. Contact with the skin or inhalation of vapours can result in impairments to health.

Operating manual

Safety warnings, signs Safety warnings

Protection against heat Make sure that all holders and protective shields have been installed correctly and are protected against vibration, chafing and heat buildup.

2.3.4 Seeing and being seen Field of view As the machine operator, you perceive most of the information for your work visually. You can only minimise possible dangers for yourself and others providing you have adequate visibility whilst you are driving and working. A line of sight is not available to all areas in the surroundings, therefore viewing devices (e.g. mirrors and cameras) have been fitted on the machine. These viewing devices must be used for the areas around the machine that cannot be seen directly. WARNING Some add-ons and attachments can restrict the machine operator's visibility! Danger of accidents! u Be careful when the field of view is restricted and watch out for blind spots. u Work with a spotter, if necessary. Comply with national regulations regarding visibility in the operator's cab. The standard ISO 5006:2006 prescribes measuring and assessment methods for the machine operator's field of view. The field of view is tested with standard equipment in this case. Modifications to the machine such as adding or converting components are not allowed to impair the field of view. If modifications do impair the field of view, it is necessary to carry out a test acc. to ISO 5006:2006 or the regulations applicable at the place of use. Corresponding measures must be taken, depending on the test result. The machine operator must be informed of the modifications.

Measures before and during operation Make sure that people contact the machine operator before approaching the machine. 2. Check the viewing devices are functioning, clean and set correctly. 3. Set the viewing devices so that the best possible all-round visibility is guaranteed. 4. Clean the viewing devices and the windows of the operator's cab immediately if dirt impairs visibility. 5. Immediately repair defective viewing devices or have them replaced. 6. Do not use sun visors if they impair visibility. 7. Observe the surrounding area at all times in order to detect potential dangers in good time. 8. Avoid reversing if possible. 9. Obtain a direct line of sight if possible: plan the work so that visibility of the working area will not be impaired by obstacles. 10. Always work with a spotter if undertaking activities involving restricted visibility or if the viewing devices are defective. Agree on hand signals, and additionally establish voice contact for difficult tasks (e.g. via radio). 11. Use illumination in conditions of poor visibility, and in accordance with the applicable regulations.

LHB/11110170/02/2011-07-21/en

LH 120 C-1103 / 49287

Safety warnings, signs

Operating manual

Safety warnings

2.3.5 Protection against vibration The dynamic load in mobile construction machines is chiefly a result of the way they are used. The following parameters have a major influence: – Ground conditions: rough surface and potholes – Operating techniques: speed, steering, braking, controlling the control elements of the machine when driving and when working To a great extent, the machine operator determines the current dynamic loads because it is the operator who selects the speed, the gear ratio, the working method and the route taken. As a result, there is a wide range of different dynamic loads for the same machine type. The body vibration load on the machine operator can be reduced if the following recommendations are complied with: – Select the appropriate machine, attachment components and additional devices for the particular job. – Keep the seat in good repair and adjust it as follows: the setting for the seat and its shock absorption should be selected according to the weight and size of the operator. Regularly check the shock absorption and adjusting mechanisms of the seat and make sure that these properties of the seat are retained according to the specifications of the seat manufacturer. Check how well the machine has been maintained, in particular the tyre pressure, brakes, steering, mechanical connections, etc. Do not perform any of the following activities suddenly: steering, braking, accelerating and changing gear; also moving and loading the working attachments of the machine. Adjust the speed of the machine to the route taken in order to reduce the vibration load. – Cut your speed when you are travelling over rough ground. – Travel around obstacles and avoid extremely rough terrain. Make sure the properties of the site where the machine is working and travelling are kept in a good condition: – Remove large stones and obstacles. – Fill in channels and holes. – Keep machines ready for establishing and maintaining suitable ground conditions, and calculate sufficient time for this. Travel longer distances (e.g. on public roads) at an appropriate (moderate) speed. If machines are frequently used for travelling, you might consider using special auxiliary systems for travelling, and regulate your speed in order to avoid the machine "swaying".

Always carry out a thorough inspection tour all round the machine before taking it into operation. Check that all warning signs are in place and are legible. Check the machine for leaks of fuel, coolant, hydraulic oil and gear oil. Check the machine is functioning correctly. Notify your manager immediately if you notice any defects. Have the defects repaired without delay. When there is a change of personnel, make sure that the subsequent user of the machine is also informed. Do not take the machine into operation if it is damaged.

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

2.3.6 Before taking into operation

Operating manual

Safety warnings, signs Safety warnings

Adjust the operator seat, the mirrors and other viewing devices. Put on the safety belt. Keep the operator's cab free from objects that you do not need during work with the machine. Stow away and secure all other objects before starting. Make sure that all caps, covers and doors are closed but that the locks are not activated. Secure the doors and windows against inadvertent movements. Check whether there is anyone close to the machine. Ask these people to move away from the machine, if necessary.

2.3.7 Getting in and out Avoid any risk of accidents posed by muddy paths, ice, snow, traffic on the access ways and constrained space in the parking area. The uppercarriage must be positioned in relation to the undercarriage so that the steps and ladders are in line with one another. Keep steps, ladders, anti-slip mats, hand rails and handles free from dirt, oil, ice and snow and check regularly that they are in perfect condition. Have defective parts renewed without delay. Clean mud, grease, ice and snow off your shoes and any equipment used for climbing before you step onto the machine. Use gloves to provide you with a secure hold. Climbing on and off using tyres, wheel hubs, rims or caterpillar tracks is prohibited. Remember that external influences (e.g. wind) can make it difficult to open and close the door. Therefore, always guide the door with your hand. Make sure that the opened or closed door has engaged correctly. Machine with operator's cab elevation: You may have to climb up a little before you reach the door. When you can reach the door with your free hand, first open the door before climbing up any further. When climbing up or down, face the machine and always use the three-point support (always two hands and one foot or two feet and one hand are in contact with the access system). Do not hold the steering column or the operating levers when climbing in and out. This can result in inadvertent movements of the machine and lead to accidents. Never leave the operator seat while the machine is still moving. Never jump down from the machine. Instead, use the steps, ladders, hand rails and handles provided for climbing in and out. LHB/11110170/02/2011-07-21/en

Familiarise yourself with the emergency exit.

2.3.8 Starting the machine Move all control elements to their neutral position and move the safety lever upwards. Only start the machine from the operator seat. Check the indications as well as the warning and indicator lights before and after starting the engine. Make sure the engine is running at a smooth low idle, pay attention to unusual smoke and noise from fans, the diesel engine and hydraulic system.

LH 120 C-1103 / 49287

Safety warnings, signs

Operating manual

Safety warnings

Do not run the diesel engine in enclosed rooms unless there is adequate ventilation. If necessary, open the doors and windows of the building in order to ensure an adequate fresh-air supply. Bring the diesel engine and the hydraulic oil to operating temperature. Low oil temperatures have the effect of the control system operating sluggishly. Carefully drive the machine onto open ground and check all operating functions. Check the brakes and the steering system. Make sure that all functions are working correctly before you start work.

2.3.9 Working Before starting work, familiarise yourself with the special features of the construction site and the locally applicable regulations. These include: obstacles in the working and travel area, load-bearing capacity of the ground and necessary protection for people and machinery against public roadways. Before starting work, check whether there are any special hazards which require particular precautionary measures to be taken, e.g. toxic, explosive gases, bad condition of driveways, unstable ground. Take suitable measures to ensure safe operation. Convince yourself that no-one is in the working area before you set the machine in motion. Only work when sitting down, and with the safety belt fastened. Never leave the machine unsupervised with the engine running. Use the machine in such a way that its stability is assured. Do not exceed the permissible load lift. The figures in this operating manual relate to level ground with a sufficient load-bearing capacity. Pay attention to influences due to different operating conditions, e.g. application on soft or uneven ground, on a slope or if loads could slip. Find out what is the size of the loads to be lifted and consider what effects these loads could have on the stability of the machine. Position the uppercarriage parallel with the undercarriage when moving, and keep the load close to ground level. The maximum permissible incline and lateral slope that can be driven on depend on the attachments fitted and on the ground. Keep the machine sufficiently far from pits and bank edges to ensure that there is no risk of falling.

Familiarise yourself with the position of overhead electrical lines (high-voltage cables) and work with care in the vicinity of them. Maintain the required safety clearances from high voltage cables. In case of contact with a high voltage cable despite these precautions: – Do not move the machine or the working attachments. – Remain in the operator's cab. Touching the machine and the ground at the same time is fatal. – Make sure that other people stay away from the machine and the hanging cable. – Arrange for the electricity to be switched off. Adjust your travel speed to match local conditions. copyright by

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Familiarise yourself with the position of underground utility lines on the construction site before you start digging. Maintain the required safety clearances from these utility lines.

Operating manual

Safety warnings, signs Safety warnings

Avoid working movements which could result in the machine tipping over. When working on a slope, if at all possible make sure you are operating uphill or downhill rather than at a sideways angle to the slope. Do not exceed the permissible speed when travelling downhill, otherwise you could lose control of the machine. Shift to the lowest gear step in order to allow the engine braking effect to restrict the maximum speed. When loading a truck, insist that the truck driver leaves the truck cab, even if a protection device against falling objects is fitted. During demolition work, ground clearing, working with lifting tackle, etc., always use the protective devices appropriate for the specific application. Get a guide to assist you when working on ground with poor visibility and whenever such assistance is necessary. In this case, always arrange for only one person to give you instructions. Only entrust experienced persons with the job of attaching loads and guiding machine operators. The spotter must be in the field of view of the operator or have voice contact with the operator. The working attachment can cause serious or even fatal injuries. Never allow someone to remain in the danger zone. Never allow someone to guide the tool attachment with their hand. If a large or wide tool attachment is moved in the vicinity of the operator's cab, it can touch or penetrate the cab and thereby endanger the machine operator. Move the tool attachment at sufficient distance from the operator's cab. Depending on the equipment combination, there may be a risk of collision between the working tool and undercarriage, operator's cab, cab protection, hydraulic cylinders and other parts of the equipment. Take the greatest of care when a working tool is moved in the vicinity of the named components, in order to avoid damage.

2.3.10 Transfer loading Never exceed the maximum permitted load lift of the grapple. Ascertain the density and weight of the material to be transferred. Do not lift heavier loads than specified in the load lift chart. Due to its height, the machine has a relatively high centre of gravity. This affects the driving and working properties, and reduces the machine's dynamic stability. Due to the high centre of gravity, the machine must be aligned horizontally before the application. The best possible stability is achieved when in the horizontal position.

LHB/11110170/02/2011-07-21/en

The machine can rock and be made to tip, despite having been aligned! Therefore, the following procedures and precautionary measures are essential.

Driving Do not move the machine whilst suspending loads. Turn the uppercarriage so it is parallel with the undercarriage (transport position). Draw the attachment as close to the machine as possible. Only then are the outriggers allowed to be moved in and the machine moved. Ensure that the travel route leads over firm and even ground. Potholes and unevenness in the carriageway endanger the stability of the machine.

LH 120 C-1103 / 49287

Safety warnings, signs

Operating manual

Safety warnings

Adapt your driving style to the properties of the machine (high centre of gravity) and the ambient conditions. Reduce your travel speed so that sudden braking and steering manoeuvres can be avoided. Avoid sudden speed changes. Travel up or down slopes at right angles to the slope. Take particular care when driving through narrow passages. Travel slowly!

Transferring loads Before turning the uppercarriage out of the transport position, make sure to position the machine horizontally. If there are outriggers, use them for alignment. It is essential to check the support surface where the outriggers will be placed (load-bearing capacity of the ground). Sinking of the outriggers or the travel gear may have very serious consequences. Carry out all movements with extra care. In order to slew the machine when carrying a load, first make sure the attachment is positioned as low and as close to the machine as possible. Pay attention to the danger posed by a swinging grapple if loads are moved close to the operator's cab. Avoid abrupt braking or acceleration of the attachment and of the uppercarriage.

2.3.11 Shutting down the machine Park the machine on level and firm ground, and avoid parking it on a slope if at all possible. If the machine must be parked on a slope, secure it with wedges to prevent it from rolling away. Lower the working attachment so it is lying on the ground. Move all control elements to their neutral position. Apply the parking brake and slewing gear brake. Shut down the diesel engine as described in the operating manual and move the safety lever upwards before you leave the operator seat. Lock all caps, covers and doors. Pull out all keys and secure the machine to prevent unauthorised use.

2.3.12 Maintenance, repair Qualification of the personnel

Make sure that a sufficiently equipped workshop is available to carry out this work, and that the responsible personnel have the necessary qualifications. The inspection and maintenance schedule defines precisely who is allowed to or who must perform which jobs. Certain jobs are allowed to be performed by the machine owner (or the machine owner's personnel), other jobs are only allowed to be performed by specialist personnel who have the corresponding training. Work on travel gears, braking and steering systems is only allowed to be performed by trained specialist personnel. Only personnel with special knowledge and experience are allowed to work on hydraulic equipment.

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Maintenance and repair work is only allowed to be performed by trained specialist personnel.

Operating manual

Safety warnings, signs Safety warnings

Safety in the workplace. Keep unauthorised people away from the machine during maintenance or repair. Cordon off a large area around the maintenance zone if necessary. Inform the operating personnel before starting to undertake special and maintenance work. Appoint a supervisor. Unless specified otherwise in the operating manual, all maintenance work on the machine must be performed on level, firm ground with the working attachment lowered and the diesel engine switched off. During maintenance work, particularly involving work under the machine, affix a warning sign with the message "Do not switch on!" in a clearly visible location on the starter lock. Pull out the starter key and turn the battery main switch to the 0 position. When working above head height, use safe ladders and working platforms intended for this purpose. Do not climb on parts of the machine if they are not intended for this purpose. Wear safety harnesses when working at height. Keep all handles, steps, railings, pedestals, gantries and ladders free from dirt, snow and ice. Always support the machine so that possible shifts of weight will not endanger its stability, and avoid metal-on-metal contact when doing this. Never go under a raised machine unless it has been supported in a proficient and stable manner. When working in enclosed rooms with the diesel engine running, channel the exhaust gases outside and ensure that the rooms are well ventilated.

Diesel engine Only perform maintenance work on the diesel engine with the engine stopped and the ignition key pulled out.

Hydraulic system Do not search for hydraulic leaks using your hand. Use cardboard or a similar material in order to locate leaks. Wear protective gloves when doing so. Do not unfasten lines and fittings of the hydraulic system unless the following conditions have been met: â&#x20AC;&#x201C; The diesel engine is switched off. â&#x20AC;&#x201C; The pressure in the hydraulic system has been dissipated. â&#x20AC;&#x201C; The internal tank pressure of the hydraulic tank has been dissipated.

LHB/11110170/02/2011-07-21/en

Pressure accumulator Pressure accumulators contain stored energy and operate under high pressures. All work on pressure accumulators (e.g. repair, replacement, filling, pressure checking) is only allowed to be performed by specialist personnel who have been trained to do so. Do not take any damaged pressure accumulators into operation. Do not perform welding or brazing work on pressure accumulators, and do not carry out any mechanical work on them either. Pressure accumulators can become hot during operation, danger of burns.

LH 120 C-1103 / 49287

Safety warnings, signs

Operating manual

Safety warnings

Pressure accumulators are indelibly marked with the operating data (minimum and maximum pressure). Make sure that the marking remains visible.

Hydraulic hoses and hose lines Repairs to hydraulic hoses and hose lines are prohibited! All hoses, hose lines and fittings must be checked for leaks and externally visible damage every two weeks. Damaged parts must be renewed without delay. Remember that oil spraying out under high pressure can penetrate the skin. In addition, leaking oil can cause fires. Even when stored and used correctly, hoses and hose lines are subject to natural ageing. This restricts their service life. Incorrect storage, mechanical damage and impermissible loading are the most frequent causes of accidents. Use at the limits of the permissible load can shorten the service life (e.g. high temperatures, frequent movement cycles, extremely high pulse frequencies, multi-shift working).

Note the following when renewing hoses and hose lines: – Exclusively use genuine spare parts. – Install and fit the hoses and lines proficiently, and make sure that the correct connections are used. – Always make sure that the hoses and hose lines are installed without torsion. With high-pressure hoses, it is always necessary to attach the bolts of the half clamps or full flanges at both hose ends, and only having done this should they be tightened. – For high-pressure hoses and hose lines with an elbow fitting, always first tighten the flange at the end with the elbow fitting, and only subsequently at the end with the straight fitting. – Any fastening clamps in the middle of the hose are not allowed to be fitted and tightened until afterwards. – Check every day that all clamps, covers and protective devices have been fastened correctly. This will avoid vibration and damage during operation. – Install the hoses and hose lines so as to avoid any possibility of chafing on other hoses, hose lines or other parts. – A minimum distance from the other parts of approx. 1/2 the external diameter of the hose is recommended. However, the distance should not be less than 10 mm to 15 mm. – When renewing hoses and hose lines on moving parts, check that there are no restrictions, chafe marks or overlapping lines anywhere along the entire range of movement.

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Hoses and hose lines must be replaced if an inspection reveals the following circumstances: – Damage to the outer layer down as far as the insert (e.g. chafe marks, cuts and tears). – Embrittlement of the outer layer (crack formation in the hose material) – Deformation that does not correspond to the natural shape of the hose or hose line, both in depressurised and in pressurised condition or in the case of bends, e.g. delamination, blister formation – Leaks – Failure to comply with the installation requirements – Damage or deformation to the hose fitting which reduces the strength of the fitting or of the connection between the hose and the fitting – Dislocation of the hose from the fitting – Corrosion on the fitting which impairs function and strength

Operating manual

Safety warnings, signs Safety warnings

Safety devices If it is necessary to remove safety devices, the safety devices must be re-attached and checked immediately on completion of the work.

Electrical and electronic systems Do not get close to the diesel engine. People with pacemakers are not allowed to approach the diesel engine when it is running (minimum distance 50 cm). When the diesel engine is running, do not touch any live parts on the electrical connection of the injection pumps which are controlled by solenoid valves. Check the electrical system regularly. Any faults such as loose connections, blown fuses and bulbs, charred or chafed cables must be repaired by specialist personnel without delay. Only use genuine fuses with the prescribed amp ratings. Only a qualified electrician is allowed to work on high-voltage modules. Do not work on live components. When working on medium and high-voltage modules, switch the voltage off and ground the power cable in order to discharge any remaining charge. First check the parts are no longer live, ground and then short-circuit them. Provide insulation against adjacent live parts. Disconnect the battery before you start work on the electrical system or conduct arc welding work on the machine.

Heavy parts Do not attempt to lift heavy parts. Use lifting devices with sufficient load-carrying capacity. Use suitable and functional lifting tackle with a corresponding loadcarrying capacity to replace individual parts or large assemblies. This is in order to guarantee safe movement during installation. Never stand under suspended loads, and do not work under such loads either. Wear protective gloves when handling wire ropes. Only entrust experienced persons with the job of attaching loads and guiding crane operators. The spotter must be in the field of view of the operator or have voice contact with the operator.

Lubricants and service products LHB/11110170/02/2011-07-21/en

When handling oils, greases and other chemical substances, comply with the safety instructions applicable to the product in question. Make sure that service products, consumables and replaced parts are disposed of in a safe and environmentally acceptable manner. Take care when working with hot lubricants and service products (danger of burns and scalds).

Spare parts Spare parts must correspond to the technical requirements defined by the manufacturer. This is always assured when genuine spare parts are used. Spare parts

LH 120 C-1103 / 49287

Safety warnings, signs

Operating manual

Safety warnings

that do not correspond to the technical requirements of the manufacturer can impair the safety and function of the machine. When replacing parts, re-secure unscrewed bolt-connections with the correct torque.

Maintenance intervals The intervals specified for recurrent checks and inspections in this operating manual must be complied with.

2.3.13 Modifications, add-ons and conversions Do not undertake any modifications, add-ons and conversions on the machine without the approval of the manufacturer, if such modifications, add-ons and conversions could impair safety. This also applies to the installation and adjustment of safety devices and safety valves, as well as to welding on load-bearing parts. Third-party attachments and add-on parts, or parts which do not have a general approval from Liebherr for installation or attachment, are not allowed to be fitted to or in the machine without the written approval of Liebherr. The necessary technical documents must be provided to Liebherr for this purpose.

2.3.14 Removal and installation of attachment pins Never align the holes using your fingers. If possible, use a hydraulic pin press in order to push pins out of the attachment. If you have to drive out a pin using a sledgehammer: use a drift and a guide tube that is held by another person. In order to drive in a pin, you must screw the impact bolt supplied in the tool kit into the threaded hole of the pin. Only strike this bolt in order to drive in the pin. When installing pins that are secured using a crown nut and cotter pin, first drive in the pin as far as the stop. Then screw on the crown nut by hand until it makes contact, and only tighten it further until the cotter pin can be inserted.

Liebherr offers optional operator's cab protection systems for certain machine applications. These systems are either a cab protection extending completely over the roof and front of the cab (falling objects protective structure = FOPS) or a front and upper guard in order to protect the cab and windscreen against falling objects (e.g. rocks or debris). The cab guard extending over the entire cab roof and front is bolted onto the uppercarriage, representing an independent protection system. The front and upper guards are bolted onto the operator's cab either individually or combined. In this case, the operator's cab is also part of the protection system. Dangerous situations can arise even if the protective device is intact, depending on the application and the working method. Do not operate a machine with a damaged cab protection system. Damage to the operator's cab can be caused by the following work and incidents: â&#x20AC;&#x201C; Welding, cutting or drilling of holes

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

2.3.15 Rock protection (FOPS)

Operating manual

Safety warnings, signs Safety warnings

– Attaching holders – Deformations after an accident – Falling objects Structural changes or repairs of any kind are prohibited.

2.3.16 Checking for cracks Depending on their application, place of use, duration of use and the operating conditions, machines are subject to different loads. Different duty cycles result in different lengths of service life for the various components of the machine. As a result, cracks and loose connections can arise, especially on load-bearing parts. To maintain its operational reliability, the machine must therefore be checked regularly for cracks, loose connections or other visible damage. In order to check for cracks, it is essential for the machine to be kept clean and to be cleaned regularly. The checks must be performed in accordance with the inspection and maintenance schedule. Pay particular attention to the following points: – Steel structure of undercarriage with axle and gearbox mountings, outriggers, lower slewing ring support with tower and slewing ring – Steel structure of uppercarriage with bearing block for boom and hoist cylinder, upper slewing ring support, cab suspension, mounting of slewing gear and counter weight – Steel components of the working attachments, e.g. boom, stick, quick change adapter, digging tool and grapple – Hydraulic cylinders, axles, steering, pins and pin connections, steps, ladders and fastening elements Perform a visual inspection for cracks. If you suspect you have found a crack, or if there is poor visibility (e.g. on the slewing ring support), use the dye penetration process to check for cracks. Immediately repair any damage found. Only certified welders are allowed to perform welding work on load-bearing parts, and such work must be performed according to the recognised rules of welding technology. Contact Liebherr customer service to agree on suitable measures.

2.3.17 Regular checks

LHB/11110170/02/2011-07-21/en

The machine must be subjected to a regular safety check. Records must be kept of these checks. The checks must be performed by suitable and technically proficient personnel who have been authorised to do so. National regulations must be complied with.

LH 120 C-1103 / 49287

Safety warnings, signs

Operating manual

LHB/11110170/02/2011-07-21/en

Safety warnings

LH 120 C-1103 / 49287

3 Control and operation

3.1 Control and operating elements 3.1.1 Overview of operator's platform

LHB/11110170/02/2011-07-21/en

Fig. 11: Operator's platform 1 2 3 4 5 5a 5b

Cab adjustment lever Travel gear lever Safety lever Joystick left Control auxiliary functions Push button Proportional control4)

9 10 11 12 13 A B

Control knob Joystick right Indicating unit Emergency stop Starting switch Control unit Control unit

See next page for continuation of the image legend

4) Special

equipment copyright by

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control and operating elements

6 7 8

Power socket / cigarette lighter Operator seat Engine speed controller

C D

Control unit Control unit

12 13

Grapple Turning grapple, auxiliary function Beacon Quick change system Overload warning system5) Magnet system5)

Fig. 12: Control unit A, key assignment 1 2 3 4 5 6

Engine start / stop Sensor-controlled low idle automatic Headlight Slewing gear brake Central lubrication system Quick access menu 16)

14 15 16 17

See next page for continuation of the image legend

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

3.1.2 Control unit A

Operating manual

Control and operation Control and operating elements

Quick access menu 26)

8 9 10 11

Temperature Blower power Defrost/defog Recirculated air

19 20 21

ECON (operation without cooling function) AUTO (automatic mode)5) MODE (operating mode)5) Fast gear / creeper gear

Key function: – On = LED lit – Off = LED out

3.1.3 Control unit B

Fig. 13: Control unit B, key assignment7) 1

Working attachment headlights

Front operator's cab headlights

Rear operator's cab headlights

Windscreen wiper, floor glass panel8) Windscreen wiper, roof glass panel Windscreen wiper, windscreen

LHB/11110170/02/2011-07-21/en

Key function: – On = LED lit – Off = LED out

5) Special

equipment / equipment variant key 7) Different key assignments are possible depending on equipment variant 8) Model variant / no function in machines without floor glass panel 6) User-programmable

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control and operating elements

3.1.4 Control unit C

Fig. 14: Control unit C, key assignment9) 1 2 3

Bypass stick cylinder shut-down AutoLift Stick active operating mode

4 5 6

Radio muting Parking brake Reversible fan drive

LHB/11110170/02/2011-07-21/en

Key function: â&#x20AC;&#x201C; On = LED lit â&#x20AC;&#x201C; Off = LED out

9) Different

key assignments are possible depending on equipment variant copyright by

LH 120 C-1103 / 49287

Operating manual

Control and operation Control and operating elements

3.1.5 Control unit D

Fig. 15: Control unit D, key assignment10) 1 2 3

Grapple pressure reduction Access control (enable slewing gear) Hoist cylinder deactivation

4 5

Cab lift Slewing gear mode

LHB/11110170/02/2011-07-21/en

Key function: â&#x20AC;&#x201C; On = LED lit â&#x20AC;&#x201C; Off = LED out

10) Different

keyboard assignments are possible depending on equipment variant copyright by

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

3.2 Control 3.2.1 Battery main switch

Fig. 16: Battery main switch 1 2

Switch Limit stop

3 4

Padlock Bracket

The battery main switch is located at the passage (step in front of the engine compartment) The battery main switch establishes the connection between the batteries and the machine's electrical system. When the battery main switch is switched on, the machine's electrical system is supplied with voltage. The machine cannot be started if the battery main switch is switched off. Switch setting

Function

switched on

OFF

switched off

Tab. 6: Battery main switch

Secure the battery main switch if necessary (e.g. for maintenance work): u Turn the battery main switch to position OFF. u Guide the bracket through the openings in the switch and the limit stop, and close the padlock.

3.2.2 Entering and exiting the machine The access system consists of ladders, railings and walkways. These elements are arranged differently depending on the equipment variant. Learn how to enter and exit the access system of your machine correctly.

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

The battery main switch can be secured with a padlock to prevent it from being switched on inadvertently.

Operating manual

Control and operation Control

DANGER Danger of falling! Falling from the machine can lead to very serious injuries, and can even have fatal consequences under certain circumstances. u Only enter and exit the machine using the access system. u Never use control elements to hold on to. u Never jump down from the machine. If you use a ladder: u Turn your face to the ladder and use the â&#x20AC;&#x153;three-point supportâ&#x20AC;?11) . u Line up the ladders with one another: before leaving the machine, position the uppercarriage parallel with the undercarriage. u Gantry machine: align the access point and control door. Before leaving the machine, position the uppercarriage parallel with the undercarriage. DANGER Parts of the rotating uppercarriage can catch persons and cause them to be snagged. This may cause very serious injuries, and may even have fatal consequences! u Never allow any persons to remain on the machine during operation. Exception: instructor seat. u Never exit or enter the machine during operation. u Never exit or enter the operator's cab during operation. If you would like to leave the operator seat or the machine: u Move the safety lever up. u Only open the cab door for entering and exiting the operator's cab (the door must remain closed during operation). u Close all doors and barriers on railings again after you have passed through them.

LHB/11110170/02/2011-07-21/en

u Sit on the operator seat (instructor seat) before starting work. Also, adjust the operator seat and put on the seat belt before starting work.

11) Three-point

support: always have two hands and one foot or two feet and one hand in contact with the access system. copyright by

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

LH 120 C and LH 120 C HR

Fig. 17: The route to the operator's cab 1 2

Undercarriage ladder Uppercarriage ladder

3 4

Cab door Passage

You can use either the ladders on the side of the operator's cab or on the opposite side. u Use the ladder on the side of the operator's cab. or

LHB/11110170/02/2011-07-21/en

Use the ladder on the opposite side and the passage.

LH 120 C-1103 / 49287

Operating manual

Control and operation Control

LH 120 C G Operator's cab in the upper park position (on the uppercarriage)

LHB/11110170/02/2011-07-21/en

Fig. 18: Walkway to the operator's cab in park position 1 2 3 4 5

Ladder to the platform Platform Control door Left access point Cab door

6 7 8 9 10

Passage Right access point Bell Light switch Key box, pushrod

A B C

Ladder detail Control door detail View from above

The control helps you to position the operator's cab correctly. Raise the operator's cab in automatic mode until the movement stops in the upper park position. In this position, the operator's cab is positioned correctly on the uppercarriage. Make sure that the operator's cab is locked in the park position.

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

DANGER Danger of falling if the wrong access point is used. u When climbing down, make sure that the access point you have selected is above the control door. The access point you must use depends on the position of the uppercarriage: – Uppercarriage swivelled in travel direction: left access point (on the side of the operator's cab) – Uppercarriage swivelled through 180°: right access point u Position the required access point so it is directly above the control door. u Use the specified route. u Use the left access point. or Use the right access point and the passage.

Operator's cab in the lower park position

Fig. 19: Access to the lowered operator's cab 1 2 3

Spacing Cab ladder Cab door

A B

Upper cab ladder Lower cab ladder

Make sure that the following preconditions are met: q The spacing between the operator's cab and the ground is sufficient for the cab ladder to be moved out. q The operator's cab is positioned over firm, level ground.

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

The control helps you to position the operator's cab correctly. Lower the operator's cab in automatic mode until the movement stops automatically. In this position, the spacing between the operator's cab and the ground is correct, and there is sufficient room for the cab ladder.

Operating manual

Control and operation Control

How to use the cab ladder:

Fig. 20: Locking mechanism of the cab ladder 1

Knob on the locking lever

Cab ladder

u Remove the weight from the locking mechanism: raise the cab ladder slightly u Release the locking mechanism: grip the knob of the locking lever and pull it upwards. u Lower the cab ladder.

LHB/11110170/02/2011-07-21/en

Before taking into operation: u Push the cab ladder upwards until you can hear the locking mechanism engage.

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

Access control The access control is a function integrated in the control. The access control assists you in making sure that the slewing gear will not be used unless there is no-one on the machine except for you. The access control blocks the slewing gear when the following events occur: – The control door is opened. – The cab ladder is lowered. – The ignition is switched on. The uppercarriage cannot be swivelled when the slewing gear is blocked. If necessary, the indicating unit prompts you to check the cause and rectify it. You must make sure that there is no-one on the machine except for you. It is only possible to release the slewing gear by confirmation involving pressing two keys in succession. For reasons of safety, the control door can only be opened from the outside with a key. Symbol

Explanation

Measure

The control door is open.

Close the control door.

The cab ladder is down.

Pull up the cab ladder.

Access control prompt

Press the access control key (first step).

Confirmation required

Press the confirmation key (second step).

Tab. 7: Access control, status symbols and keys Make sure that the following preconditions are met: q The cab ladder is locked in the upper position. q The control door is closed. q The ignition is switched on. q The “access control prompt” status symbol appears on the indicating unit. Once all preconditions have been met, the LEDs in the access control key flash. The key flashes to indicate that you can now confirm.

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Slewing gear blocked. Signals that you are Confirm access control. trying to operate the slewing gear without having confirmed the access control.

Operating manual

Control and operation Control

How to confirm the access control: By pressing the key, you confirm that no-one is on the machine except for you. If you are working with a trainer, you confirm that no-one is on the machine except for you and the trainer. You also confirm that the trainer and you will exclusively remain in the operator's cab during operation. u First step: press the access control key. w You now have a few seconds to complete the confirmation with the second step. w The â&#x20AC;&#x153;confirmation requiredâ&#x20AC;? symbol appears on the indicating unit. u Second step: press the confirmation key. w The slewing gear is enabled. If you do not complete the second step: u start again with the first step.

Procedure when changing operators You or someone else are only allowed to use the access system if you first move the safety lever to the upper position or shut down the engine. The new machine operator is not allowed to enable the slewing gear before you have left the machine. The control door must be opened from the outside using the key. On the inside, use the door latch.

Key storage Make sure that only authorised persons have a key for the control door in their possession. Restrict the number of persons in question as far as possible.

Ringing the bell There is a bell button at the bottom end of the ladder leading to the platform and on the control door. When it is pressed, a bell sounds in the operator's cab. No-one is allowed to approach the machine during operation. This means the bell button must only be used when the machine is stationary. Approaching the machine must be coordinated with the machine operator by eye contact or verbal communication.

Switching on the light The light switches off automatically after a preset time. LHB/11110170/02/2011-07-21/en

What to do in an emergency Control door If the machine operator cannot climb down under his own power or has to be rescued, another person may gain access to the machine. There is a key box located next to the control door. By breaking the glass, it is possible to remove a key for the control door.

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

Floor hatches

Fig. 30: Floor hatches on the walkways of the uppercarriage. If the uppercarriage cannot be aligned in the travel direction, there will not be any access point exactly above the control door. In this case, you cannot use the specified walkway and must open a floor hatch instead. The machine is designed so there will always be at least one floor hatch located above a weight-bearing surface on the platform, whatever position the uppercarriage is in. The platform can be accessed inside the railings. DANGER Danger of falling! u Only open a floor hatch which is above the platform. u Only use floor hatches with the assistance of emergency ladders. Climbing down from the uppercarriage using a floor hatch. u Block the slewing gear: move the safety lever upwards, shut down the engine. w The access control blocks the slewing gear. u Search: Which floor hatch is located above a weight-bearing surface inside the railings? u Open the floor hatch you have selected. u Open the floor hatch from above and place the emergency ladder into the opening. LHB/11110170/02/2011-07-21/en

u Insert the hook of the emergency ladder onto the mesh frame.

LH 120 C-1103 / 49287

Operating manual

Control and operation Control

Climbing from the platform through a floor hatch up to the uppercarriage

Fig. 31: Climbing through a floor hatch up to the uppercarriage 1 2

Break the glass covering the key box (in an emergency only) Open the control door

Take the emergency ladder

Position the emergency ladder

u Block slewing gear: open control door. w The access control blocks the slewing gear. u Search: Which floor hatch is located above a weight-bearing surface inside the railings? u Open the floor hatch from below with the emergency ladder and place the emergency ladder into the opening. u Insert the hook of the emergency ladder onto the mesh frame. Restoring the original condition u Return the emergency ladder to the location provided for it and secure it. u Close floor hatches. u Make sure the emergency ladders remain on the uppercarriage and on the undercarriage.

LHB/11110170/02/2011-07-21/en

If the key box glass has been smashed: u repair.

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

3.2.3 Emergency exit

Fig. 32: Emergency hammer The emergency hammer is located next to the operator door under the cab roof. u Break the left side window with the emergency hammer.

3.2.4 Fire extinguisher

Fig. 33: Fire extinguisher

LHB/11110170/02/2011-07-21/en

The fire extinguisher is located in the operator's cab.

LH 120 C-1103 / 49287

Operating manual

Control and operation Control

3.2.5 Safety lever The servo control is protected with a safety lever in order to protect against inadvertent movements of the machine. The safety lever interrupts all hydraulic functions. The safety lever must be in the upper position when the operator enters or exits the operator's cab The engine can only be started in this position. Safety lever 1

Safety lever up: The servo control is switched off. Operating the control elements does not result in machine movements. The parking brake and slewing gear brake are applied.

Safety lever down: The servo control is switched on. The previously selected setting of the brakes is re-established.

Tab. 8: Safety lever settings u Before starting work from the operator seat, move the safety lever to the lower position.

LHB/11110170/02/2011-07-21/en

u Before leaving the operator seat, move the safety lever to the upper position.

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

3.2.6 Operator seat

Fig. 35: Operator seat

2 3 4 5 6 7 8

Adjusting seat position with arm rests Adjustment of seat position Safety belt Adjustment of arm rest inclination Arm rest Head restraint Seat heater, air conditioning12) Lumbar support mechanical / pneumatic12)

12) Model

Adjustment of height of arm rests

10 11 12

Adjustment back rest Safety belt buckle Horizontal suspension12)

13 14

Adjustment of seat Adjustment for body weight and seat height12) Shock absorption

LHB/11110170/02/2011-07-21/en

version, special equipment copyright by

LH 120 C-1103 / 49287

Operating manual

Control and operation Control

DANGER The machine can move unexpectedly if control elements are actuated accidentally when adjusting the seat. Accident hazard! u Do not adjust the seat during operation. u Park the machine and apply the parking brake. u Turn the safety lever up.

Adjust seat position

Fig. 36: Adjust seat position u Move operator seat together with the arm rests: pull middle lever up. u Move seat, release lever. u Move seat without arm rests: pull outer lever up. u Move seat, release lever. w The lever must audibly click into the required position. w After locking into position it should not be possible to move the seat.

Adjust inclination of arm rests

LHB/11110170/02/2011-07-21/en

Fig. 37: Adjust inclination of arm rests u Turn hand wheel at the bottom to the right or left. w The arm rest will move up or down.

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

Adjust height of arm rests

Fig. 38: Adjust height of arm rests u Unlock pushbutton (one turn to the left). u Pull out the pushbutton and hold in this position. u Push arm rest up or down. u Release pushbutton. u Push the arm rest to the next stop. w The pushbutton must audibly click into the required position. u Tighten pushbutton (turn to right). w After locking into position it should not be possible to move the arm rest.

Adjust seat surface

Fig. 39: Adjust seat surface A

Adjust height of seat surface

Adjust inclination of seat surface

u Adjust height of seat surface: raise right push button and push seat surface to the required position.

LHB/11110170/02/2011-07-21/en

u Adjust inclination of seat surface: raise left push button and push seat surface to the required position.

LH 120 C-1103 / 49287

Operating manual

Control and operation Control

Adjust back rest

Fig. 40: Adjust back rest u Pull lever up. u Apply or remove pressure on the back rest to move it to the required position. u Let go of the lever. w The lever must audibly click into the required position. w After locking into position it should not be possible to move the back rest.

Adjust head restraint

Fig. 41: Adjust head restraint u Change height: Push head restraint down or pull up over perceptible stop clicks. u Change inclination: Push head restraint forwards or backwards. u Remove head restraint: Pull head restraint up and pull hard to slide it over the final stop.

LHB/11110170/02/2011-07-21/en

Adjust shock absorption

Fig. 42: Adjust shock absorption Suspension can be adapted to individual operational conditions. – 1 = hard – 2 = medium – 3 = soft

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

u Turn handle to required position and let go.

Adjust horizontal suspension

Fig. 43: Adjust horizontal suspension Under certain operating conditions it is preferable to activate the horizontal suspension. This means impacts in the direction of travel can be better absorbed by the operator seat. – 1 = horizontal suspension OFF – 2 = horizontal suspension ON u Turn handle to the required position. u On setting position 1 the lever must click into position: move the seat backwards until it clicks into position audibly.

Adjust height / seat to body weight

Fig. 44: Adjust height / seat to body weight A

Manual adjustment

Pneumatic adjustment12) LHB/11110170/02/2011-07-21/en

Manual adjustment Before adjusting, set the shock absorption to “soft”. During adjustment to your body weight remain seated calmly.

12) Model

version, special equipment copyright by

LH 120 C-1103 / 49287

Operating manual

Control and operation Control

NOTICE The compressor can be damaged by permanent use of the height adjustment. u Do not use the lever for longer than one minute without interruption. u Adjust seat to body weight: Pull lever up briefly. w The seat will adjust to your body weight. u Adjust height: Pull lever fully upwards or push downwards and keep it in this position. When the seat is at the required height: u Let go of the lever. w The seat will remain in the new position. w If the final stop (top or bottom) is reached during adjustment: the seat will automatically adjust the height to ensure minimum spring travel.

Pneumatic adjustment12) The seat adapts automatically to the body weight. The height is adjusted via the rocker switch. Before adjusting, set the shock absorption to â&#x20AC;&#x153;softâ&#x20AC;?. NOTICE The compressor can be damaged by permanent use of the height adjustment. u Do not use the rocker switch for longer than one minute without interruption. u Wait for the seat to adjust automatically to your body weight. When automatic adjustment is completed: u Adjust the height. u Adjust height: Press the rocker switch up or down and keep it pressed down.

LHB/11110170/02/2011-07-21/en

When the seat is at the required height: u Release the rocker switch. w The seat will remain in the new position. w If the final stop (top or bottom) is reached during adjustment: the seat will automatically adjust the height to ensure minimum spring travel.

12) Model

version, special equipment copyright by

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

Adjust lumbar support

Fig. 45: Adjust lumbar support A

Mechanical adjustment

Pneumatic adjustment12)

Mechanical adjustment Use the hand wheel to adjust the bulge of the back cushion. u Turn the hand wheel to the right or left in order to adjust the bulge of the back cushion.

Pneumatic adjustment12) Use switches 1 and 2 to adjust the bulge of the back cushion in the upper and lower section. Press plus (+) to increase the bulge, press minus (–) to reduce the bulge. u Use switches 1 and 2 to adjust the bulge of the back cushion.

Seat heating Seat heating is switched on and off via the rocker switch. – 0 = seat heating OFF – 1 = seat heating ON

Seat heating with climatisation12) Active seat climatisation ensures a dry seat surface. Body moisture is extracted by the integrated ventilation system. Seat heating and climatisation is switched on and off via the rocker switch.

12) Model

LHB/11110170/02/2011-07-21/en

– 0 = seat heating and climatisation OFF – 1 = seat heating ON (climatisation OFF) – 2 = climatisation ON (seat heating OFF)

version, special equipment copyright by

LH 120 C-1103 / 49287

Operating manual

Control and operation Control

3.2.7 Instructor seat

Fig. 48: Instructor seat The instructor seat is intended for the instructor when training the machine operator on the machine. u Only allow people to travel in the machine if there are suitable seats available. u Comply with the instructions on fastening the safety belt (see "Safety belt" chapter).

3.2.8 Safety belt

Fig. 49: Safety belt LHB/11110170/02/2011-07-21/en

1 2

Belt reel Safety belt tongue

3 4

Belt buckle assembly Locking mechanism

The safety belt is an automatic safety belt. There is no need to adjust the belt length. Pull the belt evenly out of the belt reel. Pulling quickly or pulling when the machine is standing at an angle can result in the belt blocking.

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

WARNING If the machine operator and instructor are not wearing safety belts, they could be thrown around the operator's cab or out of the machine in the event of sudden braking or in an accident. Risk of injury! u It is essential to put on the safety belt before starting work. u When putting on the safety belt, ensure that it is not twisted. u Regularly check the condition, function and attachment of the belt. Immediately renew damaged parts. u Put on: pull the safety belt tongue out of the belt reel and insert it into the belt buckle assembly. u Check: pull the safety belt tongue and check that it is firmly retained in the belt buckle assembly. u Open: press the lock on the belt buckle assembly and guide the belt back smoothly so all of it is taken up by the belt reel.

3.2.9 Cab lift (special equipment) Applies to machines with three-way cab lift adjustment The cab lift permits infinitely variable adjustment of the height and reach of the operator's cab. For certain jobs, it can be beneficial to adjust the position of the operator's cab to the visibility conditions where the machine is working. The cab lift is controlled using adjustment levers. The control monitors the movement of the operator's cab and helps you to prevent collisions between the operator's cab and the machine. DANGER The control can help you to prevent collisions between the operator's cab and the machine! Nevertheless, it is possible for the operator's cab to collide with obstacles! Increased danger of accidents! u Make sure there are no obstacles in the range of movement of the operator's cab. u Move the operator's cab to the upper park position before starting to travel. u Getting in and out: move to the end positions (upper or lower park position) using automatic mode. u Move to the end positions slowly. LHB/11110170/02/2011-07-21/en

u Driving: watch out for obstacles on the route.

LH 120 C-1103 / 49287

Operating manual

Control and operation Control

DANGER The operator's cab can trap persons when it is moving down. Risk of injury, possibly with fatal consequences! u Make sure no-one is in the danger zone (under the operator's cab). u Rapid and correct response in an emergency: learn how to operate the emergency discharge. u Keep your distance from moving parts when the operator's cab is moving down. If the machine is being repaired or serviced: u Choose to carry out the work with the operator's cab lowered if possible.

LHB/11110170/02/2011-07-21/en

If the operator's cab must be repaired in the raised position: u Support the operator's cab from below using suitable means.

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

Cab lift menu, operating variants

Fig. 50: Cab lift menu: operation and position indicator 1 2

5 X

Slewing gear angle of rotation Automatic mode (bottom park position) Collision check off Automatic mode (top park position) Operator's cab Longitudinal axis of the vehicle

Distance from zero point

3 4

Z Z1

Vertical axis of the vehicle Distance from zero point

0 a

Zero point Distance (uppercarriage)

b c

Distance (middle of machine) Distance (undercarriage / ground)

Activate the cab lift using the cab lift key. The indicating unit automatically changes to the “cab lift” menu. When the cab lift is activated, it is not possible to operate the tracked travel gear, slewing gear and working attachment. Collision check: The control ascertains the shortest distance between the operator's cab and three collision points on the outline of the machine. The illustrated dimensions (a, b and c) vary depending on the position of the operator's cab and uppercarriage. The vertical dimension (c) describes either the distance between the operator's cab and the tracked travel gear or the distance between the operator's cab and the ground, depending on the situation.

The cab lift control supports three operating variants: – Automatic mode (upper park position): move operator's cab to the upper park position – Automatic mode (lower park position): move operator's cab to the lower park position – Manual operation (automatic mode off): free adjustment of the operator's cab In automatic mode, the operator's cab automatically moves towards the park position, subject to the collision check. It does not matter which adjustment lever you operate in this case. In manual operation (automatic mode off), you yourself determine the movements of the cab lift using the adjustment levers. The collision check switches individual movements off if necessary.

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

The cab lift switches off if the distance between the operator's cab and parts of the machine or the ground is too short. The rotary motion of the uppercarriage also stops if necessary. In this case, the cab lift and the uppercarriage must be moved so that the distance from the collision point increases.

Operating manual

Control and operation Control

How to select the operating variant: u Select the automatic mode top or automatic mode bottom symbol. w The “confirmation required” symbol appears on the indicating unit. w Now, you have a few seconds of time to confirm the operating variant. u Press the confirmation key. w The operating variant is activated. u Switch off automatic mode: select the symbol again and confirm.

Note If the collision check is switched off, you yourself must ensure that the operator's cab does not collide with the machine! Increased danger of accidents! u Only switch off the collision check in an emergency. u Take extreme care when adjusting the operator's cab. u Switch off the collision check: select the collision check off symbol and confirm. w Without the collision check, it is only possible to adjust the operator's cab extremely slowly.

Adjusting the operator's cab

LHB/11110170/02/2011-07-21/en

Fig. 55: Adjusting the operator's cab 1 2

Adjustment lever, stick Adjustment lever, boom

Adjustment lever, cab inclination

The adjustment levers for the cab lift are located to the left of the operator seat. If you operate an adjustment lever, the indicating unit automatically changes to the “cab lift” menu.

Manual operation u Switch off “automatic mode”.

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

u Move out stick: move adjustment lever 1 in direction a. u Move in stick: move adjustment lever 1 in direction b. u Lower boom: move adjustment lever 2 in direction a. u Raise boom: move adjustment lever 2 in direction b. u Tilt operator's cab: move adjustment lever 3 in direction a or b. u Before leaving the operator's cab: move the operator's cab to the upper or lower park position.

Automatic mode up/down u Select “automatic mode (upper park position)”. u Operate any adjustment lever of the cab lift. w The operator's cab automatically moves to the park position (top). u Select “automatic mode (lower park position)”. u Operate any adjustment lever of the cab lift. w The operator's cab automatically moves to the park position (bottom). u Before leaving the operator's cab: move the operator's cab to the upper or lower park position.

3.2.10 Sun visor / sun blind

Fig. 58: Sun blind Handle

Pull cord

LHB/11110170/02/2011-07-21/en

u Pull the sun blind to the desired position with the handle. u Pull the sun blind again or pull the pull cord to roll it up.

LH 120 C-1103 / 49287

Operating manual

Control and operation Control

3.2.11 Side windows

Fig. 59: Window handle in the side window 1

Handle

Hand lever

u Press the hand lever on the handle and move the side window. u When closing the side window, make sure that the hand lever engages.

3.2.12 Lighting Key

Function Working attachment headlights

Front operator's cab headlights

Rear operator's cab headlights13)

LHB/11110170/02/2011-07-21/en

Beacon13)

Tab. 9: Key assignment u Push key: on u Push key again: off

13) Special

equipment copyright by

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

3.2.13 Cab lighting system

Fig. 64: Cab lighting system The reading light and cab lighting system can be used even when the ignition is switched off.

3.2.14 Windscreen wiper Key Windscreen

LEDs in key Roof glass panel

Rear window

Function off

Windscreen washer system on

Intermittent operation

Continuous operation

Tab. 10: Key assignment Select the operating mode of the windscreen wiper by pressing the corresponding key several times. Press and hold the key to switch the windscreen washer system on.

u Switch on the windscreen washer system: press and hold the key. w The windscreen wiper runs continuously and washing water is sprayed onto the windscreen. w The windscreen wiper returns to its previous operating mode when the key is released.

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

u Select operating mode: press the key several times until the windscreen wiper is in the desired operating mode.

Operating manual

Control and operation Control

3.2.14 Indicating unit

Fig. 72: Indicating unit, main menu 1 2

Menu bar Menu display

3 4

Status symbol display Warning symbol display

The indicating unit is the central source of information about machine operation. It provides information about operating data and functions in the form of texts and symbols. The machine is set, monitored and operated from the touch-sensitive touch screen with graphic user interface.

3.2.15 Touch screen Symbols with a grey background are functions or menus which can be selected by touching the surface of the screen. u Select and enter: touch the symbol.

LHB/11110170/02/2011-07-21/en

u Select menu: touch the menu symbol.

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

3.2.16 Quick access via the menu bar The menu bar is permanently displayed along the bottom edge of the screen. The available menu options can be called up directly at any time irrespective of the currently selected screen content. A symbol with a black background indicates which menu is active.

Fig. 74: Menu bar 1 2 3 4

Main menu Camera system14) Air conditioning system Operating status

5 6 7 8

General settings Device-specific settings Information Messages

u Select the menu using the touch screen or the control knob. Refer to the corresponding chapters for information about the individual menu options.

3.2.17 Quick access via user-programmable keys The MENU 1 and MENU 2 keys are user-programmable. They are suitable for quick access to frequently used menus. How to program the key: u Select any menu on the control unit. u Press the MENU 1 or MENU 2 key and hold it until all LEDs in the key light up. w The menu is stored. The next time the key is pressed, the respective menu will appear on the indicating unit.

3.2.18 Status symbols Symbol15)

Explanation LHB/11110170/02/2011-07-21/en

Confirmation required

Confirmation fault

14) Special 15) Status

equipment symbols depending on model and equipment variant copyright by

LH 120 C-1103 / 49287

Operating manual

Control and operation Control

Symbol15)

Explanation Tool attachment: “neutral position” required (For more information see: 3.2.19 Neutral position, page 78) Pontoon actuation active

Boom adjustment active

Boom adjustment: “neutral position” required (For more information see: 3.2.19 Neutral position, page 78) Lateral boom adjustment active

Lateral boom adjustment: “neutral position” required (For more information see: 3.2.19 Neutral position, page 78) Turn signal active

Accumulator pressure service brake

Brake system inoperative

Brake system inoperative, wire break

Rotary handle: “neutral position” required (For more information see: 3.2.19 Neutral position, page 78)

LHB/11110170/02/2011-07-21/en

Slewing gear brake not functioning

Travel mode blocked (wheeled excavator)

15) Status

symbols depending on model and equipment variant copyright by

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

Symbol15)

Explanation Travel mode: “neutral position” required (For more information see: 3.2.19 Neutral position, page 78) Travel reverse

Travel reverse with Tempomat

Travel forward

Travel forward with Tempomat

Travel mode blocked (crawler excavator)

Travel mode: “neutral position” required (For more information see: 3.2.19 Neutral position, page 78) Turn grapple: “neutral position” required (For more information see: 3.2.19 Neutral position, page 78) Main movements (working attachment and slewing gear) blocked.

Main movements (working attachment and slewing gear): “neutral position” required (For more information see: 3.2.19 Neutral position, page 78) Hoist cylinder protection switched off

LHB/11110170/02/2011-07-21/en

Stick cylinder protection switched off

Cab lift blocked

15) Status

symbols depending on model and equipment variant copyright by

LH 120 C-1103 / 49287

Operating manual

Control and operation Control

Symbol15)

Explanation Cab lift raising blocked

Cab lift lowering blocked

Cab lift: â&#x20AC;&#x153;neutral positionâ&#x20AC;? required (For more information see: 3.2.19 Neutral position, page 78) Cab lift: lift pipe fracture safety open

Cab lift: hoist cylinder protection switched off

Cab lift: stick cylinder protection switched off

Cab lift: inclination cylinder protection switched off

Cab lift: adjustment of the cab angle is blocked

Charge indicator: battery is not charging

Engine power reduction: To avoid engine damage, the engine power is reduced automatically in case of malfunctions or unfavourable operating conditions (e.g. overheating). Engine power reduction: To avoid engine damage, the engine power is reduced automatically if the air pressure is too low (with increasing altitude above sea level). LHB/11110170/02/2011-07-21/en

Automatic engine shut-down

Engine delayed shut-down active

15) Status

symbols depending on model and equipment variant copyright by

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

Symbol15)

Explanation Engine start blocked

Engine shut-down blocked The engine cannot be shut down with the Engine start / stop button, because another function dependent on the engine is switched on. Example: The magnet system is switched on. Emergency stop push button 1 pressed

Emergency stop push button 2 pressed

Emergency stop push button 3 pressed

Emergency operation engine switched on

Emergency operation hydraulic system switched on

Oscillating axle support automatic, oscillating axle unlocked (wheeled excavator) Oscillating axle support automatic, oscillating axle locked (wheeled excavator) Oscillating axle locked (wheeled excavator)

Oscillating axle, sector advance warning (wheeled excavator)

Outrigger monitoring system: The outrigger support is not moved (fully) in

15) Status

symbols depending on model and equipment variant copyright by

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Oscillating axle, sector blocked (wheeled excavator)

Operating manual

Control and operation Control

Symbol15)

Explanation Service due

Servo control inoperative

Control pressure too low

Quick change system active

Quick change system 2 active

Quick change system, lock command

Quick change system 2, lock command

Quick change system is being locked

Quick change system 2 is being locked

Quick change system is being unlocked

Quick change system 2 is being unlocked

LHB/11110170/02/2011-07-21/en

Quick change system is unlocked

Quick change system 2 is unlocked

15) Status

symbols depending on model and equipment variant copyright by

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

Symbol15)

Explanation Stick cylinder shut-down active

Stick cylinder shut-down is bypassed

Hoist cylinder deactivation active

Hoist cylinder deactivation is bypassed

Overload warning

Overload warning system not available

Valves blocked

Preheating

Tab. 11: Status symbols

3.2.19 Neutral position

If the control detects a corresponding situation, the â&#x20AC;&#x153;Neutral position requiredâ&#x20AC;? status symbol prompts you to move the control element into the neutral position first. In this case, move the control element in question to the neutral position (release it). Then the function will be available again.

15) Status

symbols depending on model and equipment variant copyright by

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

The control blocks control elements if unexpected movements of the machine could result due to the control elements being operated in certain situations. Example: you actuate a pedal or a joystick inadvertently, and then release the servo control with the safety lever.

Operating manual

Control and operation Control

3.2.20 Main menu

Fig. 151: Main menu 1 2 3 4 5

Time Hourmeter (day / total)17) Tool attachment16) Operating mode Speed step

6 7 8 9 10

Set cab temperature16) Ambient temperature16) Date Coolant temperature Tank content

Fig. 152: Main menu with camera image

LHB/11110170/02/2011-07-21/en

If the machine is equipped with a camera system16) , the camera image appears in the main menu.

16) Special 17) The

equipment odometer is displayed when travelling. copyright by

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

3.2.21 Camera system menu

Fig. 153: Camera image menu Due to machine design, the field of view from the operator's cab is partially restricted. In addition to the mirrors, the camera system also functions as a viewing device. It helps the machine operator to observe areas that cannot be seen directly. The indicating unit shows the camera image. DANGER The camera system is only an assistant and obstacles may be shown with a distorted perspective or even not at all! It does not warn about people and objects in the danger zone! u Essential note: the machine operator is responsible for monitoring the working area and the route. u If the camera system fails, only travel with the help of a spotter. How to display the camera image on the full screen (full-screen image). u Select the Camera system menu. u Exit full screen: select Main menu.

3.2.22 Air conditioning system Applies to machines with a manually controlled air conditioning system A climate in the operator's cab which is ideally suited to the needs of the operator helps to prevent fatigue and promotes safe operation of the machine.

The ventilation system feeds fresh outside air into the operator's cab. The screen shows different control elements depending on the operating mode of the machine. The air-conditioning system wil provide optimum performance under the following conditions: â&#x20AC;&#x201C; The diesel engine is running. â&#x20AC;&#x201C; Windows and doors are closed. â&#x20AC;&#x201C; The air vents are open.

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

The cooling function is only guaranteed when the diesel engine is running. When the cooling function is activated, the ambient humidity in the operator's cab is reduced simultaneously.

Operating manual

Control and operation Control

DANGER Restricted visibility if the windows are fogged up during recirculating air mode with the cooling function switched off! Only a little fresh air is supplied to the operator's cab in recirculating air mode! Increased risk of accidents when working with the windows fogged up. u Do not use ECON operation (operation without cooling function) during recirculating air mode. u Do not switch on recirculating air mode for long periods.

Operation via the menu

Fig. 154: Air Conditioning menu 1 2 3

Temperature– Temperature+ Operating state for vents

7 8 9

4 5 6

Vent at head height Vent at chest height Vent at floor height

10 11

Blower performance+ Blower performanceECON (operation without cooling function) Recirculated air Defrost / dehumidify

Set temperature u Select symbol Temperature– or Temperature+.

Select blower setting LHB/11110170/02/2011-07-21/en

u Select symbol Blower– or Blower+.

Select vent u Select symbol Head height, Chest height or Floor height

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

Recirculated air mode u Select symbol Recirculated air. w The air in the operator's cab is recirculated. Penetration of contaminated outside air (e.g. exhaust gases) is limited.

Defrosting and dehumidifying This function is used to defrost the windows or dehumidify the operator's cab when the windows are misted over. u Select symbol Defrost / dehumidify. w The blower power and air outlets are set automatically. When the windows are no longer misted over: u Turn off the function by re-selecting the symbol Defrost / dehumidify.

ECON mode ECON mode is used to save fuel. The cooling function is deactivated in ECON mode. u Select ECON symbol. w The cab temperature is only influenced by heating or ventilating.

Operation via the keyboard

Fig. 161: Control panel on the keyboard Blower performance

2 3

Recirculated air Defrost / dehumidify

5 6

ECON (operation without cooling function) Temperature function not available

The functions ECON mode, defrosting/dehumidifying and recirculated air are activated and deactivated by pressing the corresponding button.

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Operating manual

Control and operation Control

Set temperature Key

LEDs in key

Temperature level Level 1 to 4 Level 5 to 8 Level 9 to 12

Tab. 12: Temperature key Press the Temperature button to raise the setpoint by one temperature level; repeat to increase. When the highest temperature level is reached, the system switches back to the lowest temperature level.

Select blower setting Key

LEDs in key

Indication on display

Blower power 0% (OFF)

1% to 9%

10% to 20%

21% to 40%

41% to 60%

61% to 80%

81% to 100%

Tab. 13: Blower power key LHB/11110170/02/2011-07-21/en

The blower performance can be set at 6 levels. Press the Blower Performance button to switch to the next highest level. When the highest level is reached, the system switches back to the lowest level.

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

3.2.23 Operating status menu

Fig. 178: Operating status menu 1 2 3

Engine oil pressure Coolant temperature Charge air pressure

4 5

Hydraulic oil temperature Electrical system voltage

In normal operation, the "coolant temperature" and "hydraulic oil temperature" symbols are displayed in white; they are shown in red if there is a warning. Meaning of the red symbols: – Coolant temperature too high – Hydraulic oil temperature too high

Fig. 179: General settings menu 1 2 3

Reset meter Windscreen wiper interval Radio remote control18)

4 5 6

Unit changeover18) Language Time/time zone

“Language” and “Time/time zone” are part of the System settings menu (For more information see: System settings, page 87) .

18) Special

equipment copyright by

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

3.2.24 General settings menu

Operating manual

Control and operation Control

Reset meter

Fig. 180: Reset meter menu 1 2

Day hourmeter Day odometer19)

Reset meter

u Select the Reset meter symbol next to the displayed value. w The meter is reset (0).

Setting the windscreen wiper interval

LHB/11110170/02/2011-07-21/en

Fig. 181: Windscreen wiper interval menu 1

Front windscreen wiper–

2 3

Front windscreen wiper+ Roof glass panel windscreen wiper–

5 6

Roof glass panel windscreen wiper+ Rear windscreen wiper+ Rear windscreen wiper–

This menu sets the intermittent operation of the windscreen wipers20) . Adjust the time (indication in seconds) to set the pause between wiping cycles. Wipe less frequently: increase the time 19) Odometer

for the model variant wheeled excavator; no function assigned in machines with tracked travel gear 20) The number of windscreen wipers depends on the equipment. copyright by

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

Wipe more frequently: reduce the time

Radio remote control

Fig. 182: Radio remote control menu 1 2 3

Menu selection Volume− (quieter) Volume+ (louder)

4 5 6

Muting Audio source Additional functions (depending on model)

The menu provides access to the most important functions of a radio. For more information, refer to the radio manufacturer's operating manual.

Unit changeover

Select the indicating unit with which the speed, pressure and temperature should be displayed. – Speed: kilometres per hour (km/h) or miles per hour (mph) – Pressure: bar or psi – Temperature: degrees Celsius (°C) or degrees Fahrenheit (°F)

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Fig. 183: Unit changeover menu

Operating manual

Control and operation Control

System settings

Fig. 184: System settings menu bar 1 2 3 4

Main menu System diagnosis Time/time zone Language changeover

5 6 7 8

CAN bus info Access rights Test system Help

In the System settings menu (SCOTTI21) ), it is possible to set the time, time zone and language. The other menu options are intended for Liebherr customer service. The control unit provides information about software and operating statuses of the machine at this point.

Setting the language

Fig. 185: Language menu Select your language. The language change comes into effect when the indicating unit is restarted.

LHB/11110170/02/2011-07-21/en

u Restarting the indicating unit: switch off the engine, switch off the ignition, switch on the ignition.

21) SCOTTI

= Service Control Tool and Technical Information System copyright by

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

Setting the time and time zone

Fig. 187: Time and time zone menu 1 2 3

Move time zone to the west Move time zone to the east Daylight saving time on/off

4 5

Hourâ&#x2C6;&#x2019; / Minuteâ&#x2C6;&#x2019; Hour+ / Minute+

3.2.25 Device-specific settings menu

1 2 3 4 5

Central lubrication system23) Engine ventilation mode24) Service indication Sensor-controlled low idle automatic Fine adjustment of the control

6 7 8 9

Cab lift26) Hoist cylinder deactivation Stick cylinder shut-down Auxiliary heater auxiliary tank25)

User profile

22) The

indication can vary depending on the equipment. or semi-automatic central lubrication system 26) Applies to machines with cab lift 24) Maintenance activity; applicable for engines that have to be vented with the support of the electronic system. 25) Applies to machines with an additional fuel tank for the auxiliary heater 23) Fully

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Fig. 188: Device-specific settings menu22)

Operating manual

Control and operation Control

Central lubrication system, fully automatic

Fig. 189: Fully automatic central lubrication system menu 1 2 3

Mode 1 (light) Mode 2 (medium) Mode 3 (heavy)

4a 4b 5

Cycle rate27) Time27) Period

It is possible to set how intensively the central lubrication system should operate, according to the machine operating conditions. The selected "mode" determines how much grease the grease pump pumps to the bearings. Three modes are available. Fully automatic central lubrication system Mode

Operating conditions

Greasing

for light-duty operation

low volume of grease

for medium-duty operation

medium volume of grease

for heavy-duty operation

high volume of grease

Tab. 14: Lubricating modes Mode 1 is set in the example (see: fig. 189, page 89) .

LHB/11110170/02/2011-07-21/en

Depending on the design of the grease pump, the mode determines either the cycle rate or the duration of the grease process. â&#x20AC;&#x201C; Cycle rate 4a: 5 lubrication cycles take place within 60 minutes. â&#x20AC;&#x201C; Time 4b: The grease pump operates for 5 minutes within 60 minutes. The menu is split into two columns if the central lubrication system is equipped with two grease pumps. This means that the grease pumps can be set independently of one another.

27) Cycle

rate or time, depending on version of the grease pump copyright by

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

Central lubrication system, semi-automatic

Fig. 190: Semi-automatic central lubrication system menu 1

Time of last grease process

The menu provides information about when the last grease process took place. In the example, the semi-automatic central lubrication system was last started with a meter reading of 850 operating hours.

Engine ventilation mode

Fig. 191: Ventilation mode menu

The drained fuel system first must be bled manually (see Maintenance chapter). At the same time, a residual amount of air remains in the high-pressure fuel system. This air can only escape when the diesel engine is started. The engine control assists this process with bleeding mode. The high-pressure fuel system is automatically bled in this process. The diesel engine starts more easily. For more information, refer to the Fuel system section in the Maintenance chapter. u Switch on the ignition. u Select the bleeding mode symbol. w Bleeding mode is switched on when the engine is next started. u Start the diesel engine.

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

If the fuel system is completely drained as a result of maintenance work or runs dry due to a failure to refuel, it might not be possible to restart the diesel engine. In this case, the diesel engine must be bled.

Operating manual

Control and operation Control

Service indication

Fig. 192: Service indication menu 1 2 3 4 5

Time until the next service Time of last service Diesel engine service Hourmeter Hydraulic system service

6 7 8 h

Mechanical system service Message: Service due Confirm message Operating hours

The service indication menu states when a service was performed and how much time remains until the next service. The information is based on the hourmeter. The example (see: fig. 192, page 91) shows the menu from a machine with components (diesel engine, hydraulic system and mechanical system) that have to be serviced every 500 operating hours. Left figure: the last service was performed at 500 operating hours. 795 operating hours have now elapsed. The next service is due in 205 operating hours. Right figure: the “Service due” symbol appears 100 operating hours before the next service, as well as the Confirmation symbol. 983 operating hours have now elapsed. The next service is due in 17 operating hours. When the “Service due” symbol appears, you can confirm that you have seen the message. u Confirm message: Select Confirmation symbol. w The “Service due” status symbol is no longer displayed.

LHB/11110170/02/2011-07-21/en

u Have service performed at the appropriate time (contact Liebherr customer service).

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

Sensor-controlled low idle automatic

Fig. 193: Sensor-controlled low idle automatic menu 1 2

Timeâ&#x20AC;&#x201C; Time+

Time window

LHB/11110170/02/2011-07-21/en

With sensor-controlled low idle automatic activated: if the joysticks or the travelling pedal are not operated within the set time window, the engine speed is automatically reduced. This saves fuel and reduces noise emissions. Gripping the joystick or operating the pedal restores the original engine speed.

LH 120 C-1103 / 49287

Operating manual

Control and operation Control

Fine adjustment of the control

Fig. 194: Fine adjustment menu with menu bar (example) 1 2

Minus– Plus+

3 4

Fine adjustment menu bar28) Scroll up/down

The fine adjustment of the control is performed in this menu. Here, you define how strongly the activation of control elements affects the performance of the individual functions. Use the fine adjustment to set the control character suitable for your work. Each function can be accessed using the “Fine adjustment menu bar”. The fine adjustment of the functions can be adapted using the Plus+ or Minus– symbols. The value (percentage or pressure) symbolises the maximum achievable speed or force of the affected machine components. The function can be used without restriction at the highest value (e.g. 100%). The higher the value is set, the more strongly the machine responds to the control. Select a lower value if you find the control too direct, or if you wish to control individual functions of the machine more sensitively. All settings in the Fine adjustment menu are stored individually in the currently active user profile (For more information see: User profile, page 96) . WARNING After the fine adjustment has been changed, you may be unused to the control response. Increased danger of accidents! u Only change the fine adjustment in your own user profile.

LHB/11110170/02/2011-07-21/en

u Before continuing to work: check how the machine responds to the changed setting.

28) The

indication can vary depending on the equipment. copyright by

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

Fine adjustment menu bar29) Symbol

Fine adjustment of

Explanation

Note

Servo control

Control pressure limitation The value set here is the upper limit for all functions that can be set in the menu. An identical or a lower value can be selected for the targeted fine adjustment of individual functions. A higher value is not possible.

Applies to machines with adjustable control pressure limitation

Slewing gear

Speed

Travel gear

Dynamics

Applies to wheeled excavator

Tracked travel gear

Speed

Applies to machines with tracked travel gear

Grapple

Speed and force of grapple shells and rotating device

Boom and stick

Speed

Adjustable boom

Speed

Applies to machines with adjustable boom

Laterally adjustable boom

Speed

Applies to machines with laterally adjustable boom

AutoLift

Speed and force for the automatic lifting of the boom while the grapple is closed.

Applies to machines with AutoLift

Rotary handle

Speed

Applies to machines with rotary handle

Cab lift

Speed

Applies to machines with cab lift

Cab tilt

Speed

Applies to machines with adjustable cab tilt

Tab. 15: Fine adjustment menu bar

LHB/11110170/02/2011-07-21/en

u Increase value: select the Plus+ symbol. u Reduce value: select the Minusâ&#x20AC;&#x201C; symbol.

29) The

display can vary depending on the equipment and model variant. copyright by

LH 120 C-1103 / 49287

Operating manual

Control and operation Control

Cab lift

Fig. 207: Cab lift menu

LHB/11110170/02/2011-07-21/en

The menu assists operation of the cab lift and shows the position of the operator's cab. The function and the corresponding menu is activated with the Cab lift key (For more information see: 3.2.9 Cab lift (special equipment), page 64) .

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

User profile

Fig. 209: User profile menu 1 2

Factory settings User profiles

Onscreen keyboard

A user profile makes it possible to store the fine adjustment of the control individually (For more information see: Fine adjustment of the control, page 93) . This is advantageous if several persons work with the same machine and you would like to call up your personal settings quickly and easily. When a user profile is activated, the last saved settings are restored. Several user profiles are available, according to the setting of the machine. The name of the user profile can be changed using the onscreen keyboard. The "factory settings" user profile is intended for maintenance work or for Liebherr customer service. It resets all settings without changing any of the other profiles.

Fig. 210: Onscreen keyboard

u If required, select the Onscreen keyboard symbol and rename the user profile. u You can adapt the â&#x20AC;&#x153;fine adjustment of the controlâ&#x20AC;? to your personal requirements if you wish (For more information see: Fine adjustment of the control, page 93) . u Start the machine.

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

u Switch on the ignition and select a user profile.

Operating manual

Control and operation Control

Auxiliary heater auxiliary tank

Fig. 211: Auxiliary heater auxiliary tank menu 1

Fill level

Filling

The auxiliary heater of a machine with cab lift is supplied with diesel fuel from an auxiliary tank on the rear of the cab. This menu shows the fill level of the auxiliary tank. During operation, the auxiliary tank is automatically topped up with fuel from the fuel tank of the uppercarriage. The â&#x20AC;&#x153;fillingâ&#x20AC;? function tops up the auxiliary tank immediately. It may be necessary to start filling manually if the auxiliary tank is empty (e.g. after maintenance work or before the initial filling). This is not required in normal operation. u Select the filling symbol. w The auxiliary tank is filled.

Stick cylinder shut-down, hoist cylinder shut-down Moving the working attachment results in considerable heights and reaches. The working attachment and the suspended load can collide with the machine, the operator's cab or nearby obstacles within its range. Inattentiveness by the machine operator could result in endangering the operator, the operator's cab, the surroundings and the working attachment with the suspended load. In order to support the machine operator, the movement range of the working attachment can be restricted. The shut-off points of the attachment components can be adjusted for this purpose.

LHB/11110170/02/2011-07-21/en

Authorization: It depends on the configuration whether or not you can adjust the reach of the working attachment. If the symbols in the menu are inactive then you do not have the required authorization. In this case, contact the responsible machine owner or Liebherr customer service.

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

DANGER The shut off serves as assistance for the machine operator! The working attachment cannot stop abruptly due to its function. The faster the working attachment is moved, the longer the stopping distance. The machine can rock! Danger of accidents due to collision with the working attachment! u Set the shut-off points so that a safe distance is provided even when the working tool is swinging, and there is a long stopping distance. u Establish the authorization: Who is responsible for setting the shut off? u Inform all users of the machine about the changes to the shut-off points. Make sure that the stick cylinder shut-down or the hoist cylinder shut-down is deactivated during the setting. Note Increased risk of accidents with the shut off deactivated. u Only deactivate the shut off for adjustment work, then reactivate it. u Exercise increased care when moving the working attachment.

Setting the stick cylinder shut-down

Fig. 212: Stick cylinder shut-down menu 1 2

On/off Outer shut-off point (reach)

3 4

Inner shut-off point (reach) Confirmation required

u Move the stick out to the required reach. u Select the Outer shut-off point symbol. w The “Confirmation required” symbol appears. w Now, you have a few seconds of time to confirm the reach. u Press the confirmation key. w The outer shut-off point is stored. u Move the stick in to the required reach. u Select the Inner shut-off point symbol. w The “Confirmation required” symbol appears.

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Setting the shut-off points allows the maximum possible movement range of the stick to be restricted.

Operating manual

Control and operation Control

w Now, you have a few seconds of time to confirm the reach. u Press the confirmation key. w The inner shut-off point is stored.

Setting the hoist cylinder deactivation

Fig. 214: Hoist cylinder deactivation menu 1 2

On/off Top shut-off point (reach)

3 4

Bottom shut-off point (reach) Confirmation required

Setting the shut-off points allows the maximum possible movement range of the boom to be restricted. u Move the boom up to the required reach. u Select the Top shut-off point symbol. w The “Confirmation required” symbol appears. w Now, you have a few seconds of time to confirm the reach. u Press the confirmation key. w The top shut-off point is stored. u Move the boom down to the required reach. u Select the Bottom shut-off point symbol. w The “Confirmation required” symbol appears. w Now, you have a few seconds of time to confirm the reach.

LHB/11110170/02/2011-07-21/en

u Press the confirmation key. w The bottom shut-off point is stored.

LH 120 C-1103 / 49287

Control and operation

Operating manual

Control

3.2.26 Information menu

Fig. 216: Information menu 1 2 3

Operating time Fuel consumption Key assignment

4 5

Electrical outputs Electrical inputs

Driving in normal gear Modes Diesel engine at maximum speed Diesel engine in low idle

Operating time

1 2 3

Joysticks Slewing gear Working tool

5 6 7

Driving in high gear

The menu provides information about the operating time of individual functions, operating modes and rpm.

100

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Fig. 217: Operating time menu

Operating manual

Control and operation Control

Fuel consumption

Fig. 218: Fuel consumption menu 1

Consumed fuel30)

2 3

Average consumption30) Measurement period

Average consumption in the past 60 seconds Reset meter

Key assignment

Fig. 219: Key assignment menu

LHB/11110170/02/2011-07-21/en

The menu shows the key assignment of two control units depending on the equipment.

30) since

the last meter reset copyright by

LH 120 C-1103 / 49287

101

Control and operation

Operating manual

Control

Electrical outputs

Fig. 220: Electrical inputs and outputs menu The menu is a quick overview for Liebherr customer service. It shows the operating conditions of the electrical outputs.

Electrical inputs

Fig. 221: Electrical inputs menu

LHB/11110170/02/2011-07-21/en

The menu is a quick overview for Liebherr customer service. It shows the configuration of electrical inputs (control elements).

102

LH 120 C-1103 / 49287

Operating manual

Control and operation Control

3.2.27 Messages menu

Fig. 222: Messages menu 1

Message text

2 3 4

Page up Page down Message symbol

6 7

Unconfirmed message, no longer valid Confirmed message Unconfirmed message

The menu lists information and error codes in the form of text messages. The message symbol appears in various colours, depending on the content of the menu: – White: no messages – Flashing red: messages present – Flashing white: messages have been confirmed, but the faults have not yet been rectified. If the message symbol flashes red: u Display the messages menu. u Read the messages carefully and confirm them. u Confirm message: touch the confirmation symbol next to the text. u Contact Liebherr customer service if necessary for fault rectification.

LHB/11110170/02/2011-07-21/en

3.2.28 Radio system (special equipment)

Fig. 223: Radio system u Comply with the manufacturer's operating manual. u Radio remote control31) : see Chapter "Indicating unit, General settings menu, Radio remote control"

LH 120 C-1103 / 49287

103

Control and operation

Operating manual

Control

u Radio mute: Press the Radio mute key. w Playback is interrupted.

LHB/11110170/02/2011-07-21/en

u Press the Radio mute key again. w Playback is continued.

31) Special

equipment copyright by

104

LH 120 C-1103 / 49287

Operating manual

Control and operation Operation

3.3 Operation 3.3.1 Inspection tour before commissioning Checkpoint

Activity

Overall status

Check the machine for loose pins, cracks, wear, leaks and damage. Never take a defective machine into operation. Have damage repaired immediately.

Warning signs

Check that all warning signs on the machine are in place and are clearly legible. Replace signs that are missing or illegible.

Protective devices

Check that all protective devices on the machine are in place and are functioning (e.g. safety belt, steps, railings, etc.).

Intake area

Clean the engine bonnet and uppercarriage in the area of the cooling air and combustion air intake to remove dirt, ice and snow.

Window panes and mirrors

Clean window panes and mirrors. Adjust the mirrors. Windscreen washer system: check the fill level in the tank, replenish cleaning agent if necessary. Check the antifreeze concentration.

Doors and covers

Close all caps, covers and doors but do not activate the locks, so that the source of any fire can be accessed quickly. Close the doors and secure the windows against inadvertent movements.

Diesel engine

Check the oil level.

Cooling system

Check the coolant fill level. Check the radiator for contamination, clean it if necessary.

Fuel system

Check the fuel system for damage and leaks. Drain water from the fuel pre-filter.

Hydraulic system

Check the oil level. Check the hydraulic lines for damage and leaks.

TyresA)

Check the tyres for damage, missing or loose wheel nuts, sufficient pressure and tread depth. Have defects repaired immediately.

Crawler unitA)

Check the crawler unit for damage, missing or loose parts. Have defects repaired immediately.

People in the danger zone

Make sure that no-one is working on or under the machine. Sound the horn to warn people in the vicinity before taking the machine into operation. Do not start operation if people do not leave the danger zone in spite of being warned.

Climbing facilities

Have missing or defective steps, railings and handles renewed. Clean contaminated, slippery climbing facilities. Keep both hands free for climbing.

LHB/11110170/02/2011-07-21/en

Tab. 16: Inspection tour A)

depending on travel gear type u Always carry out a thorough inspection tour all round the machine before taking it into operation. u Make sure that the machine is protected against rolling away. Ensure there is free access to the areas that have to be checked.

LH 120 C-1103 / 49287

105

Control and operation

Operating manual

Operation

3.3.2 Refuelling

Fig. 225: Fuel tank, tank lid The tank lid can be secured with a lock. We recommend that the lock should be attached at all times to guard against theft of diesel fuel. Note If the fuel tank is completely drained with the engine running, the fuel system will suck in air. The fuel lines will then have to be bled, which is a time-consuming procedure. u Never run the fuel tank empty. u Refuel in good time. DANGER Fuel is highly inflammable! Risk of explosion! u When refuelling, do not smoke or use naked flames.

LHB/11110170/02/2011-07-21/en

u Unscrew the tank lid and fill fuel through the strainer.

106

LH 120 C-1103 / 49287

Operating manual

Control and operation Operation

3.3.3 Refuelling from a tanker (special equipment)

Fig. 226: Hose drum for pressurised refuelling 1 2 3 4

Hose drum with return spring Hose coupling Stop cock Pressure hose

5 6 7

Socket for fill level monitoring Holder for cable Cable

DANGER Fuel is highly inflammable! Risk of explosion! u When refuelling, do not smoke or use naked flames. Note Never run the fuel tank empty! If the fuel tank is completely drained with the engine running, the fuel system will suck in air. The fuel lines will then have to be bled, which is a time-consuming procedure. u Never run the fuel tank empty. LHB/11110170/02/2011-07-21/en

u Refuel in good time. Note Refuelling procedure with fill level monitoring! The machine is equipped with fill level monitoring in the fuel tank; this interrupts the refuelling procedure when the maximum fill level in the fuel tank is reached. For this purpose, an electrical connection is established between the refuelling pump on the tanker and the fuel tank of the machine. u Do not refuel if the fill level monitoring, connecting line, plugs or shut-off mechanism in the tanker are damaged.

LH 120 C-1103 / 49287

107

Control and operation

Operating manual

Operation

u Park the tanker with its refuelling pump on the right-hand side of the machine. u Climb up to the hose drum for pressurised refuelling. u Lower the cable attached to the hose end 7 to the ground. u Pull the connecting line from the tanker upwards using the cable. u Connect the plug of the connecting line into the socket 5. u Lower the cable back to the ground. Note Unroll the hose: the hose reeling device can be locked each time there is a clicking noise. There are two locking opportunities in each rotation. After locking, it is possible to work with the hose free from tension. u Unreel the hose from the hose drum until the required length is achieved. u Pull the pressure hose downwards on the cable. u Connect the hose coupling 2 to the connection on the tanker. u Open the stop cock 3 on the pressure hose. u Start the refuelling: switch on the refuelling pump at the tanker. u After refuelling: close the stop cock on the pressure hose and disconnect the hose from the tanker. Note Reel in the hose: unreel the hose by about a quarter turn. This releases the locking mechanism. The hose is reeled in automatically. u For safety reasons, and in order to avoid injuries and damage to the hose drum, guide the hose by hand when reeling in. u Reel in the hose. u Pull the plug of the connecting line on the fuel tank out of the socket and lower to the ground with the cable. u After use, reel in the cable onto the holder 6.

3.3.4 Starting the engine Make sure that the electrical system (battery main switch) is switched on. u Turn the starter key to position 1. w The ignition is switched on. w Once the ignition has been switched on, the self-check of the indicator lights (LEDs) starts: all indicator lights light up briefly. u During the self-check: observe the function of the indicator lights Have defective indicator lights renewed.

108

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

u Move the safety lever to the upper position.

Operating manual

Control and operation Operation

Note Preheating of the engine is started at low ambient temperatures. The "Preheating" status symbol appears on the indicating unit. It disappears at the end of the preheating phase. u Do not start the engine in the preheating phase. u Start the engine at the end of the preheating phase. NOTICE Cold start! The engine can be damaged! u If the engine oil is cold, do not run the engine at full load immediately after starting. u Start the engine and run the engine at idle rpm for 15 seconds. u Slowly warm the engine up by running it at medium load and medium rpm. u Press the Engine start / stop key. w The engine is started. w The control operates the starter until the engine is running smoothly.

Troubleshooting If the engine does not start The control automatically cancels an unsuccessful start attempt after 30 seconds. If there are two unsuccessful start attempts, it is highly probable that there is a malfunction. If the starting process is still unsuccessful: u wait for at least one minute before the next start attempt. u Press the Engine start / stop key again. u If there are two unsuccessful start attempts, establish the cause of the fault and eliminate it.

3.3.5 Starting process at low ambient temperatures

LHB/11110170/02/2011-07-21/en

When starting at temperatures below -18 Â°C, it is recommended for the machine to be equipped with one of the start assist functions offered by Liebherr.

LH 120 C-1103 / 49287

109

Control and operation

Operating manual

Operation

3.3.6 Operating mode and engine speed

Fig. 230: Operating mode, speed step 1

Operating mode

Speed step (1 to 10)

An operating mode is an optimised and energy-saving combination of preset values for specific use of the machine power. The control combines engine speed and hydraulic performance in accordance with the selected operating mode. Operating mode Key

LEDs in key

Application Mode S (SENSITIVE)

For especially precise work or lifting loads

E (ECO)

For particularly economical and environmentally friendly work.

P (POWER)

For high transfer loading performance and heavyduty applications.

P+ (POWER PLUS)

For maximum transfer loading performance and heavy-duty applications.

Tab. 17: Operating modes

Select operating mode P+ by selecting speed step 10 using the Engine speed controller. You can exit operating mode P+ again by reducing the speed step or pressing the MODE key again. The operating mode and engine speed cannot be set independently of one another. Adjusting the speed step automatically results in a jump to the matching operating mode. Adjusting the operating mode automatically results in a jump to the matching speed step.

110

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Select operating mode S, E and P by pressing the MODE key several times or using the Engine speed controller.

Operating manual

Control and operation Operation

NOTICE The LED for the most recently activated operating mode flashes after the engine is started. However, the operating mode is only activated by pressing the MODE key again. After a cold start, activating an operating mode with a high engine speed too soon can result in engine damage. u Before changing to P or P+ operating mode: slowly warm the engine up by running it at medium load and medium rpm. u Press the MODE key until the required operating mode is active. or Turn the Engine speed controller to the right or left. w The controller automatically selects the operating mode matching the speed step, and vice versa.

3.3.7 After starting DANGER Risk of suffocation due to exhaust fumes when the engine is run inside buildings. u Do not run the engine in enclosed rooms unless there is adequate ventilation. u Open the doors and windows of the building in order to ensure an adequate fresh-air supply. WARNING Low oil temperatures have the effect of the control system operating sluggishly. Risk of accidents if the functional check is not carried out. u Before exposing the machine to full load, bring the engine and hydraulic oil to operating temperature. u Carefully drive the machine onto open ground and check all safety-relevant functions. Note The power and service life of the diesel engine will be reduced significantly once a certain altitude is reached, with corresponding ambient temperatures! Under these circumstances, there is an increased risk of overheating in the coolant circuit. To avoid engine damage, the performance is automatically reduced in line with increasing altitude above sea level and ambient temperature. LHB/11110170/02/2011-07-21/en

u Under the specified conditions, pay more careful attention to the temperature of the engine and the hydraulic system. Check during operation: – Is the oil pressure constant? – Are performance and rpm constant? – Is the exhaust colourless? – Is the coolant temperature stable? – Are the engine noises normal? u Plan a warm-up phase.

LH 120 C-1103 / 49287

111

Control and operation

Operating manual

Operation

u Monitor the engine during operation in order to be able to recognise faults in good time. Troubleshooting Is there an engine fault? u Shut down the engine immediately.

3.3.8 Sensor-controlled low idle automatic

Fig. 237: Main menu, Sensor-controlled low idle automatic 1

Speed step 1

Stored speed step

The sensor-controlled low idle automatic reduces the engine speed automatically when the safety lever is in the upper position or the joystick and the travel gear control are not operated. This saves fuel and reduces noise emissions. Gripping the joystick or operating the travel gear restores the original engine speed. Activate the function with the Sensor-controlled low idle automatic key. The main menu displays two rpm values when the sensor-controlled low idle automatic is activated. The white pointer is for speed step 1. The blue pointer is for the previously selected speed step. The length of time between the release of the control elements and the reduction of the engine speed can be adjusted: see the "Device-specific settings" menu.

NOTICE When the engine is shut down, the engine control unit remains active for about 40 seconds in order to store system data! In rare cases, switching off the battery main switch during this period can result in the diesel engine no longer being able to be started! u Do not interrupt the engine control unit's storage procedure. u Wait for one minute before switching off the battery main switch when the engine has been shut down.

112

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

3.3.9 Shutting down the engine

Operating manual

Control and operation Operation

NOTICE The auxiliary heater (if fitted) continues to operate for some time after the ignition is switched off. Switching off the battery main switch during this period can damage the auxiliary heater! u Do not interrupt the shut-down delay procedure of the auxiliary heater. Once the delayed shut-down is terminated: u Switch off the battery main switch. u Move all control elements to their neutral position. u Press the Engine start / stop key. w The engine speed is automatically reduced to speed step 1 (low idle), and then the engine is shut down. w If the engine was already at low idle, it is shut down immediately. u Turn the starter key to position 0. u Pull out the starter key.

3.3.10 Driving operation Running in / instructions on use Running in A new travel gear must be run in. The way the machine is driven in the first few operating hours has a significant effect on the quality and later wear of moving drive parts. The travel gear components will only have a long service life if they are run in correctly. – When travelling for the first time, travek carefully and accelerate moderately. – During the first operating hours only drive at a low speed and avoid long routes.

Driving percentage The service life of travel gear components is also significantly dependent on the operating conditions. Frequent driving and working on uneven ground leads to increased wear. This can result in additional maintenance costs LHB/11110170/02/2011-07-21/en

The machine should be driven as little as possible. The ideal percentage is less than 5 % driving per operating hour. Driving frequently over long distances and turning in a narrow turning radius should be avoided wherever possible.

Long distances “A long distance” for this machine means: – driving along a distance of more than 100 m – uninterrupted driving for more than three minutes On long distances the temperature of the travel gear rises considerably, increasing the load on moving parts.

LH 120 C-1103 / 49287

113

Control and operation

Operating manual

Operation

In order to prevent the travel gear overheating, the machine should not be moved more than 200 m per operating hour. If it is essential to travel significantly further, the temperature of the drive components must be monitored. An assistant using a temperature gauge is to be recommended. If the temperature of one of the moving parts (drive, chains, track idlers) exceeds the ambient temperature by more than 20 Â°C, the machine must be stopped immediately. Allow the travel gear to cool down sufficiently before moving again. Alternative methods can prevent overheating and accelerate cooling down, e.g. by spraying the travel gear with water. We recommend holding a large amount of water ready, e.g. in a tanker.

Driving

Fig. 241: Driving straight ahead: Front idler A

Idler

Travel drive

WARNING From the point of view of the machine operator, the directions have been inverted when the upper carriage is pivoted to the rear. Increased risk of an accident! u Align the upper carriage so that the idler is in the front and the travel gear is to the rear when driving forwards. Driving direction 1

forwards

forwards and to the right

backwards and to the right

backwards

backwards and to the left

forwards and to the left

Tab. 18: Travel lever The travel gear can drive in any direction. When driving in a straight line (forwards or backwards) both chains move at the same speed. When driving around a bend (to the right or to the left) the inside chain moves more slowly than the outside chain.

114

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Travel lever

Operating manual

Control and operation Operation

Special aspect when cornering: if the travel lever is moved to the right or left by 3/4 of its movement travel, the track on the inside of the bend stops. The one on the outside of the bend continues to run. If the travel lever is deflected further, the track on the inside of the bend runs in the opposite direction. The radius of the turn decreases as the deflection of the travel lever is increased. Full deflection causes the machine to rotate on the spot. Note When the chains run in opposite directions, the wear on the drive increases! u Avoid having the chains run in opposite directions or turning the machine on the spot. u Plan the route so that there is sufficient space for manoeuvring. u Ensure that the route is free and can be travelled without any risk. u Move the height-adjustable operator's cab33) to the upper park position. u Move the travel lever slowly in the direction you wish to take. w The speed of travel will increase the further the travel lever is moved to the front or rear. w The turning radius will decrease the further the travel gear is moved to the right or left. Troubleshooting Objective: reduce the dynamic load in a height-adjustable operator's cab 33) . u Travel slowly, avoiding uneven ground.

Braking WARNING If the travel lever is released quickly, the machine will come to an abrupt stop! You may find it difficult to stay on your seat! The machine can start to rock! Increased risk of an accident! u Avoid heavy braking manoeuvres.

Hydraulic brakes The hydrostatic travel drive also acts as an operating brake. When driving on gradients brake valves prevent the machine from acclerating excessively. The permitted speed is not exceeded. LHB/11110170/02/2011-07-21/en

u Release the travel lever slowly. w The tracked travel gear is no longer driven, the machine is braked.

Mechanical brakes The machine is secured against rolling away when the travel lever is in neutral position. The parking brake is applied automatically approx. five seconds after the travel lever is released. However, the working attachment can still be moved.

33) Special

equipment, e.g. cab lift copyright by

LH 120 C-1103 / 49287

115

Control and operation

Operating manual

Operation

Applying the parking brake If the parking brake has to be applied before it is done automatically, press the parking brake button. The parking brake must be released while working.

3.3.11 Observe the inclination angle The stability of the machine is at its greatest when it is set up horizontally. The stability is reduced the greater the inclination of the machine (inclination angle). The inclination angle must therefore be as low as possible, and must be adapted to the work as well as the ground on which the machine is working. The inclination angle is significantly limited in machines with a high centre of gravity. An angle measuring instrument (circular spirit level) in the operator's cab of these machines helps you to observe the maximum permitted inclination angle. Function of the circular spirit level: an air bubble is trapped in the liquid above the scale, and indicates the inclination angle of the machine. The air bubble is in the middle of the scale when the machine is horizontal, and moves towards the outside as the inclination angle increases.

Fig. 244: Angle measuring instrument: circular spirit level34)

Application

LH 120 C HR

LH 120 C G

Working

2.5°

Driving

5°

Tab. 19: Maximum permitted inclination angle u Select level ground for the machine. u Position the machine so the air bubble is as close as possible to the centre of the scale (inclination angle 0°). u Do not exceed the maximum permitted inclination angle.

34) applicable

to LH 120 C HR and LH 120 C G copyright by

116

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Maximum permitted inclination angle34)

Operating manual

Control and operation Operation

Troubleshooting The machine is equipped with a cab lift 35) and the inclination angle of the machine is hard to measure? The hydraulic levelling of operator's cab can result in angle deviations in the longitudinal axis of the vehicle. u Move the operator's cab to the home position (park position). u Check the inclination angle once in the longitudinal axis of the vehicle (uppercarriage in travel direction) and once at right angles to the longitudinal axis of the vehicle (uppercarriage turned through 90°). If the inclination of the operator's cab can be adjusted. u Set the inclination and align the cab floor in parallel with the uppercarriage.

3.3.12 Operating the working attachment

Fig. 245: Operating the working attachment 1

Joystick left

Joystick right

The left joystick controls the stick and slewing movements: – Movement direction a and b: stick is retracted and extended. – Movement direction c and d: uppercarriage is turned to the left or right. LHB/11110170/02/2011-07-21/en

The right joystick controls the boom and grapple movements: – Movement direction e and f: grapple is closed or opened. – Movement direction g and h: boom is raised or lowered. Note The machine is equipped with PCSA controls as standard. On request, the machine can be equipped with controls different from the PCSA controls. u Observe the additional instructions for the different controls.

35) Special

equipment copyright by

LH 120 C-1103 / 49287

117

Control and operation

Operating manual

Operation

Control the stick with the left joystick 1: u Move the joystick in direction a. w The stick retracts. u Move the joystick in direction b. w The stick extends. Control the boom with the right joystick 2: u Move the joystick in direction g. w The boom is raised. u Move the joystick in direction h. w The boom is lowered. Control the grapple with the right joystick 2: DANGER The grapple represents a danger of fatal injury for persons in the vicinity! u Never allow anyone to guide the grapple by hand. u Move the joystick in direction e. w The grapple is closed. u Move the joystick in direction f. w The grapple is opened.

3.3.13 Turning and braking the uppercarriage Turning the uppercarriage Make sure that the slewing gear brake is released. Turn the uppercarriage with the left joystick 1: u Move the joystick in direction c. w The uppercarriage turns to the left. u Move the joystick in direction d. w The uppercarriage turns to the right.

Braking the uppercarriage The uppercarriage can be braked hydraulically with the joystick. The mechanical slewing gear brake locks the stationary uppercarriage in any position.

u Move the joystick to the neutral position (release). w The uppercarriage is braked hydraulically to a sufficient extent. u Move the joystick in the opposite direction. w The uppercarriage is braked hydraulically to the maximum extent.

118

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Hydraulic braking

Operating manual

Control and operation Operation

Mechanical braking NOTICE Braking during turning can damage the mechanical slewing gear brake! u Only apply the mechanical slewing gear brake when the uppercarriage is stationary. u Release and apply the slewing gear brake: press the slewing gear brake key.

3.3.14 AutoLift (special equipment) The AutoLift function causes the working attachment to be raised slightly when the grapple closes. This reduces the danger of the grapple damaging the ground. Sample application: protection of the loading surface, ship's bottom or similar base structures. Activate the function with the AutoLift key. Note AutoLift provides assistance for the machine operator. The ground can be damaged due to inattentiveness even if the function is switched on. u Always move the working attachment with the greatest possible care.

3.3.15 Overload warning device (special equipment) Function and explanation The overload warning device measures the current load on the working attachment. It gives a visible warning (symbol) and an audible warning (warning sound) before the maximum permitted load lift is reached. The time of the warning is selected so that the stability factors of the machine can be maintained. This is intended to prevent the maximum permitted load lift from being exceeded inadvertently.

LHB/11110170/02/2011-07-21/en

The overload warning device does not release the machine operator from the responsibility of only lifting loads which are known will not exceed the safe working load of the machine. At the same time, the local accident prevention instruction must be complied with. If a warning is triggered, the reach must be reduced or the load put down without thereby increasing the reach. The maximum permitted load lift depends on the configuration of the machine (undercarriage, working attachment). This can be found on the load lift chart in the operator's cab. The load lift chart states the maximum permissible loads that can be lifted at the end of the stick, depending on the reach. Given the specified values, the uppercarriage can be swivelled through 360Â° on firm and level ground. The load capacity values achieve a maximum of 75% of the tip load or 87% of the hydraulic lifting power acc. to ISO 10567.

LH 120 C-1103 / 49287

119

Control and operation

Operating manual

Operation

No load lifting work is allowed to be performed if the overload warning device is defective. The machine must be repaired by an expert. The load lift values are changed by adding or removing attachment components and tool attachments.

Operation Activate the function with the overload warning device key. The overload warning status symbol appears in conjunction with a warning sound when the maximum permitted load lift is reached.

DANGER The overload warning device does not switch off the working attachment. It merely informs the machine operator that the maximum permitted load lift has been reached! Danger of accidents due to incorrect expectations on the overload warning device! If the overload warning device is triggered: u Do not increase the load and the reach under any circumstances. u Reduce the reach or put down the load without thereby increasing the reach.

Daily functional test The machine operator must check the overload warning device before each shift. u Raise the boom and extend the hoist cylinders as far as the stop. u Move the joystick further in the â&#x20AC;&#x153;raise boomâ&#x20AC;? direction. w If the overload warning device is intact, the warning symbol appears in conjunction with a warning sound. In case of a malfunction: u Do not perform any load lifting work. u Have the overload warning device repaired as soon as possible.

Technical check

LHB/11110170/02/2011-07-21/en

The overload warning device must be checked before commissioning and then once a year by an expert in accordance with Liebherr's testing and adjustment guidelines.

120

LH 120 C-1103 / 49287

Operating manual

Control and operation Operation

3.3.16 Turning and moving the tool attachment

Fig. 250: Mini-joystick on the left joystick 1 2

Turn function (e.g. turning grapple) Lock bolts, hydraulic quick change system

Left

Right

A mini-joystick on the left joystick is used for turning or moving tool attachments. This involves the "turning grapple" function which is used for grapples or other tool attachments. The further the mini-joystick is moved in one direction, the faster the tool attachment moves. u Press the mini-joystick to the left. w The tool attachment turns to the left. w The lock bolts move out.

LHB/11110170/02/2011-07-21/en

u Press the mini-joystick to the right. w The tool attachment turns to the right. w The lock bolts move in.

LH 120 C-1103 / 49287

121

Control and operation

Operating manual

Operation

3.3.17 Magnet system (special equipment) The magnet system controls and supplies power to a magnet that can be mounted on the attachment, e.g. a load lifting magnet for moving scrap. DANGER The magnet can drop the load if there is a loss of electrical power! Danger of accidents! u Always make sure there is no-one under the load. u Make sure that the control elements are not operated at the wrong time or inadvertently. DANGER The magnetic field can damage electronic equipment and magnetic data storage media! The vicinity of the magnet represents a danger of fatal injury for people with pacemakers! u Make sure that people with pacemakers stay away from the magnet. u Keep magnetically sensitive equipment36) away from the magnet. How to operate the magnet system: Activate the magnet system using the Magnet system push-button, switch the magnet using the Magnet system push-button on the right joystick.

Fig. 251: Joystick right, activate magnet 1

Joystick right

Magnet system push-button

The control automatically prevents low engine speeds to guarantee the power supply for magnet operation. When the magnet system is activated, the engine can only be operated at higher speed steps. u Activate magnet: Press the magnet system push-button. u Pick up the load, move carefully.

36) E.g.

mobile phones, digital cameras, computers, radio equipment, credit cards, memory cards copyright by

122

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

u Switch on the magnet system: press the Magnet system key. w The LEDs in the key light up. w The engine speed increases automatically. w The sensor-controlled low idle automatic function is inoperative.

Operating manual

Control and operation Operation

u Put down the load, only then switch off the magnet. u Deactivate magnet: Press the magnet system push-button again. u Deactivate magnet system: Press the magnet system push-button again.

3.3.18 Reversible fan drive (special equipment) The reversible fan drive is intended for machines which frequently have severe contamination in their air intake area (ventilation slots, grille, radiator), e.g. dustintensive operation. The function allows the air intake area to be cleaned quickly and easily. This can prevent overheating of the engine and the hydraulic system. The fan drive can reverse its direction of rotation, and thus the airflow direction. In this case, the air is no longer drawn into the engine compartment from outside, but is blown out of the engine compartment through the radiator. The air can carry contamination away with it. If the air intake area is frequently heavily contaminated, the airflow direction must be reversed correspondingly frequently. Activate the function using the reversible fan drive key. NOTICE Dirt in the air intake area reduces the cooling power! The reversible fan drive cannot remove stubborn contamination! The engine and hydraulic system can overheat! u Do not reverse the airflow direction more frequently than once within 10 minutes. u Regularly check the air intake area and clean it by hand if necessary. Procedure for reversing the airflow direction: u Press and hold the key. w The LEDs in the key light up. w The fan stops and turns in the opposite direction of rotation after about 15 seconds. w The cleaning phase starts and continues until the key is released, for a maximum of 60 seconds. u Keep the key pressed until the air intake area has been cleaned.

LHB/11110170/02/2011-07-21/en

u Release the key. w The LEDs in the key go out. w The cleaning phase is finished. The fan stops and then runs in the original direction of rotation.

LH 120 C-1103 / 49287

123

Control and operation

Operating manual

General working methods

3.4 General working methods 3.4.1 Safety belt The probability of surviving an accident increases if the safety belt is fastened. The safest place in an accident is the protective operator's cab, with the safety belt fastened. Many severe and fatal injuries are due to the operator not having the seat belt fastened and attempting to jump out of the operator's cab in case of an accident. In the majority of cases, it is better to remain in the operator's cab. The accident prevention instructions demand that a safety belt must be fastened, and that it must be serviced and checked regularly.

3.4.2 Drugs and alcohol misuse Safe operation of large and powerful machinery is significantly dependent on the performance of the operator. Alcohol and drugs affect sensory perception. They slow reaction times, reduce attentiveness and make it more difficult to detect problematic situations. The consumption of alcohol and drugs not only endangers the operator himself, but also everyone else at the place of use. Misuse of alcohol and drugs can have severe or fatal consequences and lead to damage. Do not consume either alcohol or drugs at the workplace.

Comply with the following points in order to increase the service life of the machine and to avoid unnecessary damage and the need to carry out repairs as a result: – Repeated striking of the working attachments against hard material will lead to damage to the machine. Do not use the working attachment to strike against material or objects to be demolished. – Certain combinations of boom, stick and working tool mean that the working tool can strike against or penetrate the operator's cab. This can damage the operator's cab and injure the machine operator. – The slewing gear can be damaged if the rotary motion is obstructed by an opposing force. Do not use the slewing gear to force the working attachment to penetrate material. – The machine can be damaged by being raised using the working attachment. Do not lift the machine using the working attachment. If this does happen inadvertently nevertheless, lower the machine slowly onto the ground. Do not allow the machine to drop quickly, and do not attempt to cushion the drop using the hydraulics.

124

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

3.4.3 Working without damaging the machine

Operating manual

Control and operation General working methods

NOTICE High pressures, torques and stresses can build up in the working equipment when tool attachments are used. The load is at its greatest when the hydraulic cylinders are completely extended or retracted (limit position) or the attachment is fully extended! Incorrect handling of the tool attachment can exceed the load limit. Attachment components, hydraulic cylinders and machines can be damaged! u Do not move the hydraulic cylinders in or out all the way. u Move the hydraulic cylinders carefully and slowly in the area of the limit positions (boundary area). u When turning tool attachments, maintain a distance of at least 10Âş from the limit position of the tilt cylinder.

Fig. 254: Permissible working range for hydraulic cylinders 1 2

4 5

Boom or stick Hydraulic cylinder

LHB/11110170/02/2011-07-21/en

Possible slewing range Permissible working range with 10Â° distance from the limit position Boundary area

LH 120 C-1103 / 49287

125

Control and operation

Operating manual

General working methods

3.4.4 Preparatory work

Fig. 255: Protect yourself

WARNING Risk of injury during work! u Wear safety boots. If required for certain jobs, wear a protective helmet and safety glasses. u Put on the safety belt before starting work. u Give a warning signal with the horn before starting work.

Fig. 256: Plan view of the danger zone of the machine 1 2

Machine Reach of the working attachment

Danger zone

DANGER Risk of fatal injury within the reach of the working attachment!

u Position the transport vehicle and machine so that the machine operator can easily see the load which is to be moved.

126

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

u Make sure that no-one is in the danger zone.

Operating manual

Control and operation General working methods

3.4.5 Working position

Fig. 257: Working position A

Idler

Travel drive

Only flat, level and stable ground is suitable for working with the machine. u Prepare the working area accordingly, remove obstacles. u Align the machine horizontally (see the â&#x20AC;&#x153;Aligning the machine horizontallyâ&#x20AC;? chapter). u Give preference to performing work with the machine using the idler.

3.4.6 Working with the grapple DANGER Danger of fatal injury due to a swinging grapple! The grapple can damage the operator's cab and injure the machine operator. The grapple can injure people standing in the vicinity. The stability of the machine can be endangered. u Never allow anyone to remain within the danger zone. u Make sure that the grapple does not swing too close to the operator's cab. u Position the stick so that the grapple cannot swing against the operator's cab during movement or braking. u Prevent the grapple from swinging: move the joystick carefully and slowly. LHB/11110170/02/2011-07-21/en

u Do not raise heavy loads with the boom and stick moved too far out. u Note the load lift chart37) .

37) The

load lift chart states the permissible loads that can be lifted at the end of the stick, depending on the reach. copyright by

LH 120 C-1103 / 49287

127

Control and operation

Operating manual

General working methods

3.4.7 Transferring loads DANGER Incorrect operation and unsuitable ground endanger the stability of the machine! The machine can rock and be made to tip! The travel gear can sink into the ground! u Check the ground has a sufficient load-bearing capacity. u Carry out all movements with increased care. u Do not move the machine whilst suspending loads. Put the load down (empty the grapple) before starting to travel. u Note the load lift chart. u Pick up the load carefully. u Keep the load close to the undercarriage and move it close to the ground if possible. u Make sure there is adequate safety clearance to the machine and the operator's cab (swinging grapple!). u Carefully swing the attachment over the loading area of the transport vehicle or the unloading point. u Put down the load (empty the grapple).

3.4.8 Loading a transport vehicle DANGER Danger of fatal injury due to falling load when loading vehicles! u Make sure that no-one is in the danger zone or in the vehicle during loading. u Do not load the transport vehicle so high that the load can drop over the sides. u Do not slew the working attachment over the cab of the vehicle. u Avoid unnecessary lifting of the load: if possible, position the machine higher than the transport vehicle. u Move up the transport vehicle so that it can either be loaded from the rear or the side. u Slew the working attachment over the loading area of the transport vehicle.

3.4.9 Load-lifting work Load-lifting work refers to lifting, transporting and lowering loads with the help of lifting tackle (cable, chain, etc.). The assistance of other persons is required in order to attach and release the load. This includes removing and lowering pipes, manhole rings or containers.

128

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

u Distribute the load evenly over the loading area.

Operating manual

Control and operation General working methods

DANGER Missing or non-operative safety devices for load-lifting work! Danger of accidents due to the lifted load dropping, if the permitted load lift is exceeded or hydraulic cylinders are damaged. u Only operate the machine for load-lifting work if the safety devices are present and functional. In accordance with European Standard EN 474-5, machines for load-lifting work must be equipped with the following safety devices:: – Lifting tackle for safe attachment of a load Safe lifting tackle includes load lift hooks that are mounted instead of the digging tool. Load lift hooks can also be replaced by safety hooks that are welded onto the digging tool. – Overload warning system The overload warning system must indicate to the machine operator by visible and audible means when the maximum permitted load lift is exceeded. – Pipe fracture safety valve on the hoist cylinders The pipe fracture safety valve must meet the requirements of ISO 8643. – Load lift chart in the operator's cab

LHB/11110170/02/2011-07-21/en

If the aforementioned points are not complied with, or not complied with in full, then no load-lifting work is allowed to be performed.

LH 120 C-1103 / 49287

129

Control and operation

Operating manual

Parking and exiting the machine

3.5 Parking and exiting the machine u Shut down the machine on level and firm ground. u Move the safety lever up. w The parking brake is applied. u Stop the engine. Troubleshooting You are planning not to use the machine for an extended period? The battery can discharge during extended periods on non-use.

LHB/11110170/02/2011-07-21/en

u Switch off the battery main switch before extended periods of none-use.

130

LH 120 C-1103 / 49287

Operating manual

Control and operation Transport and assembly

3.6 Transport and assembly Normally, the machine is only fully assembled at the place of use. The individual working steps are performed in accordance with Liebherr assembly guidelines. Assembly, disassembly and transport are only allowed to be carried out by trained specialist personnel from Liebherr, or by partners authorised by Liebherr.

LHB/11110170/02/2011-07-21/en

Contact the responsible customer service if the machine is to be transported or converted.

LH 120 C-1103 / 49287

131

Control and operation

Operating manual

Emergency operation

3.7 Emergency operation 3.7.1 Lowering the working attachment with the engine shut down

Fig. 258: Lower the working attachment: starter key in position 1 The working attachment can be lowered without power under its own weight. If the ignition is switched on and the control is functioning without problems, the working attachment can also be lowered with the engine shut down. Note A pressure reserve in the servo control makes it possible to lower the working attachment without power. The pressure reserve is limited and is only sufficient for a few movements of the control element! u In an emergency, only use the control elements (joysticks) for lowering the working attachment. If the motor stops and cannot be restarted with the working attachment raised: u Turn the starter key to position 1.

LHB/11110170/02/2011-07-21/en

u Operate the joystick until the working attachment is lowered.

132

LH 120 C-1103 / 49287

Operating manual

Control and operation Emergency operation

3.7.2 Operator's cab emergency discharge Applies to machines with three-way cab lift adjustment There are emergency discharge levers for manually lowering the operator's cab located on the back of the operator's cab and on the platform of the uppercarriage. Which emergency discharge should be used depends on the situation: Emergency discharge

Who?

In what situation?

Operator's cab

Machine operator

The control fails and the operator's cab cannot be moved to the park position using the cab adjustment levers.

on the uppercarriage

Auxiliary person

The machine operator cannot lower the operator's cab by himself, and needs to be rescued. The operator's cab should be moved into the park position.

Tab. 20: Emergency discharge depending on situation DANGER The operator's cab can trap persons when it is moving down, and also collide with the machine. Risk of injury, possibly with fatal consequences! u Make sure no-one is in the danger zone (under the operator's cab). u Rapid and correct response in an emergency: learn how to operate the emergency discharge. u Before the operator's cab collides with the machine: stop the movement (turn the emergency discharge lever back).

LHB/11110170/02/2011-07-21/en

u Keep your distance from moving parts when the operator's cab is moving down.

Fig. 259: The sticker identifies the emergency discharge 1

Stick emergency discharge lever

Boom emergency discharge lever

LH 120 C-1103 / 49287

133

Control and operation

Operating manual

Emergency operation

Lower the operator's cab: u Turn the emergency discharge lever for the boom or stick to the “emergency discharge” position, depending on the requirement. w The operator's cab moves downwards. u Use the emergency discharge lever so that the operator's cab arrives in the upper or lower park position. The operator's cab cannot be raised any longer when the emergency discharge lever is in the “emergency discharge” position.

LHB/11110170/02/2011-07-21/en

u After lowering, turn the emergency discharge lever to the “normal operation” position.

134

LH 120 C-1103 / 49287

4 Malfunctions

The indicating unit signals operating faults by means of symbols and messages, possibly in conjunction with a warning sound. The messages facilitate fault diagnosis. Operating faults are often due to the machine not being operated or maintained correctly. If there is a fault, re-read the corresponding chapter in the operating manual. Attempt to find the cause of the fault and have it rectified without delay.

Fig. 260

Note Contact Liebherr customer service if the cause of the operating fault cannot be detected or rectified. u Only perform work that you are qualified for or have been instructed in. u Describe the operating fault and all associated circumstances as accurately as possible.

LHB/11110170/02/2011-07-21/en

u State the machine type, serial number and year of manufacture.

LH 120 C-1103 / 49287

135

Malfunctions

Operating manual

Service code tables

4.1 Service code tables 4.1.1 Warning symbols Symbol

Explanation

Effect, characteristic

Remedy

Battery voltage too high; alternator defective

Electrical system can be damaged; malfunction

Shut down diesel engine; contact Liebherr customer service

Operating voltage too low; alternator defective

Malfunction possible

Oil level in the hydraulic tank too low

Hydraulic system can be damaged; hydraulic power is automatically reduced

Top up the hydraulic oil

Advance warning: hydraulic oil temperature rises significantly

Hydraulic system can be damaged; hydraulic power is automatically reduced

Shut down diesel engine; check hydraulic oil cooler for contamination; clean it if necessary; if the symbol is still displayed: contact Liebherr customer service

Fuel tank is almost empty.

Refuel

Water in the fuel filter; water in the fuel tank

Diesel engine malfunction possible

Drain water from fuel filter; drain water from fuel tank

Advance warning: fuel pressure Diesel engine malfunction is somewhat too high or too low possible (fuel filter contaminated, fuel lines clogged)

Renew fuel filter; if the symbol is still displayed: contact Liebherr customer service

Hydraulic oil temperature too high

Advance warning: fuel pressure Diesel engine malfunction is somewhat too high (fuel filter possible contaminated, fuel lines clogged)

Renew fuel filter; if the symbol is still displayed: contact Liebherr customer service

Fuel pressure is too high (fuel filter contaminated, fuel lines clogged)

136

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Fuel pressure is somewhat too high or too low (fuel filter contaminated, fuel lines clogged)

Operating manual

Malfunctions Service code tables

Symbol

Explanation

Effect, characteristic

Advance warning: fuel pressure Diesel engine malfunction is somewhat too low (fuel filter possible contaminated, fuel lines clogged)

Remedy Renew fuel filter; if the symbol is still displayed: contact Liebherr customer service

Fuel pressure is too low (fuel filter contaminated, fuel lines clogged) Advance warning:Rail 1, fuel pressure fault

Diesel engine malfunction possible

Shut down diesel engine; contact Liebherr customer service

Diesel engine malfunction possible

Shut down diesel engine; contact Liebherr customer service

Diesel engine malfunction possible

Renew fuel filter; if the symbol is still displayed: contact Liebherr customer service

Diesel engine malfunction possible

Shut down diesel engine; clean radiator; if the symbol is still displayed: contact Liebherr customer service

Rail 1, fuel pressure fault

Advance warning:Rail 2, fuel pressure fault Rail 2, fuel pressure fault

Advance warning: fuel pressure on supply side is somewhat too low Fuel pressure on supply side is too low Advance warning: fuel temperature is somewhat too high Fuel temperature is too high

LHB/11110170/02/2011-07-21/en

Advance warning: coolant level is Diesel engine can be somewhat too low damaged

Shut down diesel engine; top up coolant; if the symbol is still displayed: contact Liebherr customer service

Coolant level is too low

Advance warning: coolant temperature is somewhat too high

Diesel engine can be damaged

Coolant temperature is too high

Shut down diesel engine; reduce load; top up coolant; clean radiator; if the symbol is still displayed: contact Liebherr customer service

LH 120 C-1103 / 49287

137

Malfunctions

Operating manual

Service code tables

Symbol

Explanation

Effect, characteristic

Remedy

Advance warning: air filter contaminated, dust collecting tank full

Diesel engine can be damaged; engine power is automatically reduced

Empty dust collecting tank; renew air filter

Diesel engine can be damaged; engine power is automatically reduced

Clean radiator; if the symbol is still displayed: contact Liebherr customer service

Diesel engine can be damaged

Shut down diesel engine; contact Liebherr customer service

Diesel engine control fault

Diesel engine can be damaged

Shut down diesel engine; contact Liebherr customer service

Advance warning: oil pressure is somewhat too low; engine oil level is too low

Diesel engine can be damaged

Shut down diesel engine; top up engine oil; if the symbol is still displayed: contact Liebherr customer service

Advance warning: engine oil level Diesel engine can be too low damaged

Shut down diesel engine; top up engine oil; if the symbol is still displayed: contact Liebherr customer service

Air filter contaminated, dust collecting tank full Advance warning: charge air overheated Advance warning: charge air overheated Advance warning: fault in engine speed control Fault in engine speed control

Oil pressure is too low; engine oil level is too low

Diesel engine control fault

Diesel engine can be damaged

Shut down diesel engine; contact Liebherr customer service

Diesel engine control fault

Diesel engine can be damaged

Shut down diesel engine; contact Liebherr customer service

Engine speed sensor defective

Diesel engine can be damaged

Shut down diesel engine; contact Liebherr customer service

138

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Engine oil level too low

Operating manual

Malfunctions Service code tables

Symbol

Explanation

Effect, characteristic

Remedy

Fault in injection system

Diesel engine can be damaged

Shut down diesel engine; contact Liebherr customer service

Control fault, diesel engine emer- Diesel engine can be gency shut-down recommended damaged

Shut down diesel engine; contact Liebherr customer service

Control fault

Diesel engine can be damaged

Shut down diesel engine; contact Liebherr customer service

Synchronisation control fault

Diesel engine can be damaged

Shut down diesel engine; contact Liebherr customer service

General control fault

Function impairment; machine Shut down diesel engine; contact can be damaged Liebherr customer service

Oscillating axle malfunction

Setting of oscillating axle Shut down diesel engine; contact cannot be changed; danger of Liebherr customer service accidents

Pump distributor gear oil temperature too high

Pump distributor gear can be damaged

Central lubrication system grease Bearings can be damaged container empty due to inadequate lubrication.

Shut down diesel engine; reduce load; clean radiator; if the symbol is still displayed: contact Liebherr customer service Top up grease container

Central lubrication system grease container 1 empty Central lubrication system grease container 2 empty

LHB/11110170/02/2011-07-21/en

Screenwash fill level low

Windscreen cleaning impaired Top up screenwash

Fuel tank of the auxiliary heater is Auxiliary heater does not func- Top up fuel tank of the auxiliary almost empty tion heater

Tab. 21: Warning symbols

LH 120 C-1103 / 49287

139

Malfunctions

Operating manual

Fault – Cause – Remedy

4.2 Fault – Cause – Remedy

Malfunction / error

Cause

Remedy

Starter does not turn

Main fuse defective

Renew the fuse

Battery connections loose or corroded

Clean the battery connections and secure them

Starter circuit discontinuity

Contact Liebherr customer service

Starter defective

Contact Liebherr customer service

Battery voltage too low

Charge or renew the battery

Battery connections loose or corroded

Clean the battery connections and secure them

Ambient temperature too low

Observe measures for winter operation

Starter does not turn

see above

Fuel tank empty

Refuel, bleed the fuel system

Negative pressure in the fuel tank

Remove the tank lid

Fuel filter clogged

Clean or renew the fuel filter

Ambient temperature below 0 °C

Comply with the information for starting at low ambient temperatures

Pre-heat system defective

Contact Liebherr customer service

Fuel tank empty or negative pressure in the fuel tank

Refuel and bleed the fuel system

Fuel filter clogged

Clean or renew the fuel filter

Use of excessively viscous engine oil at low ambient temperature

Use an engine oil with a suitable viscosity class

Dry air filter clogged

Clean or renew the dry air filter

Air in the fuel system

Bleed the fuel system

Breather on fuel tank blocked

Clean

Fuel line or tank filter clogged

Clean

Fuel line kinked

Contact Liebherr customer service

Dry air filter clogged

Clean or renew the dry air filter

Injection nozzles defective

Contact Liebherr customer service

Turbocharger defective

Contact Liebherr customer service

Starter turns slowly

Engine does not start

Engine starts but stops again straight after or does not run smoothly

Smoking, exhaust is grey or black

Smoking, exhaust is constantly white Water is entering the combustion (water vapour) chamber

Contact Liebherr customer service

Injection system is not set correctly

Contact Liebherr customer service

Pre-heat system defective

Contact Liebherr customer service

140

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

4.2.1 Diesel engine and fuel system

Operating manual

Malfunctions Fault â&#x20AC;&#x201C; Cause â&#x20AC;&#x201C; Remedy

Malfunction / error

Cause

Remedy

Blue exhaust gases

Oil level too high

Correct the oil level

Engine oil is entering the combustion Contact Liebherr customer service chamber Crankcase ventilation defective

Contact Liebherr customer service

Engine pings

Combustion is incorrect

Contact Liebherr customer service

Engine knocks

Excessive valve lash

Contact Liebherr customer service

Injection nozzles damaged or conta- Contact Liebherr customer service minated by carbon deposits

Engine does not reach full speed

Low engine power

LHB/11110170/02/2011-07-21/en

Low engine power, power reduction by engine control unit

Bearing damage

Contact Liebherr customer service

Piston rings worn or broken

Contact Liebherr customer service

The engine speed is not set to the maximum value

Select a higher speed step or a different operating mode

Injection system is not set correctly

Contact Liebherr customer service

Dry air filter clogged

Clean or renew the dry air filter

Poor fuel supply, water in the fuel

Clean or renew the fuel filter, check the fuel lines, drain water from the fuel tank

Poor fuel supply, water in the fuel

see above

Defective fuel system

Contact Liebherr customer service

Charging pressure too low

Look and check for loose clamps, defective seals and hoses; clean or renew the dry air filter

Injection system defective

Contact Liebherr customer service

Compression too low

Contact Liebherr customer service

Control defective

Contact Liebherr customer service

Charging air temperature too high

Clean the intercooler, contact Liebherr customer service

Coolant temperature too high

Check the coolant level; check the radiator for contamination and clean it if necessary; check the fan and thermostat: contact Liebherr customer service

Fuel temperature too high

Shut down the engine and allow the fuel tank to cool down; check the radiator for contamination and clean it if necessary; contact Liebherr customer service

Hydraulic oil temperature too high

Reduce the power demand

Lack of oxygen in the combustion air, low air pressure at high altitude

Improve operating conditions, reduce the power demand

LH 120 C-1103 / 49287

141

Malfunctions

Operating manual

Fault â&#x20AC;&#x201C; Cause â&#x20AC;&#x201C; Remedy

Malfunction / error

Cause

Remedy

Engine overheats

Coolant level too low

Correct the coolant level

Coolant pump, thermostat or temperature sensor defective

Contact Liebherr customer service

Radiator contaminated

Clean the radiator

Oil level too low

Shut down the engine immediately, top up engine oil

Oil pressure switch defective

Shut down the engine immediately, contact Liebherr customer service

Oil loss

Engine leak

Contact Liebherr customer service

High oil consumption

Compression too low

Contact Liebherr customer service

Unusual noises, noise emissions from the exhaust system

Exhaust system leaking

Contact Liebherr customer service

Engine oil pressure too low

4.2.2 Hydraulic system Malfunction / error

Cause

Remedy

Unusual noises, noise emissions, hydraulic pumps are drawing in air

Stop valve on hydraulic tank closed, hydraulic oil level too low

Shut down the engine immediately, check the stop valve and fill level

Machine is moving too slowly

Selected speed step is too low

Select a higher speed step or a different operating mode

Power modes do not achieve the required performance

Control defective

Contact Liebherr customer service

Hydraulic oil temperature too high

Radiator contaminated

Clean the radiator

Fan drive defective

Shut down the engine, contact Liebherr customer service

Hydraulic oil level too low

Oil loss, leakage on the hydraulic system

Contact Liebherr customer service

Control elements inoperative

Servo control off, safety lever in the upper position

Switch on the servo control, move the safety lever down

Brake (slewing gear, travel drive) engaged

Release the brake

Control defective

Contact Liebherr customer service

Malfunction / error

Cause

Remedy

Oil leak on travel drive, track rollers, support rollers or idler

Seal damaged

Contact Liebherr customer service

Poor track guidance, track sagging substantially, track jumps off or over

Excessive play in idler guide

Contact Liebherr customer service

Inadequate chain tension

Adjust the chain tension

Idler or track sprocket worn

Contact Liebherr customer service

142

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

4.2.3 Travel gear

Operating manual

Malfunctions Fault â&#x20AC;&#x201C; Cause â&#x20AC;&#x201C; Remedy

Malfunction / error

Cause

Remedy

Correctly tensioned track quickly loses tension during operation

Track tensioning cylinders damaged

Contact Liebherr customer service

Travel gear blocked

Travel gear heavily contaminated

Clean the travel gear

4.2.4 Electrical system Malfunction / error

Cause

Remedy

Charge indicator symbol is displayed V-belt loose or torn after the engine starts Alternator defective

Tension or change V-belt

Batteries are not charged, or not charged sufficiently

Batteries faulty

Renew batteries

Battery connections loose or corroded

Clean the battery connections and secure them

Loose or damaged cables

Connect or renew cables

Detached or damaged cables, control defective

Contact Liebherr customer service

Fuse defective

Renew fuse

Malfunction of control and indicating elements

Engine speed cannot be changed

Contact Liebherr customer service

Sensor-controlled low idle automatic Switch off sensor-controlled low idle is switched on automatic or touch joystick

Sensor-controlled low idle automatic Incorrect control signal does not function, engine speed does not drop automatically

Contact Liebherr customer service

4.2.5 Heating, ventilation, air conditioning system Malfunction / error

Cause

Remedy

Heating does not provide warm air

Heat supply interrupted, control defective

Contact Liebherr customer service

Blower does not turn

No electrical power supply, blower motor defective

Contact Liebherr customer service

Insufficient blower power

Filter clogged

Renew filter

Air outlet closed

Open air outlet

Air conditioning condenser contaminated

Clean the air conditioning condenser

Temperature sensor, a/c compressor or other parts of the air conditioning system defective.

Contact Liebherr customer service

LHB/11110170/02/2011-07-21/en

Air conditioning system is not cooling

4.2.6 Working attachment Malfunction / error

Cause

Remedy

Hydraulic cylinder yields under load

Piston seal damaged, hydraulic line broken

Contact Liebherr customer service

LH 120 C-1103 / 49287

143

Malfunctions

Operating manual

Fault â&#x20AC;&#x201C; Cause â&#x20AC;&#x201C; Remedy

Malfunction / error

Cause

Remedy

Excessive bearing play on the working attachment

Bearings worn

Contact Liebherr customer service

Tool attachment cannot be operated Function is not switched on

Connect hydraulic line

LHB/11110170/02/2011-07-21/en

Hydraulic lines are not connected

Switch function on

144

LH 120 C-1103 / 49287

Operating manual

Malfunctions Problem remedy

4.3 Problem remedy 4.3.1 Fuses and relays DANGER Working on live parts can result in short circuits! Subsystems of the electrical system are directly connected to the battery and are still live even after the battery main switch has been turned off! Danger of accidents, fire risk, electric shock hazard! u Qualification: work on the electrical system may be carried out only by an electrician with knowledge of the corresponding circuit diagram. u Before working on the electrical system and before opening switch cabinets or safety covers, turn the battery main switch off. u Before working on components which are permanently live: disconnect the batteries. DANGER Incorrect or bridged fuses do not provide the necessary protection for persons and for the machine. Danger of accidents, fire risk, electric shock hazard! u Use genuine fuses only. u Only use fuses with the specified rating. u Do not bridge fuses. u Do not renew fuses before correcting the cause of the fault.

LHB/11110170/02/2011-07-21/en

For more information, refer to the supplied circuit diagram.

LH 120 C-1103 / 49287

145

Malfunctions

Operating manual

LHB/11110170/02/2011-07-21/en

Problem remedy

146

LH 120 C-1103 / 49287

5 Maintenance

5.1 Maintenance and inspection schedule Abbreviations used in this section: "oph" or "h" = operating hours Various symbols (circle, box, star - filled and circle, box, star - empty) divide the maintenance work into two groups. The symbols mean: Table with circle, box, star - filled In this case, the machine owner or the maintenance personnel must carry out the maintenance work under their own responsibility. Applicable for maintenance intervals: every 10 and 50 operating hours (h) and special intervals. The symbols mean: Table with circle, box, star - empty In this case, the maintenance and inspection work must be carried out by or led by authorised specialist personnel from Liebherr or a Liebherr dealership. Applicable for maintenance intervals: on delivery and every 500, 1000, 2000 operating hours (h) and special intervals.

LHB/11110170/02/2011-07-21/en

A list of spare parts required for maintenance and inspection work can be found in the â&#x20AC;&#x153;SERVICE PACKAGEâ&#x20AC;? of the spare parts list.

LH 120 C-1103 / 49287

147

Maintenance

Operating manual

Maintenance and inspection schedule Customer:..........................Machine type:.....................................Serial no.:...................Service hours:.........................Date:.................................

Other intervals

All 3000 h

All 2000 h

All 500 h

All 1000 h

All 50 h

All 8-10 h

On handover

Maintenance / inspection after service hours

Tasks to be performed By maintenance staff n Once-only activity l Repeat interval ÂŞ As necessary T Annually before the winter

See page

with authorised specialist staff o Once-only activity m Repeat interval Â˛ As necessary

Diesel engine o l l m m m m l m m m m

Checking the oil level

174

Visual check (leak tightness, contamination, damage)

174

m m m m

Checking the diesel engine brake (exhaust flap)

m m m m

Checking the exhaust gas recirculation shut-off flap

m m m m

Change the diesel engine oil (at least once a year). Take account of aggravating factors and shortened change intervals.

m m m m

Renewing the oil filter cartridge (at least once a year) Renewing the oil separator filter cartridge (at least every year)

m m m m m m m

Check the belt drive for damage, renew if necessary. Check the ribbed V-belt and tensioning pulley for damage. Checking the tension and setting if necessary

o m m m

Checking the intake system and exhaust system for damage, mounting and leak tightness

m m m

Greasing the starter ring gear on the flywheel (keep the sensor ring gear free from grease)

m m m

Checking the oil pan, engine mounts and engine brackets for firm seating Checking valve lash, adjusting if necessary

m m m m T

Checking the heater flange

m10000h Renewing the heater flange m3000h

Checking the vibration damper for deformation

m m m m

Checking the control unit mountings for damage

m m m m

Checking the sensors and cable connections for damage Cooling system Checking the cooling system for contamination, cleaning

o l l m m m m m m m m

175

Check the corrosion protection and antifreeze concentration in the coolant.

175

Checking the cooling system and heating system for leak tightness and condition

m m m m m m m m

Checking the coolant level

LHB/11110170/02/2011-07-21/en

l l m m m m

Â˛

Checking the cooling units and heat exchanger for contamination, cleaning if necessary Changing the coolant (at least every two years) Fuel system

l l m m m m l m m m m

Checking the water separator on the fuel pre-filter, draining water if necessary

176

Draining water and sediments in the fuel tank

177

148

LH 120 C-1103 / 49287

Operating manual

Maintenance Maintenance and inspection schedule

Customer:..........................Machine type:.....................................Serial no.:...................Service hours:.........................Date:.................................

Other intervals

All 3000 h

All 2000 h

All 500 h

All 1000 h

All 50 h

All 8-10 h

On handover

Maintenance / inspection after service hours

Tasks to be performed By maintenance staff n Once-only activity l Repeat interval ª As necessary T Annually before the winter

See page

with authorised specialist staff o Once-only activity m Repeat interval ² As necessary

Checking the lubricating oil and fuel system for leak tightness and condition (shorten the maintenance interval if necessary, depending on the application conditions, e.g. dust-intensive operating conditions, barrel fuelling)

m m m m

Renewing the fuel pre-filter (shorten the maintenance interval if necessary, depending on the application conditions, e.g. dust-intensive operating conditions, barrel fuelling)

m m m m

Renewing the fuel fine filter (shorten the maintenance interval if necessary, depending on the application conditions, e.g. dust-intensive operating conditions, barrel fuelling)

Bleed the fuel system (CAUTION! Injection lines must be renewed after being unscrewed three times). Air filter Checking the low pressure indicator of the air filter

178

Renewing the main element (according to maintenance indicator / every year)

178

Renewing the safety element (on every third renewal of main element / every year)

178

Emptying the dust collecting tank

179

Check the clean-air lines for damage and leak tightness every time the air filter is renewed.

180

o l l m m m m

l m m m m

Hydraulic components Checking the oil level in the hydraulic tank

181

Renewing the breather filter on the hydraulic tank (note the maintenance intervals are shorter in dust-intensive operations)

183

Renewing the filter cartridge on the control oil unit

183

Clean the magnetic rod in the return filter (do this every day during the first 300 operating hours)

185

o m m m

Renewing the filter cartridge in the return filter (note the maintenance intervals are shorter in dust-intensive operations)

185

o m m m

Cleaning or renewing the filter cartridge in the leakage oil filter (renew after cleaning a maximum of three times)

187

Changing hydraulic oil (optimise intervals by taking oil analyses)

188

Bleeding the hydraulic pumps (after the hydraulic oil change)

190

o l l m m m m m m m m m

LHB/11110170/02/2011-07-21/en

o n l m m m m

l m m m m

Checking the contamination level in the bypass oil filter (special equipment), renewing the filter element if necessary

o m m m

Renewing the filter cartridge in the return filter

Renewing the filter element in the bypass filter (special equipment) (every 250 operating hours under dust-intensive operating conditions)

m m m m

Renewing the supply oil filter on the slewing gear pump

LH 120 C-1103 / 49287

149

Maintenance

Operating manual

Other intervals

All 3000 h

All 2000 h

All 500 h

All 1000 h

All 50 h

All 8-10 h

On handover

Maintenance / inspection after service hours

Tasks to be performed By maintenance staff n Once-only activity l Repeat interval ª As necessary T Annually before the winter

See page

with authorised specialist staff o Once-only activity m Repeat interval ² As necessary

m m m m

Checking the component mountings

m m m m

Draining water from the hydraulic tank (if using biodegradable fluids the max. water content is 0.1%, use a bypass filter, take an oil sample)

m m m

Checking the hydraulic system for leak tightness and function

m m m

Checking / setting the servo, primary and secondary pressures Pump distributor gear Changing the gear oil in the pump distributor gear

m m m m

Slewing gear mechanism o

Checking the oil level and leak tightness

m m m m m m m

Checking the function and effectiveness of the slewing gear brake

m m m

Checking the mounting of the gearbox and hydraulic motor Changing the oil

o m m m m m m

Checking the mounting bolts on the slewing ring are firmly seated

m m m

Checking the meshing of the slewing gear pinion Crawler drive

l m m m m m m m o l l m m m m o m m m

Checking the mounting of the track pads and drive wheels

192

Checking the mounting of the travel drive and hydraulic motor

192

Checking the track tension, tightening if necessary

193

Changing the oil

196

m m m m

Checking the acid density and acid level in the battery cells

197

m m m m

Checking and cleaning the wire terminal and terminal posts of the batteries

197

m m m m

Checking the condition and correct installation of the central degassing hoses for the batteries

197

o l l m m m m

Checking warning lights and indicating device when switching on

m m m m

Checking lighting

m m m m

Spraying slip rings (if fitted) of the slewing gear connection with Cramolin contact spray

Checking function of the entire machine and components

m m m

Windscreen washer system Checking / topping up the screenwash in the screenwash container.

l m m m m

199

Automatic lubrication system o

l m m m m

m m m m

Topping up the grease container

200

Performing a functional test

150

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Electrical system

Operating manual

Maintenance Maintenance and inspection schedule

Customer:..........................Machine type:.....................................Serial no.:...................Service hours:.........................Date:.................................

Tasks to be performed

Other intervals

All 3000 h

All 2000 h

All 500 h

All 1000 h

All 50 h

All 8-10 h

On handover

Maintenance / inspection after service hours

By maintenance staff n Once-only activity l Repeat interval ª As necessary T Annually before the winter

Checking the maintenance of the entire system, pumps and control (at least once a year)

See page

with authorised specialist staff o Once-only activity m Repeat interval ² As necessary

Quick change system Checking the function of the visual and audible warning devices

o l l m m m m l l m m m m

Checking the lock bolt for damage when in extended position

l l m m m m

Checking the condition of the hydraulic hoses and the electrical cable Lubricating the lock bolt

l m m m m

Cleaning the screen filter

Working attachment and working tools l l

Checking the stability of the pin connections

201

l l

Performing a functional test

201

l l

Checking the steel structure for cracks

201

Checking the amount of wear on the teeth

201

Lubricating the bearings of the pins

201

Checking the bearings of the pins for wear.

201

Renewing the teeth

201

Overall machine

Checking the function of the heating system

Applying silicone or talcum powder to the sealing rubber profiles on the operator's cab.

Applying silicone or talcum powder to the sealing rubber profiles on the maintenance doors. Checking the entire machine has been maintained properly and is in good condition

m m m m

Lubricating all bearings on the machine (lubricate every day depending on the application of the machine or when working more than one shift in a day)

l m m m m

LHB/11110170/02/2011-07-21/en

m250h

Checking parts for cracks

m m m m

Checking the mounting of the ballast weight and tank

m m m m

Checking line and screw connections are firmly seated

m m m

Checking the hinges, quick fasteners and gas pressure springs of doors and hoods

Informing the operating personnel about the designated use of the attachment

Having the operating personnel lubricate the machine according to the lubricating chart, and pointing out possible operating errors

m m m m

Explaining the machine literature to the operating personnel (especially the operating manual and the safety instructions)

LH 120 C-1103 / 49287

151

Maintenance

Operating manual

Filling quantities and lubrication chart

5.2 Filling quantities and lubrication chart 5.2.1 Recommended lubricants Designation

Recommended lubricant

Symbol

Diesel engine

Liebherr Motoroil 10W-40

70.0 l

Hydraulic system (system content / oil change volume / tank content)

Liebherr Hydraulic HVI

1700 l / 1160 l / 860 l

Slewing gearbox

Liebherr Gear Basic 90 LS

40.0 l

Travel gear mechanism

Liebherr Gear Basic 90 LS

2 x 30.0 l

Pump distributor gear

Liebherr Gear Basic 90 LS

14.0 l

Central lubrication system, lube points of machine and tool attachment

Liebherr Universalfett 9900

Hinges, joints, locks

Engine oil

Quantity38)

Tab. 22: Recommended lubricants

5.2.2 Recommended service materials Designation

Recommended service product

Symbol

Fuel tank

Commercially available diesel fuel

3350.0 l

Coolant

Liebherr-Antifreeze Mix

115.0 l

Windscreen washer system

Commercially available screenwash or denatured alcohol

Quantity39)

8.0 l

LHB/11110170/02/2011-07-21/en

Tab. 23: Recommended service materials

38) Guidance 39) Guidance

values values copyright by

152

LH 120 C-1103 / 49287

Operating manual

Maintenance Filling quantities and lubrication chart

LHB/11110170/02/2011-07-21/en

5.2.3 Lubricating chart

Fig. 322: Lubricating chart

LH 120 C-1103 / 49287

153

Maintenance

Operating manual

Fuels, lubricants and operating fluids

5.3 Fuels, lubricants and operating fluids 5.3.1 General information Observe the information relating to lubricants and service materials. Lubricate the machine and change the oils within the specified time intervals. For more information refer to: “Lubricating chart” and “Inspection and maintenance schedule”. Keep the workplace clean when performing these activities. This increases the reliability and service life of the machine. – Carry out all work on the machine on level and firm ground. – Shut down the diesel engine, pull out the ignition key and switch off the battery main switch. – Clean the lubrication nipple before lubricating. – Clean all filler points including the surrounding area before opening. – It is recommended to change the oil when it is at operating temperature. – After each oil change or topping-up, check the fill level in the unit in question (the specified capacities are guidance values). – Collect used oil and service materials in suitable containers, and dispose of them in an environmentally responsible manner in accordance with the applicable regulations.

5.3.2 Diesel fuels Specification Diesel fuels must meet the minimum requirements of the following fuel specifications. Approved specifications: – DIN EN 590 – ASTM D 975 (89a) - 1D and 2D A confirmation must be provided by the fuel supplier (fuel specification, sulphur content, lubrication properties, cetane number).

The following restrictions apply: – Diesel fuels with a sulphur content of more than 1% (10,000 mg/kg) are not permissible. – If using engine oil with specification E6 and observing standard oil change intervals (every 500 operating hours): diesel fuel with a sulphur content of more than 0.005% (50 mg/kg) is not permissible. – If using exhaust purification systems (particle filters): diesel fuel with a sulphur content of more than 0.005% (50 mg/kg) is not permissible. – Diesel engines with external exhaust recirculation: diesel fuel with a sulphur content of more than 0.005% (50 mg/kg) is not recommended. Further information: see oil change intervals depending on difficulty factors. DIN EN 590 prescribes lubricating properties of the diesel fuel acc. to HFRR test (lubricity, corrected "wear scar diameter" [wsd 1.4] at 60 °C): maximum 460 μm The fuel standard ASTM D 975 does not prescribe a fuel lubricity test which the fuels have to pass. The required additives should be incorporated by the supplier as part of its responsibility for the fuel.

154

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Sulphur content, lubrication properties

Operating manual

Maintenance Fuels, lubricants and operating fluids

Cetane number A cetane number of at least 45 is required for fuels acc. to ASTM D 975. A cetane number of more than 50 must be preferred, especially at temperatures below 0 °C (32 °F).

Low temperatures (winter operation) Diesel fuel produces paraffin crystals at low ambient temperatures. These crystals increase the flow resistance in the fuel filter to such an extent that an adequate fuel supply to the diesel engine is no longer guaranteed. NOTICE Incorrect fuel damages the diesel engine. Admixture of paraffin, normal petrol or other substances will cause damage to the injection system. u Do not admix paraffin, normal petrol or other additives to the diesel fuel. u If the ambient temperature drops below -20 °C: use a start-up aid (e.g. fuel filter heating). u If the machine is used in arctic conditions: use special diesel fuels with adequate flow properties.

5.3.3 Lubricants for the diesel engine Quality Only high-alloy lubricants are used nowadays in modern diesel engines. They consits of base oils mixed with additives. The lubricant instruction for Liebherr diesel engines is based on the following specifications and regulations: Designation

Specification

ACEA - classification (Association des Constructeuers Européens de l'Automobile)

E4, E6, E7; Caution: use of a particle filter only permissible with E6

API - classification (American Petroleum Institute)

CH-4, CI-4; Caution: note the reduced oil change intervals

Tab. 24: Lubricating oil specifications

LHB/11110170/02/2011-07-21/en

If Liebherr oils are not available locallly, oils compliant with the specification must be used (after checking with customer service).

Viscosity Lubricating oil viscosity must be selected in accordance with the SAE classification (Society of Automotive Engineers). The SAE class does not provide any information about the quality of a lubricating oil. The SAE class must be determined in accordance with the ambient temperature. A viscosity that is too high may cause problems with starting. A viscosity that is too low can impair lubrication.

LH 120 C-1103 / 49287

155

Maintenance

Operating manual

Fuels, lubricants and operating fluids

The temperature ranges shown in the diagram are guidelines; these can be exceeded or undercut briefly.

Fig. 325: Temperature dependent selection of the SAE Class The following Dieselmotorenöl is recommended for ambient temperatures from -20 °C (-4 °F) to +45 °C (+113 °F): – Liebherr Motoroil 10W-40, specification ACEA E4 – Liebherr Motoroil 10W-40 low ash, specification ACEA E6 The following diesel engine oil is recommended for an ambient temperature of -30 ℃ (-22 °F) to +30 ℃ (+86 °F): – Liebherr Motoroil 5W-30, specification ACEA E4

Aggravating factors also impact oil change Change intervals: see the "Inspection and maintenance schedule" chapter Oil change intervals depend on climatic zone, sulphur content in the fuel and oil quality according to the following table. Even if the number of operating hours (h) is not reached per year, the lubricant for the diesel engine must be changed at least once a year. Different aggravating factors (difficult operating conditions) affect maintenance intervals. Possible aggravating factors: – frequent cold starts – sulphur content in fuel – operating temperature If aggravating factors come into play, the oil and filter changes must be performed as shown in the tables below. Interval acc. to oil quality

Operating conditions

Sulphur content in the fuel

CH-4, CI-4

E4 / E7A)

Normal climate down to up to 0.5% -10 °C more than 0.5% up to 1%

250 h

500 h

125 h

250 h

Climate below -10 °C

up to 0.5%

125 h

250 h

more than 0.5% up to 1%

not permissible

125 h

Tab. 25: Oil change intervals depending on aggravating factors A)

TBN at least 13 mg KOH/g

156

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Aggravating factor

Operating manual

Maintenance Fuels, lubricants and operating fluids

Aggravating factor

Interval acc. to oil quality

Operating conditions

Sulphur content in the fuel

Normal climate down to up to 0.005% -10 °C more than 0.005% up to 0.05%

Climate below -10 °C

E6 500 h 250 h

more than 0.0501% up to 0.1%

125 h

up to 0.005%

250 h

more than 0.005% up to 0.05%

125 h

more than 0.0501% up to 0.1%

not permissible

Tab. 26: Oil change intervals depending on aggravating factors

5.3.4 Coolant for the diesel engine General recommendations The cooling system only functions reliably if it is operating under pressure. It is therefore essential to keep the system clean and free from leaks. The radiator cap and travelling valves must function correctly and the coolant must be at the required level. Corrosion inhibiting antifreeze products approved by Liebherr guarantee adequate protection against low temperatures, corrosion and cavitation, do not attack seals and hoses and are non-foaming. Coolants containing unsuitable corrosion inhibiting antifreeze products or which have not been prepared properly can cause the failure of components and parts in the coolant circuit as a result of cavitation or corrosion damage. In addition, deposits with thermal insulation properties can build up on components that conduct heat, leading to overheating and ultimately to failure of the engine.

Water (fresh water) Colourless, clear water which is free from mechanical impurities and is suitable for drinking can be used, subject to the following restrictive analysis values. Sea water, brackish water, brine and industrial process water are not suitable.

LHB/11110170/02/2011-07-21/en

Designation

Value and unit

Total alkaline earths (water hardness) 0.6 to 3.6 mmol/l (3 to 20 °dH) pH value at 20 °C

6.5 to 8.5

Chloride ion content

max. 80 mg/l

Sulphate ion content

max. 100 mg/l

Tab. 27: Fresh water quality Designation

Value and unit

Total alkaline earths (water hardness) 0.6 to 2.7 mmol/l (3 to 15 °dH) copyright by

LH 120 C-1103 / 49287

157

Maintenance

Operating manual

Fuels, lubricants and operating fluids

Designation

Value and unit

pH value at 20 °C

6.5 to 8.0

Chloride ion content

max. 80 mg/l

Sulphate ion content

max. 80 mg/l

Tab. 28: Fresh water quality when using DCA 441) Contact the responsible authorities for water analyses.

Coolant mixing ratio Ambient temperature up to Mixing ratio Water Corrosion inhibiting antifreeze -37 °C

50%

-50 °C

40%

60%

Tab. 29: Mixing ratio (full year)

Fig. 327: Temperature-dependent selection of the mixing ratio of water and corrosion inhibiting antifreeze A

Ambient temperature

Proportion of corrosion inhibiting antifreeze in the coolant

The coolant must contain 50% corrosion inhibiting antifreeze all year round.

Permissible corrosion inhibiting antifreeze products NOTICE Incorrect mixing of different products can impair the properties of the coolant and damage the cooling system. u Never mix together products containing silicate and silicate-free products. u If the Liebherr product is not available locally, please contact LIEBHERR customer service; use products listed in the "Coolant specification for Liebherr diesel engines".

41) DCA

= Diesel Coolant Additives copyright by

158

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

u Only use approved products; do not mix different products.

Operating manual

Maintenance Fuels, lubricants and operating fluids

Type

Product name

Concentrate

Liebherr Antifreeze Concentrate

Ready-mixed corrosion inhibiting antifreeze (premix)42)

Liebherr Antifreeze Mix

Tab. 30: Corrosion inhibiting antifreeze from Liebherr

Approved corrosion inhibiting products (inhibitors) without antifreeze NOTICE Incorrect mixing of different products can impair the properties of the coolant and damage the cooling system. u Only use approved products; do not mix different products. u Never mix together products containing silicate and silicate-free products. u If the Liebherr product is not available locally, please contact LIEBHERR customer service; use products listed in the "Coolant specification for Liebherr diesel engines". In exceptional circumstances and with ambient temperatures constantly above the freezing point, e.g. in the tropics, where it can be demonstrated that no approved corrosion inhibiting antifreeze is available, the coolant must be made up by mixing water with the following inhibitors: â&#x20AC;&#x201C; DCA 4 product (Diesel Coolant Additives 4) â&#x20AC;&#x201C; Caltex / Chevron / Havoline / Total product In such a case, the coolant must be renewed annually. The concentration must be checked during maintenance work and corrected if necessary. Product name

Manufacturer

DCA 4 (Diesel Coolant Additives 4)

Fleetguard / Cummins Filtration

Caltex XL Corrosion Inhibitor Concentrate

Chevron Texaco

Chevron Heavy Duty Extended Life Corrosion Inhibitor Nitrite Free (ELC)

Chevron Texaco

Havoline Extended Life Corrosion Inhibitor (XLI)

Chevron Texaco

Total WT Supra

Total, Paris

LHB/11110170/02/2011-07-21/en

Tab. 31: Corrosion inhibitors

5.3.5 Hydraulic oil Oils can be used as hydraulic oil if they comply with the details below. maximum water content of hydraulic oil: < 0,1 %

42) Premix

= ready-mixed product (50% water and 50% corrosion inhibiting anti-

freeze) copyright by

LH 120 C-1103 / 49287

159

Maintenance

Operating manual

Fuels, lubricants and operating fluids

Liebherr hydraulic oil Liebherr recommends the following hydraulic oils for the machine depending on the temperature range:

Fig. 329: Liebherr hydraulic oil, selection of viscosity class dependent on temperature A B

Ambient temperature Cold start range with prescribed warm-up phase

Operating range

Liebherr Hydraulic Plus and Liebherr Hydraulic Plus Arctic are suitable both for eco-friendly and for long-term use. If Liebherr oils are not available locally, engine oils compliant with the section below "Engine oil used as hydraulic oil" must be used (after checking with customer service). Hydraulic oils not from Liebherr may not be used.

Engine oil used as hydraulic oil If engine oils (third-party products) are used, we recommend that the customer should check with the oil manufacturer in advance that the specifications required below are met by the third-party product. Engine oils for use as hydraulic oil must be selected in accordance with the following values: API - CD / ACEA - E1

LHB/11110170/02/2011-07-21/en

One range oils (1)

(MB 226.0 and 227.0) Multi-range oils (2) API - CD, CE, CF / ACEA - E2, E3, E4 (MB 227.5, 228.1, 228.3 and 228.5) Tab. 32: Classification, engine oil fur use as hydraulic oil

160

LH 120 C-1103 / 49287

Operating manual

Maintenance Fuels, lubricants and operating fluids

Fig. 330: Engine oils for use as hydraulic oil, selection of viscosity class according to temperature43) A B C

Ambient temperature Cold start range with prescribed warm-up phase Operating range

1 2

Single range oils Multi-range oils

Warm-up instruction The black bar B shows ambient temperatures which lie up to 20 Â°C below the operating range C. If a cold start is performed at ambient temperatures within range B, the following warm-up instruction applies for the hydraulic oil: 1. after starting the diesel engine, set it to average engine speed (half of the maximum engine speed at most). 2. Carefully start operating hydraulic system. Actuate hydraulic cylinder and move it to the limit stop briefly. 3. After approx. five minutes start up the travel hydraulic system. Warm-up phase a total of approx. 10 minutes. If a cold start is performed at even lower ambient temperatures, the following warm-up instruction applies: Pre-heat the hydraulic tank before starting the engine. Then start the warm-up instructions at no. 1.

LHB/11110170/02/2011-07-21/en

Biodegradable motor oils which degrade rapidly and easily NOTICE Incorrect mixture of hydraulic oils! Mixing quickly and easily biodegradable, ester-based hydraulic oils with one another or with mineral oils can result in aggressive reactions. This will cause damage to the hydraulic system. u Do not mix biodegradable motor oils which decompose rapidly from different manufacturers or with mineral oils.

43) With

divergent viscosity class: check with customer service copyright by

LH 120 C-1103 / 49287

161

Maintenance

Operating manual

Fuels, lubricants and operating fluids

Liebherr recommendation for the machine, depending on the temperature range: Liebherr Hydraulic Plus or Liebherr Hydraulic Plus Arctic. These are polyalphaolefins (HEPR) according to CEC-L-33-A-93, quickly and easily biodegradable. Bypass-flow filtering is not mandatory if these hydraulic oils are used. If these oils cannot be procured locally, only oils based on fully saturated synthetic esters (HEES) may be used (after consulting with customer service). NOTICE If using synthetic esters: hydraulic system will be damaged if operated without bypass filter! If using synthetic esters, bypass filtering is mandatory in order to maintain a water content in the oil of less than 1000 ppm (0.1%). u Use a bypass filter (special equipment). When synthetic esters are used, we recommend renewing the hydraulic hoses after 4000 operating hours or four years at most. Vegetable-based oils are may not be used because of their unfavourable temperature resistance. Polyglycols are not permissible either due to the aggressive effect on paint. If third-party products are used, we recommend that the customer should check with the manufacturer in advance that the specifications required above are met by the third-party product.

Oil change, oil analysis, filter change Oil change Note Liebherr recommends analysing the oil regularly in the course of operation. u (For more information see: Oil analysis, page 163) Oil grade

Oil change No eco-friendly application without oil analysis with oil analysisA) (optional)

Liebherr mineral oil

Eco-friendly application (only permissible with oil analysisA) )

every 3000 h

every 6000 h

--C)

every 4000 h

every 8000 h

every 2000 h

--C)

Liebherr Hydraulic Basic 68 Liebherr Hydraulic Basic 100 Liebherr-PAOB) Liebherr Hydraulic Plus Liebherr Hydraulic Plus Arctic Third-party product - mineral oil

162

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Liebherr Hydraulic HVI

Operating manual

Maintenance Fuels, lubricants and operating fluids

Oil grade

Oil change No eco-friendly application without oil analysis with oil analysisA) (optional)

Third-party product - fully saturated synthetic ester

--C)

Eco-friendly application (only permissible with oil analysisA) ) every 2000 h

Tab. 33: Oil change intervals A) B) C)

If the result of the oil analysis is positive, then the oil may be used for an extended period. If the result of the oil analysis is negative, then the oil must be changed immediately. PAO = Polyalphaolefin Combination is not permissible Eco-friendly application means that the use of readily biodegradable or ecofriendly hydraulic oil is mandatory at the site of operation of the machine. If a machine is operated for less than 1000 hours a year then an oil sample must be taken once a year. Hydraulic oil that is kept in the machine for a long time should be changed after four years at the latest (mineral oils and fully saturated synthetic esters) or after six years (Liebherr-Plus oils). If a machine is mothballed for longer than six months without interruption, an oil analysis must be performed before it is brought back into operation.

Oil analysis Liebherr recommends carrying out the oil analyses at the OELCHECK company and for the oil change to be carried out according to the laboratory report: – yellow set for quickly and easily biodegradable hydraulic oils – green set for mineral oils See also customer service and product information. Reasons for regular oil analyses: – Cost saving because of longer oil change intervals – Information about the hydraulic system, components and medium – Protection of the environment and reduced use of natural resources Oil sampling / application condition Oil sampling on machines in normal use

LHB/11110170/02/2011-07-21/en

Oil sampling on machines in dust-intensive operation

The frequency of oil sampling depends on the application conditions. (For more information see: High-dust operating conditions, reduction of soiling, page 165) Tab. 34: Legend: oil sampling acc. to application condition

LH 120 C-1103 / 49287

163

Maintenance

Operating manual

Fuels, lubricants and operating fluids

Oil grade

Oil sampling No eco-friendly application (oil analysis optional)

Eco-friendly application (oil analysis prescribed)

every 1000 h

every 250 h

--B)

every 1000 h

every 250 h

First at 0 h, then every 1000 h

First at 0 h, then every 250 h

Third-party product - mineral oil First at 1000 h, then every 500 h

every 250 h

--B)

Third-party product - fully saturated synthetic ester

--B)

First at 0 h, then every 500 h

First at 0 h, then every 250 h

Liebherr mineral oil Liebherr Hydraulic HVI Liebherr Hydraulic Basic 68 Liebherr Hydraulic Basic 100 Liebherr-PAOA) Liebherr Hydraulic Plus Liebherr Hydraulic Plus Arctic

--B)

Tab. 35: Oil sampling acc. to operating condition A) B)

PAO = Polyalphaolefin Combination is not permissible

Filter change Filter change / operating conditions Changing the filter in machines in normal operating conditions

Changing the filter in machines in high-dust operating conditions The frequency of filter changes is determined by the operating conditions. (For more information see: High-dust operating conditions, reduction of soiling, page 165)

LHB/11110170/02/2011-07-21/en

Tab. 36: Legend: Filter change according to operating conditions

Return filter renewal (only Liebherr filters are permissible)

every 1000 h

every 500 h

Tab. 37: Filter renewal depending on operating conditions

164

LH 120 C-1103 / 49287

Operating manual

Maintenance Fuels, lubricants and operating fluids

Change of oil bypass filter Liebherr filters

Filter from other manufacturers

every 2,000 h or according to indication every 500 h

every 250 h

Tab. 38: Filter change according to operating conditions

High-dust operating conditions, reduction of soiling If the machine is operated generally with a hydraulic hammer or comparable conditions (heavy dust generation), there is a risk that the hydraulic oil becomes contaminated more than usual. In order to prevent early wear of hydraulic components, the oil change intervals and the intervals for taking oil samples must be shortened. The following instructions should be noted: – The filter cartridge(s) in the return filter must be changed every 500 operating hours and every time the hydraulic oil is changed. – 10 μm filter cartridges must be used for the return filter instead of the normal 20 / 5 μm filter cartridges. – The 2 μm breather filter must be replaced every 500 operating hours and every time the hydraulic oil is changed. A machine fitted with the hydraulic hammer accessory kit at the factory and a retrofitted hydraulic hammer installation kit has 10 μm filter cartridges in the return filter. Please remember this when ordering spare parts.

5.3.6 Lubricating oils for axles and gearboxes Quality Recommended lubricant

Specification

Liebherr Gear Basic 90 LS

API: GL-5 MIL-L: 2105 D ZF: TE-ML 05C, 12C, 16E, 21C

Liebherr Gear Plus 20W-40

API: level of GL4 ZF: TE-ML 05F, 06K, 17E

LHB/11110170/02/2011-07-21/en

Liebherr Gear Hypoid 90 EP

API: GL-5 MIL-L: 2105 B, C, D ZF: TE-ML 05A, 12A, 16C, 17B, 19B

Liebherr Hypoid 85W-140 EP

API: GL-5 MIL-L: 2105 D, PRF-2105 E ZF: TE-ML 05A, 07A, 16D, 21A

Liebherr Hydraulic-Gear ATF

GM: Dexron II D ZF: TE-ML 03D, 04D, 11A, 14A, 17C

LH 120 C-1103 / 49287

165

Maintenance

Operating manual

Fuels, lubricants and operating fluids

Recommended lubricant

Specification

Liebherr Syntogear Plus 75W-90 API: GL-4, GL-5, MT-1 MIL-L: 2105 D, PRF-2105 E ZF: TE-ML 02B, 05B, 07A, 12B, 16F, 17B, 19C, 21B Tab. 39: Lubricating oil specifications If Liebherr oils are not available locally, use oils in accordance with the specification instead (following consultation with the responsible customer service).

Viscosity

Fig. 347: Temperature-dependent selection of SAE class Ambient temperature Use in gearboxes Use in automatic transmissions

3 4

Use in axles Use in pump distributor gears*

The oil is not suitable for the temperature range (* / hatched) if the pump distributor gear has an oil cooler. The selection of lubricating oil viscosity is in accordance with the SAE classification (Society of Automotive Engineers). The SAE class does not provide any information about the quality of a lubricating oil. The factor for determining the correct SAE class is the ambient temperature. The function of axles and gearboxes can be impaired by an incorrect viscosity. The temperature ranges shown in the illustration are guidelines, the temperatures can deviate briefly from these ranges either upward or downward.

166

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

A 1 2

Operating manual

Maintenance Fuels, lubricants and operating fluids

5.3.7 Grease Quality Recommended lubricant

Specification

Liebherr Universalfett 9900

Grease with saponified base (lithium complex) KPF 2 N - 25 (DIN 51502) NLGI class: 2 (DIN 51818) VKA welding force: > 6000 N (DIN 51350 / 4)

Liebherr Universalfett Arctic (low-temperature use)

Grease with saponified base (lithium complex) KPFHC 1 N - 60 (DIN 51502) NLGI class: 1 (DIN 51818) VKA welding force: > 5500 N (DIN 51350 / 4)

Tab. 40 The grease is used for automatic or manual lubrication of the machine. It reaches the corresponding lube points via the central lubrication system or lubrication nipples. Examples: – Slewing ring bearings – Sprockets, gears – Pins, axles and bolts – Tool attachments

Usage temperature

LHB/11110170/02/2011-07-21/en

Fig. 349: Usage temperature of Liebherr grease A

Temperature of the grease

Not when used in central lubrication systems

Intermittent temperature peaks up to max. 200 °C (392 °F) are possible.

5.3.8 Screenwash Pure water is not sufficient for use in the windscreen washer system. Use water with a commercially available cleaning additive for windscreen washer systems in motor vehicles (with antifreeze in winter).

LH 120 C-1103 / 49287

167

Maintenance

Operating manual

Fuels, lubricants and operating fluids

5.3.9 Lubricant and care product for electrical and mechanical systems Medium, application

Product (manufacturer)

Contact spray for slip rings

Cramolin

Lubricant for pistons, piston nuts and piston bearing installation on the hydraulic cylinders

Gleitmo 800

Special corrosion inhibitor for installation spaces of sealing elements on hydraulic cylinders

Rostilo Tarp CFX

LHB/11110170/02/2011-07-21/en

Tab. 41: Lubricants and care products

168

LH 120 C-1103 / 49287

Operating manual

Maintenance Access points for maintenance work

5.4 Access points for maintenance work 5.4.1 Access points to the uppercarriage

Fig. 350: Access points to the uppercarriage

No.

Access point

Access to

Side door on right

Radiator, batteries

Engine bonnet

Engine

Engine compartment door

Engine, radiator, dry air filter, electrical and hydraulic components

Walkway in front of the engine compartment

Central lubrication system, main switch cabinet, battery main switch

Tab. 42: Access points to the uppercarriage

LHB/11110170/02/2011-07-21/en

5.4.2 Access points on the underside of the uppercarriage

Fig. 351: Access points on the underside of the uppercarriage

LH 120 C-1103 / 49287

169

Maintenance

Operating manual

Access points for maintenance work

No.

Access point

Access to

Underside of hydraulic tank

Hydraulic tank drain valve

Hydraulic tank cover

Hydraulic tank drain valve

Hydraulic system cover

Hydraulic lines

Hydraulic system cover

Hydraulic lines, pumps

Hydraulic pump suction Hydraulic system drain valve line

Engine compartment cover

Underside of diesel engine, drain valve, diesel engine

Radiator

Coolant drain valve

Radiator

Coolant drain valve

Underside of fuel tank

Fuel drain valve

Tab. 43: Access points on the underside of the uppercarriage

5.4.3 Access points to tracked travel gear

Fig. 352: Access points to tracked travel gear Track tensioner

Travel gear mechanism

LHB/11110170/02/2011-07-21/en

170

LH 120 C-1103 / 49287

Operating manual

Maintenance Cleaning and care

5.5 Cleaning and care 5.5.1 Cleaning the machine The machine should be cleaned before commencing maintenance or repair work. In particular, connection and fittings should be cleaned of oil, fuel or care products. The machine must be cleaned particularly thoroughly if it has come into contact with road salt, e.g. when being transported under wintry road conditions. By washing off the salt in good time, it is possible to prevent corrosion damage to a large extent. Note High-pressure cleaners (steam cleaners) can damage the paintwork. u Do not use high-pressure cleaners during the first two months after commissioning (or after repainting). u Observe the operating instructions for the high-pressure cleaner. This applies in particular with regard to the pressure adjustment and the distance from the high-pressure nozzle to the object to be cleaned.

Before cleaning Before cleaning with water or a high-pressure cleaner, the following activities must be performed in order to avoid water penetration. u Switch off the ignition. u Lubricate all bearings, pin connections and the slewing ring, using the central lubrication system, if required. u Cover or mask off all openings where water penetration must be prevented for reasons of safety and function49) .

Cleaning u Use lint-free cleaning cloths. u Use water to soften the dirt and then rinse it off. u Do not use aggressive cleaning agents or flammable liquids.

LHB/11110170/02/2011-07-21/en

If a fire warning and extinguishing system is fitted: u Make sure that no temperature sensors come into contact with hot cleaning agents during cleaning work in the engine compartment.

After cleaning u Remove the covers. u Check all fuel, engine oil and hydraulic lines (leaks, loose connections, chafe marks and damage). u Rectify any defects that are detected.

49) The

following components are at particular risk: electric motors, electrical components, switch cabinets, plug connections, transmitters and air filters. copyright by

LH 120 C-1103 / 49287

171

Maintenance

Operating manual

Cleaning and care

u Remove any water that may have penetrated: lubricate again all bearings, pin connections and the slewing ring. u If necessary, refresh the corrosion inhibitor on components or surfaces.

5.5.2 Clean the tracked travel gear, remove blocks NOTICE Dirt, ice and trapped foreign objects can block the tracked travel gear! Breaking loose a blocked tracked travel gear by using engine power can cause significant damage to the travel gear. u Never break frozen or blocked tracked travel gears loose by exerting force. If larger foreign objects (e.g. stones, wood, pieces of metal, cables) are trapped in the tracked travel gear: u Remove foreign objects before commissioning. If the tracked travel gear has frozen onto the ground: u Carefully heat up the track pads and melt the ice, move off carefully. u After the work (after each shift), clean any severely soiled parts of the tracked travel gear. u Clean and grease the sliding surfaces of the track tensioners. u Avoid freezing onto the ground: park the machine on boards at temperatures below zero.

5.5.3 Door locks and hinges u Regularly oil or grease the door hinges. u Regularly lubricate the door locks using a resin-free oil or commercially available door lock care product (with graphite or MoS2 compounds).

5.5.4 Rubber seals Rubber seals will last longer if they are treated with a rubber care product. Clean and service the rubber seals on the doors and covers parts regularly. This avoids premature wear and prevents the rubber seals from freezing on at low temperatures.

5.5.5 Applying corrosion protection to piston rods Prior to downtimes exceeding a period of four weeks, and especially before sea transport, protect the piston rods against corrosion. u If possible, park and transport the machine in such a way that the piston rods are completely retracted into the cylinders. u Apply a thick coat of acid-free corrosion protection grease to exposed piston rods. u Check the corrosion protection of the piston rods again after loading.

172

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Recommended care products: silicone, talc, deer tallow

Operating manual

Maintenance Cleaning and care

u Also apply corrosion protection grease to the piston rods if a cylinder is rarely moved in operation, and therefore the piston rod is not regularly coated with hydraulic oil.

LHB/11110170/02/2011-07-21/en

u Regularly check the corrosion protection on hydraulic cylinders which are not moved regularly.

LH 120 C-1103 / 49287

173

Maintenance

Operating manual

Diesel engine

5.6 Diesel engine 5.6.1 Checking the oil level

Fig. 353: Oil filler pipe and dipstick on engine 1

Oil filler pipe

Dipstick

CAUTION Danger of burns from hot engine oil! u Avoid skin contact with hot oil or parts carrying oil. The machine must be standing horizontally. u Stop the engine. u Wait a few minutes until the oil has collected in the oil pan. u Pull out the dipstick and wipe it clean with a clean, lint-free cloth. u Insert the dipstick fully. u Pull out the dipstick again and check the oil level. w The oil level must be between the min and max markings.

LHB/11110170/02/2011-07-21/en

If necessary: u Fill oil through the oil filler pipe until the level is between the min and max markings.

174

LH 120 C-1103 / 49287

Operating manual

Maintenance Cooling system

5.7 Cooling system 5.7.1 Checking the coolant level

Fig. 354: Checking the coolant level 1

Sight glass

Cover

CAUTION The engine cooling system gets hot during operation and is under pressure! Danger of scalding due to hot coolant. u Avoid contact with coolant and parts carrying coolant. u Do not open the coolant tank until the cover cap on the filler pipe has cooled down sufficiently. u Check the coolant level in the sight glass 1. The coolant level may not drop below the bottom edge of the sight glass when the engine is cold. Top up coolant if necessary: u Open the cover cap 2. u Fill in coolant. u Close the cover cap.

LHB/11110170/02/2011-07-21/en

5.7.2 Antifreeze and corrosion protection of the coolant The system must be filled with antifreeze all year round. On delivery, the engine coolant contains antifreeze for temperatures down to -37 Â°C (this corresponds to approx. 50% antifreeze). u Keep the concentration of the corrosion protection additive contained in the cooling system constant at all time, in particular when topping up. If necessary: u Add antifreeze and corrosion protection concentrate to the coolant.

LH 120 C-1103 / 49287

175

Maintenance

Operating manual

Fuel system

5.8 Fuel system 5.8.1 Draining water from the fuel pre-filter

Fig. 355: Draining water from the fuel pre-filter 1 2

container Drain tap

Bleeder screw

The fuel pre-filter is located on the rear of the radiator. u Put a suitable container underneath. u Open the bleeder screw 3. u Press the drain tap 2 and turn in the clockwise direction. u Drain the fluid until only fuel emerges. u Close the drain tap.

LHB/11110170/02/2011-07-21/en

u Close the bleeder screw.

176

LH 120 C-1103 / 49287

Operating manual

Maintenance Fuel system

5.8.2 Draining water and sediments in the fuel tank

Fig. 356: Draining water and sediments in the fuel tank Water must be drained from the fuel tank in the uppercarriage every day. If the application conditions and fuel quality permit, the maintenance interval can be extended to one week. u Put a suitable container underneath. u Open the drain valve 1. u Drain the fluid until only fuel emerges.

LHB/11110170/02/2011-07-21/en

u Close the drainage valve.

LH 120 C-1103 / 49287

177

Maintenance

Operating manual

Air filter

5.9 Air filter 5.9.1 Renewing air filters The induction air is cleaned by two air filters, protecting the engine against wear due to dust particles. The effectiveness of the air filters can only be upheld by regular maintenance. Note The effectiveness of the air filter cannot be restored by washing them out or blowing compressed air through them! Water can damage the air filter! If the filter effectiveness is reduced, engine wear can increase significantly! u Always renew contaminated filter elements, do not clean them. u Do not clean the inside of the air filter housing with compressed air.

Fig. 357: Air filters 1 2 3

Housing Cover Clamping clip

4 5 6

Seal Safety element Main element

Renewing the main element

u Stop the engine. u Open the clips and remove the cover. u Remove the main element. u Clean the inside of the housing, seal and sealing faces with a damp cloth. u Insert a new main element. u Make sure that the main element is making solid and secure contact with the sealing face. u Put on the cover and close the clips.

178

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

The main element is renewed according to the inspection and maintenance schedule. The dust collecting tank must be emptied when the indicator unit signals that the air filter is contaminated (â&#x20AC;&#x153;air filter contaminatedâ&#x20AC;? warning symbol) . If the warning symbol continues to be displayed even after the dust collecting tank has been emptied, this means the main element must be changed immediately.

Operating manual

Maintenance Air filter

Renewing the safety element The safety element must be renewed on every third renewal of the main element, but at least once a year. If it is already apparent from a visual check that the safety element is highly contaminated, then it should be renewed immediately. u Stop the engine. u Open the clips and remove the cover. u Remove the main element and the safety element. u Clean the inside of the housing, seal and sealing faces with a damp cloth. u Insert a new safety element. u Insert the main element. u Make sure that the filter elements are making solid and secure contact with the sealing face. u Put on the cover and close the clips.

5.9.2 Emptying the dust collecting tank

Fig. 359: Dust outlet on the air filter housing Part of the dust contained in the induction air is trapped in the air filter housing before reaching the filter elements. The dust falls into the dust collecting tank. The dust collecting tank must be emptied regularly via the dust outlet. u Hold a suitable container under the dust outlet. LHB/11110170/02/2011-07-21/en

u Press the dust outlet together by hand so that the slit on its underside opens. w The collected dust drops out.

LH 120 C-1103 / 49287

179

Maintenance

Operating manual

Air filter

5.9.3 Checking the clean-air line

Fig. 360: Clean-air lines The clean-air lines can be accessed from the engine compartment. They connect the components of the intake area: 1. Air filters 2. Ambient air suction hose 3. Air filter and turbocharger connection 4. Turbocharger and intercooler connection 5. Intercooler and engine connection u Check the clean-air lines for damage and leak tightness every time the air filter is renewed.

LHB/11110170/02/2011-07-21/en

If the lines are damaged: u Contact Liebherr customer service.

180

LH 120 C-1103 / 49287

Operating manual

Maintenance Hydraulic components

5.10 Hydraulic components 5.10.1 Checking the oil level in the hydraulic tank

Fig. 361: Machine in inspection position, sight glass on hydraulic tank 1

Machine in inspection position

2 A

Sight glass Minimum oil level

C D

Medium oil level (inspection position) Maximum oil level Oil level sight glass (tank protection)

Before the oil level is checked, the machine must be parked on a horizontal surface and positioned in the inspection position: boom at top, stick moved in, cab lift50) fully lowered (all hydraulic cylinders are fully retracted). The sight glass shows the oil level. The fill height depends on the oil temperature and the position of the hydraulic cylinders. The oil level rises with increasing oil temperature and when the hydraulic cylinders are retracted. The oil level falls with declining oil temperature and when the hydraulic cylinders are extended.

LHB/11110170/02/2011-07-21/en

Oil level A

Minimum. The level must not be below this marking when all hydraulic cylinders are fully extended.

Test position. The level may not be significantly below or above this marking when the machine is at inspection temperature and in the inspection position (hydraulic cylinders fully retracted).

Maximum. The level may reach and slightly exceed this marking when all hydraulic cylinders are fully retracted at operating temperature.

Tank protection. The oil level is too high if the level reaches the oil level eye. Exceeding the level can cause the tank to burst.

50) Special

equipment copyright by

LH 120 C-1103 / 49287

181

Maintenance

Operating manual

Hydraulic components

Oil level Inspection temperature: ≤ 20 °C / operating temperature: 50 °C to 80 °C Tab. 44: Oil level depending on the oil temperature and position of the hydraulic cylinders. u Make sure that the hydraulic oil is at the right temperature (inspection temperature maximum 20 °C). u If necessary, allow the machine to cool down sufficiently before the inspection. u Read off the oil level. If necessary: u Top up or drain oil.

5.10.2 Reducing the pressure in the hydraulic system Reducing the system pressure u Place the working attachment on the ground. u Stop the engine. u Switch on the ignition (ignition key in position 1). u Move the pilot control valves (joysticks and pedals) in all directions. w The system pressure is relieved.

Relieving the tank pressure

Fig. 362: Relieving the tank pressure Breather filter

Securing pin

The breather filter can be turned by hand when the securing pin is inserted. If the thread requires excessive force when turning, use an open end spanner. u Unscrew the breather filter by at most one rotation. w The pressure in the hydraulic tank is relieved. u tighten the breather filter on completion of the maintenance work. u Pull out the securing pin (anti-theft protection).

182

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

Operating manual

Maintenance Hydraulic components

5.10.3 Renewing the breather filter

Fig. 363: Renewing the breather filter 1 2

Breather filter Securing pin

Sealing ring

The breather filter can be turned by hand when the securing pin is inserted. If the thread requires excessive force when turning, use an open end spanner. u Reduce the pressure in the hydraulic system. u Unscrew and remove the breather filter. u Fit a new breather filter with a new sealing ring, screw in and tighten u Pull out the securing pin (anti-theft protection).

LHB/11110170/02/2011-07-21/en

5.10.4 Renewing the control oil filter

Fig. 364: Renewing control oil unit, control oil filter 1 2 3 4

Control oil unit filter housing Seal Filter cartridge

5 6 7

Filter cartridge seal Mounting stud Accumulator

The control oil unit can be accessed from the engine compartment. copyright by

LH 120 C-1103 / 49287

183

Maintenance

Operating manual

Hydraulic components

Make sure that the pressure in the hydraulic system has been relieved. Note The effectiveness of the filter cannot be restored by cleaning! u Always renew contaminated filter elements, do not clean them. Note The filter housing can be damaged by tension. Do not overtighten it! u Do not use a tool to tighten the filter housing. u It is essential to turn the filter housing back by a quarter turn after screwing it in. u Prepare a suitable container for collecting the hydraulic oil which flows out. u Unscrew the filter housing and remove the filter element. u Clean the filter housing. u Oil the threads and sealing faces on the filter housing, the control oil unit and on the seals with hydraulic oil. u Carefully push the new filter cartridge onto the mounting stud. u Screw on the filter housing by hand as far as the stop.

LHB/11110170/02/2011-07-21/en

u Turn the filter housing back by about 90Â° (a quarter turn).

184

LH 120 C-1103 / 49287

Operating manual

Maintenance Hydraulic components

5.10.5 Renewing the return filter

Fig. 365: Return filter overview 1 2

Hydraulic tank Return filter

Covering grille

The covering grille must be removed before the filter is renewed.

Fig. 366: Renewing the return filter LHB/11110170/02/2011-07-21/en

A B 1 2 3

Standard version with bypass filter51) Cover Magnetic rod Sealing ring

4 5 6 7 8

Filter cartridge (return filter) Bypass filter cover Filter cartridge (bypass filter) Protection cylinder Flange

Make sure that the pressure in the hydraulic system has been relieved.

51) Special

equipment copyright by

LH 120 C-1103 / 49287

185

Maintenance

Operating manual

Hydraulic components

How to renew the return filter (standard): u Unscrew the bolts on the cover and lift out the cover as well as the magnetic rod. u Carefully clean the magnetic rod. u Grip the return filter by its holding bracket and pull it out. u Grip the new return filter by its holding bracket and insert it into the hydraulic tank at right angles. u Push the return filter up to the stop by applying slight pressure. u Make sure that the return filter is aligned at right angles. u Fold the holding bracket to the side sot that it rests on the housing. u Place a new sealing ring on the flange. u Centre the cover with the magnetic rod precisely in the middle of the return filter and push it in. u Put the cover on the flange and tighten the bolts. How to change the return filter with bypass filter51) : u Unscrew the bolts on the cover and lift out the cover as well as the magnetic rod. u Unscrew the cover from the magnetic rod. u Remove the protection cylinder and the cover of the bypass filter. u Remove the bypass filter. u Carefully clean the magnetic rod. u Put the protection cylinder on the magnetic rod with a new bypass filter. u Put the cover on the bypass filter. u Screw the cover onto the magnetic rod. u Grip the return filter by its holding bracket and pull it out. u Grip the new return filter by its holding bracket and insert it into the hydraulic tank at right angles. u Push the return filter up to the stop by applying slight pressure. u Make sure that the return filter is aligned at right angles. u Fold the holding bracket to the side sot that it rests on the housing. u Place a new sealing ring on the flange.

LHB/11110170/02/2011-07-21/en

u Centre the cover with the magnetic rod precisely in the middle of the return filter and push it in. u Put the cover on the flange and tighten the bolts.

51) Special

equipment copyright by

186

LH 120 C-1103 / 49287

Operating manual

Maintenance Hydraulic components

5.10.6 Renewing the return leakage oil filter

Fig. 367: Return leakage oil filter overview 1 2

Hydraulic tank Return leakage oil filter

Covering grille

The covering grille must be removed before the filter is renewed.

Fig. 368: Renewing the return leakage oil filter

LHB/11110170/02/2011-07-21/en

1 2 3 4

Cover Flat seal ring Spring Magnetic rod

5 6 7

O-ring Filter cartridge Flange

Make sure that the pressure in the hydraulic system has been relieved. u Unscrew the cover. u Remove the pressure spring. u Remove the magnetic rod. u Remove the filter element. u Remove the O-ring.

LH 120 C-1103 / 49287

187

Maintenance

Operating manual

Hydraulic components

u Clean the magnetic rod and cover. u Oil the thread and seals with hydraulic oil. u Insert the O-ring. u Insert the new filter element. u Centre the magnetic rod precisely in the middle of the filter element and push it in. u Insert the spring. u Put the flat seal ring on the cover. u Screw the cover onto the flange.

5.10.7 Changing / topping up hydraulic oil

Fig. 369: Hydraulic tank, open return filter The machine must be moved to the inspection position before the oil change or before topping up hydraulic oil. This ensures that the oil level can be read off correctly on the sight glass of the hydraulic oil tank. For more information refer to chapter “Checking the oil level in the hydraulic tank”. At least one return filter must be opened before the hydraulic oil is drained (remove the cover with magnetic rod). The new hydraulic oil is also filled through the opening. For more information refer to chapter “Renewing the return filter”.

Draining hydraulic oil

LHB/11110170/02/2011-07-21/en

Make sure that the pressure in the hydraulic system has been relieved.

188

LH 120 C-1103 / 49287

Operating manual

Maintenance Hydraulic components

Fig. 370: Underside of the hydraulic tank: drain hydraulic oil 1

Drain valve

Drain hose

Fig. 371: Underside of the hydraulic pumps: drain hydraulic oil 1

Drain valve

Drain hose

u Prepare a suitable container for collecting the hydraulic oil. u Screw the drain hose onto the drain valves on the base of the tank and drain the hydraulic oil. u Screw the drain hose onto the drain valve of the hydraulic pumps and drain the hydraulic oil. u Remove the drain hose and fill in hydraulic oil.

LHB/11110170/02/2011-07-21/en

Filling hydraulic oil u If a filter is due to be renewed, do this before filling. u Before filling, make sure that the filter element (return filter) is installed. u Fill hydraulic oil into the open return filter until the oil level is correct. u Bleed the hydraulic pumps. u Check the oil level, top up hydraulic oil if necessary. u Close the return filter (install the cover with magnetic rod).

LH 120 C-1103 / 49287

189

Maintenance

Operating manual

Hydraulic components

5.10.8 Bleeding the hydraulic pumps If hydraulic pumps are empty or only partially filled with hydraulic oil, they must be bled before commissioning. This is required after the following activities: – Changing the hydraulic oil. – Repairing or renewing the hydraulic pump. – Any activity involving draining the hydraulic oil from the hydraulic pumps. NOTICE Air inclusions in a hydraulic pump reduce the lubrication or render it less effective! The hydraulic pump can suffer irreparable damage in a very short time! u Eliminate air inclusions in hydraulic pumps by bleeding.

LHB/11110170/02/2011-07-21/en

u Do not return the machine to operation until after bleeding.

Fig. 372: Hydraulic pump, sequence of bleeding Make sure that the hydraulic tank is sufficiently filled. Make sure that the pressure in the hydraulic system has been relieved.

190

LH 120 C-1103 / 49287

Operating manual

Maintenance Hydraulic components

The hydraulic pumps must be bled one after another in the specified sequence via the leak oil connection on each pump (hose fittings 1 to 9). Start bleeding from the lowest hydraulic pump and finish with the highest one. u Prepare a suitable container for collecting the hydraulic oil. u Open hose fitting 1 (one rotation) and allow the air to escape. As soon as hydraulic oil emerges free from bubbles: u tighten the hose fitting. u Continue with the next hose fitting. Further procedure

LHB/11110170/02/2011-07-21/en

The fill level in the hydraulic tank drops slightly when the hydraulic pumps are bled. Top up hydraulic oil if necessary.

LH 120 C-1103 / 49287

191

Maintenance

Operating manual

Crawler drive

5.11 Crawler drive 5.11.1 Checking the mounting of the travel gear components

Fig. 373: Checking the mounting of the travel gear components A

Cover

1-4 Mounting bolts

No.

Mounting bolt for

Torque

Track pads

2100 Nm

Travel drive

1120 Nm

Tumbler

1120 Nm

Hydraulic motor

960 Nm

Tab. 45: Torque of mounting bolts Make sure that the machine is standing on firm, level ground and is secured against rolling away. Use a torque wrench with an adequate measuring range.

If the mounting bolt of a track pad is loose: u Check the mounting bolts of each track pad and tighten. u Remove the cover. u Check the torque of each mounting bolt on the travel drive, tumbler and hydraulic motor. If necessary: u tighten the mounting bolts. u Reattach the cover after completion of the check.

192

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

u Check some of the track pads: on the upper side of each travel gear: check the mounting of ten track pads spaced at equal intervals apart.

Operating manual

Maintenance Crawler drive

5.11.2 Checking the track tension

Fig. 374: Checking the track tension 1

Measuring bar

Spacing

The track tension drops over time due to wear on the tracked travel gear; this is a normal occurrence. The track tension must be checked regularly and increased if necessary. The tracks must sag by 25Âą5 mm between two support rollers under application conditions. Make sure that the machine is secured against rolling away. u Move the machine forwards and backwards to release the tension in the tracks. u Position the measuring bar in the area between two support rollers. u In the middle between the support rollers, measure the distance between the lower edge of the measuring bar and the track pad.

LHB/11110170/02/2011-07-21/en

If necessary: u Tighten the tracks.

LH 120 C-1103 / 49287

193

Maintenance

Operating manual

Crawler drive

5.11.3 Tightening the track

Fig. 375: Tensioning unit, tightening the track 1 2

Cover Lubrication nipple

3 4

Lubrication nipple adapter Hose of the hand grease gun

The tensioning unit presses against the idler with a spring and a grease-filled hydraulic cylinder. The force maintains the track tension. The track tension can be increased by pressing grease into the tensioning unit. The track tension drops over time due to wear on the tracked travel gear; this is a normal occurrence. The track tension must be checked regularly and increased if necessary. Make sure that the machine is secured against rolling away. u Remove the cover. u Connect the hand grease gun to the supplied lubrication nipple adapter. u Attach the lubrication nipple adapter to the lubrication nipple. u Press in grease until the track is sufficiently tensioned. u Check the track tension. u Fit the cover. Troubleshooting You cannot establish the necessary pressure using the hand grease gun? The track cannot be tensioned? The lubrication nipple or the tensioning unit might be damaged. u Never remove the lubrication nipple. LHB/11110170/02/2011-07-21/en

u Contact Liebherr customer service.

194

LH 120 C-1103 / 49287

Operating manual

Maintenance Crawler drive

5.11.4 Slackening the track

Fig. 376: Tensioning unit, slackening the track A B

Lubrication nipple Lubrication nipple with extension

1 2

Hexagon profile External hexagon profile

DANGER The track can sag suddenly if it is not slacked correctly! Grease can squirt out under high pressure! The lubrication nipple can be fired out explosively! Risk of injury! u Wear safety glasses and working gloves. u Keep your head and hands away from the track and from the lubrication nipple. u Exclusively undo the hexagon profile 1. u Do not undo the external hexagon profile 2 (on the lubrication nipple with extension). u Use a hex wrench. Do not turn the slackened hexagon profile any further by hand. u Do not unscrew the hexagon profile fully. Make sure that the machine is secured against rolling away. LHB/11110170/02/2011-07-21/en

u Clean the track and remove any trapped objects. u Unscrew the hexagon profile by two or three turns until grease emerges from the threaded hole. Once the required track tension is reached: u Tighten the hexagon profile. u Move the machine forwards and backwards and then check the track tension again.

LH 120 C-1103 / 49287

195

Maintenance

Operating manual

Crawler drive

5.11.5 Changing the oil

Fig. 377: Travel gear mechanism, filling and drainage holes 1 2

Filling hole Filling hole

Drainage hole

Make sure that the following preconditions are met: q The travel gear mechanism is warm (operating temperature) q The tracked travel gear is positioned so that the openings are in the position shown. q The machine is standing on firm, level ground and is secured against rolling away.

Draining oil u Remove the screw plugs from the filling hole. u Remove the screw plug from the drainage hole. u Let the oil flow out into a suitable container. u Check the sealing rings of the screw plugs, renew damaged sealing rings. u Screw the screw plug into the drainage hole.

Filling oil u Fill the oil until the level reaches the bottom edge of the filling hole. LHB/11110170/02/2011-07-21/en

u Screw the screw plugs into the filling holes.

196

LH 120 C-1103 / 49287

Operating manual

Maintenance Electrical system

5.12 Electrical system 5.12.1 Battery care

Fig. 378: Starter battery 1 2

Terminal post Rubber hose

Acid tester

WARNING Battery acid is highly corrosive! u Wear safety glasses and protective gloves when working on the battery. WARNING Batteries create hydrogen! The hydrogen escapes into the atmosphere through the rubber hoses! The gas can accumulate if the rubber hoses are damaged. Risk of explosion! u Check the condition of the rubber hoses, in particular after installing a battery. u Disconnect the negative terminal (-) first, and reconnect it last. u Avoid sparks or open flames when charging, and during any activity on a battery. u Only charge batteries in well ventilated rooms.

LHB/11110170/02/2011-07-21/en

Cleanliness is very important for the function of batteries. It is essential to avoid impurities in the battery acid. The metal plates integrated in the battery cells must be covered by the battery acid. They may not protrude from the surface of the liquid. Fill level: the battery acid must be 10 mm to 15 mm above the top level of the plates. Only distilled water is suitable for topping up. Acid density when the battery is fully charged: 1.28 kg/l If the battery tester displays a lower value, this means the battery is fully or partially discharged and may have to be recharged. u Remove the plugs from the battery cells during charging.

LH 120 C-1103 / 49287

197

Maintenance

Operating manual

Electrical system

u Route the rubber hoses so they lead to the atmosphere without any kinks or constrictions. u Renew damaged rubber hoses. u Clean the terminal posts and wire terminal, and grease them with an acid protection grease that is suitable for use on battery terminals.

LHB/11110170/02/2011-07-21/en

u Measure the acid density with an acid tester.

198

LH 120 C-1103 / 49287

Operating manual

Maintenance Windscreen washer system

5.13 Windscreen washer system 5.13.1 Screenwash container

Fig. 379: Screenwash container The screenwash container is located on the rear of the operator's cab. u Open the cover. u Fill with screenwash.

LHB/11110170/02/2011-07-21/en

u Close the cover.

LH 120 C-1103 / 49287

199

Maintenance

Operating manual

Automatic lubrication system

5.14 Automatic lubrication system 5.14.1 Topping up the grease container

Fig. 380: 1 2 3

Grease container Lubrication nipple Lubricating pump

4 5 6

Adapter for filling pump Filling pump Grease gun

To ensure the correct function of the central lubrication system, it is necessary to check the fill level in the grease container regularly. NOTICE Insufficient lubrication will cause damage to the machine! If the cover is removed when refilling the grease container in order to fill the container with grease from above, this can cause an air cushion to be formed in the container. In addition, dirt can be transported into the container with the grease. The lubricating pump may run dry. The system will then no longer be supplied with grease.

u Insert a grease cartridge in the filling pump. u Connect the filling pump to the adapter. u Press the content of the grease cartridge into the grease container. If no filling pump is available: u Fill the grease container using a grease gun via the lubrication nipple.

200

LH 120 C-1103 / 49287

LHB/11110170/02/2011-07-21/en

u Only fill the grease container via the adapter or the lubrication nipple.

Operating manual

Maintenance Working attachment and working tools

5.15 Working attachment and working tools 5.15.1 Renewing the teeth of the digging tools Heavily worn teeth mean that significantly more force is required in order to penetrate the digging material. Working for a long period with increased effort can cause damage to the tooth adapter. Renew worn teeth in good time. Do not work with the machine if teeth are missing from the digging tool or are heavily worn.

U-system

Fig. 381: U-system â&#x20AC;&#x201C; renewing a tooth 1 2

Punch Roll pin

3 4

Tooth Adapter

u Use a hammer and a punch to drive out the roll pin (A). u Remove the old tooth and position the new tooth on the adapter (B). u Knock in the roll pin with the hammer (C).

LHB/11110170/02/2011-07-21/en

Z-system

Fig. 382: Z-system â&#x20AC;&#x201C; removing a tooth

LH 120 C-1103 / 49287

201

Maintenance

Operating manual

Working attachment and working tools

Fig. 383: Z-system – fitting a tooth 1 2 2a 3 4

Plug Securing pin Projection on the securing pin Square wrench Punch

5 6 7 7a

Tooth Adapter Bolt Projection on bolt

u Remove the plug from the internal square profile of the securing pin (A). u Use the square wrench to turn the securing pin in the anticlockwise direction: approx. 30° (A). u Use the hammer and punch to knock out the securing pin (B). u Remove the tooth and the bolt (C). u Insert the bolt into the recess in the adapter so that the flat side of the bolt makes contact (D). u Place a new tooth on the adapter (D). u Push in the securing pin all the way (E). u Use the square wrench to turn the securing pin in the clockwise direction: approx. 30° (F). w The projection on the securing pin slides over the projection on the bolt and engages.

LHB/11110170/02/2011-07-21/en

u Insert the plug into the internal square profile of the securing pin (F).

202

LH 120 C-1103 / 49287

Operating manual

Maintenance Overall machine

5.16 Overall machine 5.16.1 Welding Welding on any main load-bearing or power-transmitting components must only be done by the manufacturer or a dealership authorised by the manufacturer. This applies irrespective of the welding process and the scope of the repair required. NOTICE Electric welding (e.g. arc welding work) requires very powerful currents. Bearings and sealing elements may fuse if powerful currents pass through them. u Attach the earth cable of the welding equipment as close as possible to the welding point. u Attach the earth cable so that the electrical current cannot flow through parts such as the slewing ring, joints, bearings, bushings, rubber elements or seals. u Disconnect the battery before starting electric welding. u Disconnect the negative terminal (-) first, and reconnect it last.

LHB/11110170/02/2011-07-21/en

u Switch off the battery main switch.

LH 120 C-1103 / 49287

203

Maintenance

Operating manual

LHB/11110170/02/2011-07-21/en

Overall machine

204

LH 120 C-1103 / 49287