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Crawler dozer
PR 734-1481
PR 734-1482
PR 734-1659
From serial number 13743
Document ID
ORIGINAL OPERATOR'S MANUAL
Order number: 9087118
Issued: 01.10.2016
Version: 05
Author: LWT / Technical Documentation Department
Product ID
Manufacturer: Liebherr-Werk Telfs GmbH
Type: PR 734
Type no.: 1481, 1482, 1659
From Serial no.: 13743
* Vehicle ID number:
VAUZ ............................. ZT .............................
* Year of manufacture:
.............................
Commissioning date:
.................. / ................. / .................
LWT/9087118/05/01.10.2016/en
These operating instructions have been written for the machine operator and for
the maintenance personnel of the machine.
It contains the descriptions for:
– Chapter 1 “Product description”
– Chapter 2 “Safety guidelines”
– Chapter 3 “Control, operation”
– Chapter 4 “Malfunctions”
– Chapter 5 “Maintenance”
The operating instructions must be read and used carefully by all persons who
carry out work with or on the machine before putting the machine into service for
the first time and later, at regular intervals.
Work with or on the machine includes, for example:
– Operation including set up, troubleshooting during work procedure, disposal of
production wastes, care, disposal of service and auxiliary materials.
– Service, including maintenance, inspection and repair work
– Transport or loading the machine
This allows the machine operator to familiarize himself with the machine more
easily and prevent malfunctions due to improper operation.
Observation of the operating instructions by maintenance personnel:
– increases reliability in use
– extends the service life of your machine
– reduces repair costs and downtime
The operating instructions belong with the machine. Make sure that a copy is
always readily available in the compartment in the operator's cab.
The Operating instructions should be supplemented with instructions for accident
prevention and environmental protection based on existing national regulations.
In addition to the operating instructions and legally binding regulations on accident
prevention which apply in the user country and at point of use, authorized specialist
rules for safe and correct working procedures are also to be observed.
These operating instructions contain all required information for control, operation
and maintenance of your machine.
Some illustrations in these operating instructions may depict details and working
devices which differ to your machine.
LWT/9087118/05/01.10.2016/en
In some illustrations, protective devices and covers have been removed in the
interests of better presentation.
Improvements, which are always being incorporated into our machines, may result
in changes to your machine which are not yet indicated in these operating instruc-
tions.
If you need additional explanations or instructions, please don't hesitate to contact
the Technical Documentation and Service Department.
Under extreme conditions, more frequent maintenance than specified in the
inspection checklist may be required.
LWT/9087118/05/01.10.2016/en
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.
E-mail: info.lwt@liebherr.com
Excellent
Very good
Good
Satisfactory
Poor
Telephone number:
Dealer:
Notes:
LWT/9087118/05/01.10.2016/en
1 Product description 15
1.1 Technical description 15
1.1.1 Design overview 15
1.2 Technical data 17
1.2.1 Information for vibration emission 17
1.2.2 Sound emission 18
1.2.3 Maximum operating weight 18
1.3 Tightening torques 19
1.3.1 Tightening torques for hex head screws 19
1.3.2 Tightening torques for countersunk screws 21
1.3.3 Tightening torque for cutting edges, end bits and adapters 23
3 Control, operation 53
3.1 Operating and control elements 54
3.1.1 Operator's cab 54
3.1.2 Control elements on the operator's platform 56
3.1.3 Control elements on the operator's platform 62
3.1.4 Display Hydraulic oil temperature 66
3.1.5 Hydraulic oil level indicator 67
3.2 Operation 68
3.2.1 Entry 68
3.2.2 Emergency exit 68
3.2.3 Door lock 69
3.2.4 Operator's seat with mechanic suspension 71
3.2.5 Operator's seat with pneumatic suspension 73
3.2.6 Seatbelt 76
3.2.7 Armrests 78
LWT/9087118/05/01.10.2016/en
5 Maintenance 171
5.1 Maintenance and inspection schedule 171
5.2 Fill quantities, lubrication schedule 176
5.2.1 Recommended lubricants 176
5.2.2 Recommended service items 177
5.2.3 Lubrication schedule 177
5.2.4 Lubrication chart symbols 179
5.3 Lubricants and fuels 180
5.3.1 General data 180
5.3.2 Diesel fuels 180
5.3.3 Lubricating oils for Diesel engines 181
5.3.4 Coolant for Diesel engines 183
5.3.5 Hydraulic oil 186
5.3.6 Lube oils for splitterboxes 191
5.3.7 Lube oils for travel gear 192
5.3.8 Oil for duo cone (slipring) seal Travel gear 193
5.3.9 Oil for axle bearing 193
5.3.10 Grease and other lubricants
LWT/9087118/05/01.10.2016/en
193
5.3.11 Oil for hinges and joints 195
5.4 Take oil samples 196
5.4.1 Taking oil samples and oil analysis 196
5.5 Preparatory maintenance tasks 200
5.5.1 Safety instructions for maintenance 200
5.5.2 Maintenance position 200
Index 309
LWT/9087118/05/01.10.2016/en
LWT/9087118/05/01.10.2016/en
LWT/9087118/05/01.10.2016/en
The most important technical data can be found in the following enclosed brochure.
Weighted effective values in m/s2 for light, normal and hard operating
LWT/9087118/05/01.10.2016/en
conditions
Machine type Typical work cycles x-axis y-axis z-axis
light norma hard light norma hard light norma hard
l l l
Load & Carry 0,55 0,64 0,72 0,36 0,48 0,59 0,42 0,52 0,62
Crawler loader Transfer 0,29 0,41 0,54 0,26 0,35 0,44 0,45 0,60 0,75
V-operation 0,59 0,89 1,18 0,41 0,66 0,91 0,45 0,63 0,81
Weighted effective values in m/s2 for light, normal and hard operating
conditions
Machine type Typical work cycles x-axis y-axis z-axis
light norma hard light norma hard light norma hard
l l l
Telescopic Work cycle 0,20 0,37 0,55 0,19 0,28 0,38 0,42 0,56 0,71
handler
Grading 0,31 0,53 0,75 0,24 0,41 0,59 0,39 0,70 1,01
Crawler tractor with ripper 0,61 0,89 1,18 0,56 0,85 1,14 0,74 1,02 1,30
Transfer 0,31 0,62 0,93 0,29 0,57 0,86 0,63 0,97 1,31
Pipe layer Work cycle 0,09 0,15 0,21 0,09 0,16 0,24 0,10 0,24 0,38
Conveyor Work cycle 0,63 0,52 0,57
mover
Tab. 1
Refill Capacities
Fuel tank 400 l / 88 lmp.gal
Travel Drive, Control Cooling system 37 l / 8.1 lmp.gal
Transmission system Infinitely variable hydrostatic travel drive, Engine oil with oil filters 29 l / 6.4 lmp.gal
independent drive for each track Splitter box 3.1 l / 0.7 lmp.gal
Travel speed* continuously variable Hydraulic tank 144 l / 31.7 lmp.gal
Speed range 1 (reverse):
0 – 4.0 km / h / 2.5 mph (4.8 km / h / 3.0 mph) Final drive L, each side 19.5 l / 4.3 lmp.gal
Speed range 2 (reverse):
0 – 6.5 km / h / 4.0 mph (7.8 km / h / 4.8 mph) Final drive XL, each side 19.5 l / 4.3 Imp.gal
Speed range 3 (reverse):
0 – 10.0 km / h / 6.2 mph (10.0 km / h / 6.2 mph) Final drive LGP, each side 25.5 l / 5.6 lmp.gal
* Factory settings. All speed ranges can be
customized on the travel joystick
Drawbar pull 274 kN at 1.5 km / h / 0.9 mph
Electronic control Electronic engine speed control automatically Sound Emissions
adjusts travel speed and drawbar pull to match Operator sound exposure LpA = 79 dB(A)
changing load conditions ISO 6396:2008 (in the cab)
Steering Hydrostatic Exterior sound pressure LwA = 111 dB(A)
Service brake Wear-free, hydrostatic (dynamic braking) ISO 6395:1988 (to the environment)
Automatic park brake Wet multiple-disc brakes, wear-free,
automatically applied when joystick is in neutral
position Drawbar Pull PR 734-4
Cooling system Hydraulic oil cooler, integrated in combi radiator Max. 319 kN
Filter system Micro cartridge filters at 1.5 km/h / 0.9 mph 281 kN
Final drive Heavy-duty combination spur gear with at 3.0 km/h / 1.9 mph 154 kN
planetary gear, double sealed with electronic at 6.0 km/h / 3.7 mph 77 kN
seal-integrity indicator at 9.0 km/h / 5.6 mph 51 kN
Control Single joystick for all travel and steering functions
Hydraulics
Hydraulic system Open-center with load-sensing valve block and
gear pump
Pump flow max. 222 l / min / 48.8 gpm
Pressure limitation 200 bar
Control valve 2 segments, expandable to 3
Filter system Return filter with magnetic rod
Control Single joystick for all blade functions
2 PR 734-4 Litronic
Dimensions
H
T0104 T0104
D C E
B F
G
Image shows XL undercarriage
Dimensions
Undercarriage L XL LGP
A Height over cab mm 3,284 3,284 3,284
ft in 10’9” 10’9” 10’9”
B Overall length without attachments mm 4,170 4,170 4,170
ft in 13’8” 13’8” 13’8”
C Length of track on ground mm 2,630 3,136 3,136
ft in 8’8” 10’3” 10’3”
D Grouser height mm 65 65 65
in 2.56” 2.56” 2.56”
E Track gauge mm 1,830 1,830 2,070
ft in 6’0” 6’0” 6’9”
G Total width over blade-mounting trunnions mm 2,724 2,724 3,474
ft in 8’11” 8’11” 11’5”
H Ground clearance mm 497 497 497
ft in 1’8” 1’8” 1’8”
Track shoes 508 mm / 20”
F Total width without trunnions mm / ft in 2,338 / 7’8” – –
Tractor shipping weight1 kg / lb 15,291 / 33,711
Track shoes 560 mm / 22”
F Total width without trunnions mm / ft in 2,390 / 7’10” – –
Tractor shipping weight1 kg / lb 15,391 / 33,931
Track shoes 610 mm / 24”
F Total width without trunnions mm / ft in 2,440 / 8’0” 2,440 / 8’0” –
Tractor shipping weight1 kg / lb 15,533 / 34,244 16,322 / 53’7”
Track shoes 812 mm / 32”
F Total width without trunnions mm / ft in – – 2,882 / 9’5”
Tractor shipping weight1 kg / lb 17,500 / 38,581
Track shoes 865 mm / 34”
F Total width without trunnions mm / ft in – – 2,935 / 9’8”
Tractor shipping weight1 kg / lb 17,632 / 38,872
1 Includes coolant and lubricants, 20 % fuel, ROPS / FOPS cab.
PR 734-4 Litronic 3
Front Attachments
B G
A
C
T0105
T0105
D H
E
Semi-U Blade and Semi-U Blade Straight Blade Semi-U Blade Straight Blade Straight Blade
Straight Blade Undercarriage L L XL XL LGP
Blade capacity, ISO 9246 m3 5.56 4.21 5.56 4.21 4.10
yd3 7.27 5.51 7.27 5.51 5.36
A Height of blade mm 1,400 1,300 1,400 1,300 1,150
ft in 4’7” 4’3” 4’7” 4’3” 3’9”
B Width of blade mm 3,372 3,420 3,372 3,420 3,994
ft in 11’1” 11’3” 11’1” 11’3” 13’1”
C Lifting height mm 1,179 1,182 1,208 1,210 1,219
ft in 3’10” 3’11” 4’ 4’ 4’
D Digging depth mm 524 525 548 549 552
ft in 1’9” 1’9” 1’10” 1’10” 1’10”
E Blade pitch adjustment 10° 10° 10° 10° 10°
4 PR 734-4 Litronic
Front Attachments
B1 B
G
F
A C
T0106
T0106
D
H H1
PR 734-4 Litronic 5
Rear Attachments
T0085
B
C
D T0085
Ripper
Parallelogram 3-Shank Ripper
A Ripping depth (max. / min.) mm 522 / 372
ft in 1’9” / 1’3”
B Lifting height (max. / min.) mm 665 / 515
ft in 2’2” / 1’8”
C Additional length, attachment raised mm 1,199
ft in 3’11”
D Additional length, attachment lowered mm 1,531
ft in 5’0”
E Overall beam width mm 2,320
ft in 7’7”
F Distance between shanks mm 1,000
ft in 3’3”
Weight kg 1,920
lb 4,233
6 PR 734-4 Litronic
Equipment
Base Machine Operator’s Cab Control and
Air filter, dry-type, dual step • Armrests 3D adjustable • Warning Lights
Air filter with automatic dust ejector • Coat hook •
Control travel speed range (digital) •
Battery compartment, lockable • Dome light •
Control engine coolant temperature
Belly pans, heavy duty • Operator’s seat, 6-way adjustable •
(analogue) •
Engine cover, perforated • Operator’seat, mechanically suspended •
Control fuel level (analogue) •
Engine door, hinged, lockable • Pressurised cab •
Hour meter (analogue) •
Engine doors, perforated • Rear-view mirror, inside •
Indicator light Diesel engine preheater •
Fan guard • ROPS / FOPS •
Indicator light float position blade •
Fan, hydraulically driven • Safety glass, tinted •
Indicator light parking brake •
Fuel water separator • Storage compartment •
Main warning light •
Liebherr Diesel engine • Warm water heating •
Warning light air filter •
Lugs for crane lifting, front • Windshield washer system •
Warning light battery charging •
Radiator guard • Windshield wipers front, rear, on the
Warning light diesel engine •
Radiator, wide-meshed • doors, with intermittent function •
Warning light electronic travel
Tow switch • Air conditioning +
control system •
Fan, hydraulically driven, reversible + External mirrors +
Warning light fan control •
Fuel water separator with electric heater + Fire extinguisher +
Warning light fuel water separator •
LiDAT – Liebherr data transmission system + Forest sweeps +
Warning light hydraulic oil temperature •
Liebherr hydraulic oil, Plus Arctic + Operator’s seat, air-suspended +
Warning light oil return filter •
Sealing, cab – base machine + Protective grids for rear windows +
Warning light pump repleneshing pressure •
Tank guard, bottom + Protective grids for windows, all-around +
Warning light final drive seal, each side •
Tank guard, complete + Radio +
Hydraulic oil temperature gauge +
Toolkit, extended + Radio preparation +
Warning light hydraulic oil level +
Towing hitch rear + Sliding window, left +
Coal equipment + Sliding window, right +
Cold kit + Tiltable cab +
Forestry equipment + Hydraulic System
Landfill equipment + Control valve for 2 circuits •
Woodchip equipment + Undercarriage Float position blade •
Hydraulic servo control •
Master link, two-piece •
Oil filter in hydraulic tank •
Pivot shaft, separate •
Travel Drive Hydraulics, ripper +
Sprocket segments, bolted •
Hydraulics, winch +
Control, single joystick • Track frame, closed •
Hydraulic tank oil level control +
Electronic control • Track frames, oscillating •
Emergency stop • Tracks oil-lubricated •
Final drives planetary gear • Coal deflector at sprocket +
Function control, automatic • Final drive seal guards + Attachments
Hydrostatic travel drive • Sprocket segments, with recesses + Coal-U blade 1), 2) +
Load limit control, electronic • Track guard, full length + Counterweight, rear +
Oil cooler • Track guide centre part + Drawbar rear, rigid +
Parking brake, automatic • Track pads with mud holes + Lifting lugs, rear +
Safety lever • Track shoes ESS + Mechanical angle blade 2) +
Travel control, 3 speed ranges • Tracks, grease-lubricated + Mounting plate for external equipment +
Inching brake pedal + Undercarriage L + Ripper, 1 shank +
Undercarriage XL + Ripper, 3 shanks +
Undercarriage LGP + Semi-U blade 1), 2) +
PR 734-4 Litronic 7
The Liebherr Group of Companies
All illustrations and data may differ from standard equipment. Subject to change without notice.
family is the sole owner of the company.
www.liebherr.com
Metric standard Preload force FM Tightening torques MA Wrench size for Wrench size for
thread according to grades [N] according to grades [Nm] hex head socket head
screws screws
8.8 10.9 12.9 8.8 10.9 12.9 mm Inch mm Inch
M 4 x 0.7 4 050 6 000 7 000 2,8 4,1 4,8 7 9/32 3 --
M 5 x 0.8 6 600 9 700 11 400 5,5 8,1 9,5 8 5/16 4 5/32
M6x1 9 400 13700 16 100 9,5 14 16,5 10 -- 5 --
M7x1 13 700 20 100 23 500 15,5 23 27 11 -- -- --
M 8 x 1.25 17 200 25 000 29 500 23 34 40 13 1/2 6 --
M 10 x 1.5 27 500 40 000 47 000 46 68 79 (17)16 (11/16) 8 5/16
M 12 x 1.75 40 000 59 000 69 000 79 117 135 (19)18 (3/4) 10 --
LWT/9087118/05/01.10.2016/en
Metric standard Preload force FM Tightening torques MA Wrench size for Wrench size for
thread according to grades [N] according to grades [Nm] hex head socket head
screws screws
M 30 x 3.5 280 000 400 000 465 000 1 350 1 900 2 250 46 1- 22 7/8
13/16
M 33 x 3.5 350 000 495 000 580 000 1 850 2 600 3 000 50 2 24 --
M 36 x 4 410 000 580 000 680 000 2 350 3 300 3 900 55 2 - 3/16 27 1 - 1/16
M 39 x 4 490 000 700 000 820 000 3 000 4 300 5 100 60 2 - 3/8 27 1 - 1/16
Tab. 2
Preload values and tightening torques for screws with fine metric thread
according to factory standard WN 4037I
1-
M 30 x 2 321 000 457 000 534 000 1 490 2 120 2 480 46 22 7/8
13/16
M 33 x 1.5 410 000 584 000 683 000 2 050 2 920 3 420 50 2 24 -
M 33 x 2 395 000 560 000 660 000 2 000 2 800 3 300 50 2 24 -
M 36 x 1.5 492 000 701 000 820 000 2 680 3 820 4 470 55 2 - 3/16 27 1 - 1/16
M 36 x 3 440 000 630 000 740 000 2 500 3 500 4 100 55 2 - 3/16 27 1 - 1/16
M 39 x 1.5 582 000 830 000 971 000 3 430 4 890 5 720 60 2 - 3/8 27 1 - 1/16
Tab. 3
Tab. 4
Tab. 5
Tab. 6
LWT/9087118/05/01.10.2016/en
LWT/9087118/05/01.10.2016/en
Working with the machine is dangerous, serious or fatal injuries can happen to you,
the operator, the driver or maintenance personnel. If you regularly read and
observe the various safety information, you can prevent dangers and accidents.
This applies especially for personnel who is working only intermittently on the
machine, such as for set up, maintenance.
The following information comprises safety guidelines which, if followed conscien-
tiously, will guarantee your safety and that of other persons, as well as avoid
damage to the machine.
For description of work, which can pose a danger for man or machine, the required
safety precautions are described in this manual.
Tab. 7
The warning sign always appears in connection with the signal words
DANGER
WARNING
CAUTION
Tab. 8
Tab. 9
With normal dozing attachment, the machine is only designed for loosening,
moving and dumping soil, rocks, broken stones or other materials.
Machines in lifting application are subject to special conditions and must be
equipped with the specified safety devices (before lifting application, request the
information from Liebherr and observe it).
Machines utilized in underground applications (deep mining and tunnel construc-
tion) in surroundings which are not endangered by explosions must be equipped
with technologies for exhaust reduction (for example with Diesel particle filters).
The individual state requirements must be observed.
Special applications require special equipment and possibly special safety devices.
This equipment may only be installed and used after approval and according to
specifications by the basic machine manufacturer.
Any other use or use above and beyond, such as demolition of rock and buildings,
ramming poles, transporting personnel or working in explosion endangered as well
as contaminated surroundings is considered not to be destined use. The manufac-
turer is not liable for damage resulting from this action. The user is solely respon-
sible for the risk incurred.
Observing the operating instructions and the inspection / maintenance instructions
is also deemed to be appropriate use in accordance with regulations.
LWT/9087118/05/01.10.2016/en
The sign is installed on the outside, on the left and right-hand side, as well as on
the rear of the machine.
Warns of danger of accidents potentially resulting in death or very severe injuries.
Meaning: It is prohibited for anyone to remain in the danger zone!
The sign is installed on the left and right-hand side on the engine compartment
doors.
Warns of danger of accidents leading to potentially very severe injuries.
Meaning: Open only if the diesel engine is not running!
LWT/9087118/05/01.10.2016/en
The sign is installed on the left and right on the track roller frame, on the cover near
the grease cylinder.
Warns of danger of accidents leading to potentially very severe injuries.
Meaning: When releasing the track, keep your head away from the track roller
frame. Sagging track and spraying grease.
The sign is installed in the battery compartment near the hydraulic hand pump.
Warns of danger of accidents potentially resulting in death or very severe injuries.
Meaning: Do not stand under the tilted operator's platform unless the safety
support bar is in place. When the operator's platform is tilted, the machine
may not be started or driven, the safety lever must remain in park position.
Seatbelt sign
The sign is installed on the safety support bar on the operator’s platform tilt
cylinder.
Warns of danger of accidents potentially resulting in death or very severe injuries.
Meaning: Indicates the correct procedure for tilting the operator’s platform.
Carefully observe the instructions on the sign as well as those in the opera-
tor's manual.
Battery sign
The sign is installed on the left hand side on the operator’s platform.
Shows the operation of the travel joystick for the travel functions of the machine.
The sign is installed on the filler neck of the window washer fluid reservoir.
The lubrication schedule shows all parts which are filled with oil and grease as well
as their inspection and maintenance intervals.
Sign Ripper
The sign is installed on the right hand side on the operator’s platform.
Shows the operation of the ripper.
LWT/9087118/05/01.10.2016/en
The sign is installed on the right hand side on the operator’s platform.
Shows the operation of the boom attachment of the machine.
Sign Coolant
– Type
– Vehicle Id. No.
– Permissible overall weight
– Year of manufacture
– Engine power
– Maximum speed
17. Never operate a machine without a complete walk around inspection. Check if
all warning signs are on the machine and if they are all legible.
18. Observe all signs with danger and safety notes.
19. For special applications, this machine must be equipped with specific safety
devices. In this case, use the machine only if they are installed and func-
tioning.
20. Never make any changes or additions and modifications on the machine,
which could affect the safety, without obtaining explicit approval from the
manufacturer / supplier. This also applies to the installation and adjustment of
safety devices and safety valves as well as to any welding on load carrying
parts.
21. Avoid staying near the running Diesel engine. Persons with a pacemaker may
not stay near a running Diesel engine (minimum distance 50 cm).
22. Do not touch current carrying components on the electrical connection of sole-
noid valve controlled injection pumps (Unit Pumps) when the Diesel engine is
running.
6. Regularly inspect all lines, hoses and fittings for leaks and damage. Repair
any leaks immediately and replace damaged components.
Any oil escaping from leaks can easily cause a fire.
7. Be certain that all clamps and protective guards are properly installed to
prevent vibration, rubbing and heat build up.
8. Starter fluid (ether) is especially flammable! Never use cold start ether near
heat sources, open flames (for example cigarettes) or in insufficiently venti-
lated areas.
9. Never use the flame glow system or preheat systems when using cold start
ether! (Danger of explosion)
10. Know the location of fire extinguishers, make sure you know how to use them
properly and check out the location of where to report a fire and inform your-
self about fire fighting capabilities before you start to work.
6. When operating in enclosed spaces, run the engine only if there is sufficient
ventilation. If necessary, open doors and windows to ensure sufficient fresh air
supply.
7. Bring the engine and the hydraulic oil to operating temperature, low oil temper-
atures cause the controls to be sluggish.
8. Check that the control for the attachment functions properly.
9. Move the machine carefully into an open area and check all travel functions,
check travel brake, the steering function as well as the turn signals and lights.
18. The maximum permissible incline and side slope of the machine depends on
the installed attachment as well as on the ground conditions!
19. Avoid any working movements which could cause the machine to tip over.
However, if the machine does begin to tip or slide, lower the attachment imme-
diately and turn the machine downhill. If possible, always work downhill or
uphill, never sideways on a slope.
20. Always move slowly and carefully on rocky or slippery ground or on a slope.
21. Always adapt the travel speed to the working conditions.
22. Never travel on slopes which exceed the maximum permissible gradeability.
23. Travel downhill only at low travel speed, maximum 4 km/h, to prevent loss of
control over the machine. The engine must run at high idle speed and the
speed must be reduced by selecting the lower speed range. Never switch into
the lower travel speed range while already driving downhill, always switch
before approaching the slope.
24. For terrain which is difficult to gain an overview of and whenever necessary,
ask for assistance of a guide. Have only one person signal you.
25. Danger of accidents due to restriction of vision for large machines! Take suit-
able measures to ensure a safe working application of the machine on the
construction site.
26. Only permit experienced personnel to secure loads and signal the crane oper-
ator. The signaller must position himself within the view of the operator or be in
voice contact with him.
11. Check that there is enough clearance underneath all electrical lines, bridges,
underpasses and in tunnels.
12. During the unloading procedure, proceed with the same caution as during the
loading procedure.
Procedure:
• Remove all chains and wedges. Start the engine as outlined in the oper-
ating instructions.
• Carefully drive off the loading platform down the ramp.
• Have another person guide and signal you.
8. Inform the operator before carrying out any special task or maintenance work.
Appoint one supervisory person.
9. If not otherwise noted in these operating instructions, carry out all maintenance
work on the machine on firm and level ground, with the engine turned off.
10. The operator’s platform may only be tilted when the machine is at a standstill
and the engine is turned off! When tilting the operator’s platform forward or
backward, there may be no personnel within the tilt range. Work under the
tilted operator's platform may only be carried out if the machine is at a stand-
still and after placing the safety support bar. The machine may NOT be started
or driven with a tilted operator’s platform. Leave the safety lever in the upper-
most position!
11. During maintenance and repairs, make sure you always tighten any loosened
screw connections.
12. If it becomes necessary to remove any safety devices during set up, mainte-
nance and repairs, the safety devices which were removed must be reinstalled
immediately after completion of the maintenance and repair work and then be
inspected for proper function.
13. Before any maintenance and repair work, especially when working under the
machine, attach an easily visible warning sign “DO NOT TURN ON” on the
ignition switch. Pull the ignition key off.
14. Before any maintenance and repairs, clean the machine, especially connec-
tions and fittings to remove oil, fuel or cleaning substances. Never use aggres-
sive cleaning substances. Use only lint-free cleaning cloths.
15. To clean the machine, never use flammable cleaning fluids.
16. Before any welding, cutting and grinding, clean the machine and surrounding
area of dust and flammable substances and assure adequate ventilation.
• Otherwise there is a DANGER OF EXPLOSION!
17. Before cleaning with water, steam (high pressure cleaner) or other cleaning
fluids, cover / tape off all openings whose safety and function could be affected
by infiltration of water, steam or cleaning fluid.
Electrical motors, switch boxes and battery compartments are especially
endangered.
Further procedure:
• Make sure that the temperature sensor of the fire warning system and the
fire extinguisher do not come in contact with hot cleaning fluids when
cleaning the operator's cab. Otherwise they could trigger the fire extin-
guishing system.
• After cleaning, completely remove the covers and tapes.
• After cleaning the machine, check all fuel, engine oil, hydraulic oil lines for
leaks, loose connections, chafing and damage.
• Fix any defects immediately.
18. Adhere to the product safety instructions issued for handling of oils, greases
and other chemical substances.
19. Ensure safe and environmentally friendly disposal of operating and service
fluids as well as exchange parts.
20. Be very careful when handling any hot components or service fluids on the
machine as there is a danger of burns and scalding.
21. Operate combustion engines and fuel operated heaters only in sufficiently
ventilated areas. Before starting the machine in a closed area, make sure the
ventilation is sufficient. Always follow all regulations valid for the current job
site.
22. Perform any welding, cutting or grinding work on the machine only if this work
has been explicitly authorized, as there can be a danger of fire or explosion.
23. The operator’s cab windows are made of safety glass. Damaged operator’s
cab windows must always be replaced immediately.
• Only safety glass may be used for the operator’s cab windows.
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25. Do not use damaged or insufficiently sized ropes or cables. Always wear work
gloves when handling wire cables.
26. Only permit experienced personnel to secure loads and signal the crane oper-
ator. The guide must position himself within view of the operator or be in voice
contact with him.
27. When working overhead during installation work, use appropriate safe access
ladders and working platforms. Never use machine parts as access aids. Wear
a harness / anti-fall guards when working in great heights. Keep all handles,
steps, railings, platforms, ladders free of dirt, ice and snow.
28. When working on the attachment, make sure it is safely supported. Never use
metal on metal support.
29. Never lay underneath the machine unless the machine is properly and safely
supported with wooden beams.
30. Always support the machine in such a way that any shifting weight will not
endanger the stability of the machine and avoid metal to metal contact.
31. Only authorized, especially trained personnel may work on the travel gears,
brake and steering system.
32. If the machine must be repaired while parked on a slope, the track chains or
wheels must be blocked with wedges to prevent any movement. Bring the
working attachment into maintenance position.
33. Only authorized personnel with specialized training and experience in
hydraulics may work on the hydraulic system.
34. Wear protective gloves when checking for leaks. Fluid escaping from a small
hole can have enough pressure to penetrate the skin.
35. Never loosen any hydraulic oil lines or fittings before the attachment has been
lowered and the engine has been turned off. Then, with the ignition key in
contact position and the safety lever in operating position, actuate all pilot
controls (joysticks and pedals) in both directions to relieve the servo pressure
and the back pressures in the working circuits, and relieve the internal tank
pressure by releasing the breather screw.
36. Regularly inspect all hydraulic oil lines, hoses and fittings for leaks and exter-
nally visible damage. Fix any defects immediately. Oil spray can lead to inju-
ries and fires.
37. Before beginning any repairs, be sure that all air and hydraulic pressures are
relieved in any of the systems and pressure lines you need to gain access to.
38. Route and install hydraulic hoses and air pressure lines properly. Do not mix
up the connections. All fittings, including length and quality of hose lines must
match the specified requirements.
Use only Liebherr replacement parts.
39. Replace hydraulic hoses and lines in regular intervals, as stated, even if no
safety relevant defects can be seen.
40. Only qualified electricians or trained personnel under the guidance and super-
vision of a licensed electrician may work on the electrical equipment of the
machine, according to the electro-technical rules and regulations.
41. Only use Original fuses with the correct amperage. In case of problems in the
electric energy supply, turn the machine off immediately.
42. Inspect and check the electronic equipment on the machine regularly. Correct
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any defects, such as loose connections, burnt or chafed wiring or burnt out
fuses and bulbs immediately.
43. If any work is necessary on energized, voltage carrying parts, a second person
must be utilized to disconnect the emergency off or master switch in case a
problem should arise. Rope off the work area off with a red and white safety
chain and a warning sign. Use only insulated tools.
44. When working on high voltage carrying components, turn off the power supply,
then connect the supply cable to the ground and use a grounding rod to
ground these parts, such as the condensers.
45. Check all disconnected parts first if they are really free of voltage, ground them
and then short circuit them. Insulate adjacent, voltage carrying parts.
Operating instructions.
3. Even if hoses and hose lines are properly stored and used, they undergo a
natural aging process. For that reason, their service life is limited.
4. Improper storage, mechanical damage and improper use are the most
frequent causes of hose failures.
5. The service life of a hose line may not exceed six years, including a storage
period of a maximum of two years (always check the manufacturer’s date on
the hoses).
6. Using hoses and lines close to the limit ranges of permitted use can shorten
the service life ( for example at high temperatures, frequent working cycles,
extremely high impulse frequencies, multi shift operation).
7. Hoses and lines must be replaced if any of the following conditions are found
during an inspection:
Criteria:
• Damage to the outer layer as far as the intermediate layer (e.g. chafing,
cuts and cracks).
• Brittleness of the outer layer (hose material cracking);
• Deformations, which differ from the natural shape of the hose or hose line,
when under pressure or not under pressure, or in bends, e.g. separation of
layers, blisters or bubble formation;
• Leaks;
• Failure to follow installation instructions;
• Damage or deformation in the hose fittings, which reduce the stability of the
fitting or the connection from hose to fitting;
• Hose slipping out of the fitting;
• Corrosion of the fitting, which reduces function and strength;
• Storage time or service life has been exceeded.
8. When replacing hoses and hose lines, use only Original spare parts.
9. Route and install hoses and hose lines properly. Do not mix up the connec-
tions.
6. Fill the hyrdo accumulator only with nitrogen. When using oxygen or air, there
is a DANGER OF EXPLOSION!
7. The accumulator housing can become hot during operation, there is a danger
of burning.
8. New hydro accumulators must be charged to the required pressure for the
application before use.
9. The operating data (minimum and maximum pressure) is marked permanently
on the hydro accumulators. Make sure that the marks remain visible.
The seat adjustment and the suspension should be made according to the
weight and the size of the operator.
Check the suspension and the adjustment mechanism regularly and make
sure that the characteristics of the seat remains as specified by the seat manu-
facturer.
5. Check the maintenance condition of the machine, especially regarding: Tire
pressure, brakes, steering, mechanical connections, etc.
6. Do not steer, brake, accelerate and shift or move and load the attachment of
the machine in a jerky manner.
7. Match the machine speed to the travel route to avoid vibration impacts.
Decrease the speed when driving on pathless terrain.
Field of vision
You as the machine operator probably perceive the most information for your work
visually. Only if there is sufficient visibility while travelling and working can you mini-
mize possible dangers for you and others.
Since there is no direct view onto all areas in the surrounding, visual aids (such as
mirrors and cameras) are installed on the machine. These visual aids are to be
utilized for the areas around the machine which are not directly visible.
WARNING
Some installations and equipment can limit the visibility of the machine operator.
Danger of accident!
u Pay attention to limitations in the visibility field and to blind spots.
u Use the aid of a guide if necessary.
Observe national regulations regarding visibility in the operator’s cab. For countries
within the European Economic Area, the Standard ISO 5006:2006 describes the
Test and evaluation methods for the visibility field of the machine operator. The visi-
bility field is tested in this case with the standard equipment. Changes on the
machine, such as installation or modification of components may not impact the
visibility field. When changes impact the visibility field, then a test according to ISO
5006:2006 or the regulations valid on the job site must be carried out. Appropriate
measures are to be taken, depending on the test result. The machine operator
must be informed about the changes.
9. Prefer direct visibility: plan the work in such a way that the visibility onto the
work area is not limited by obstacles.
10. As a rule, always work with a guide for tasks with limited visibility or defective
visual aids. Agree on hand signals, for difficult tasks use additional voice
contact (for example via radio).
11. Use lights in bad visibility conditions and according to the valid regulations.
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30 LC display
Shows:
– the travel speed
– the Diesel engine rpm
– the Service codes
– the towing mode
– the fill mode.
If a Service code appears, take the machine out of service properly and put it back
into service. If the Service code in the LC display does not disappear, contact Lieb-
herr Service immediately.
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The LC display is deactivated when the ignition is turned on. The LC display is acti-
vated by placing the safety lever down or by starting the Diesel engine.
– when the ignition switch is in contact position as long as the Diesel engine is not
running
If the warning light - Operator's cab lights up, turn the Diesel engine off and remedy
the problem.
34 Fuel display
Shows the contents of the Diesel fuel tank.
To reduce the formation of condensation in the tank, keep the fuel level as high as
possible.
– Lights up, for example, if the V-belt for the alternator is broken.
If the indicator light lights up, turn the Diesel engine off and remedy the problem.
In case of a failure of the speed reduction pedal, the indicator light - Electronic
blinks as well as the warning light - Operator's cab.
The machine can be operated in the meantime. Contact Liebherr Service and
repair the speed reduction pedal promptly.
62 Warning buzzer
If the warning buzzer sounds: Turn the Diesel engine off and remedy the problem.
52 Horn button
53 Scroll key
– The service codes can be called up by pressing the scroll key, with the starter
key in contact position The Service codes are shown in the LC display.
Maximum 10 Service codes are shown in the display. The current service code
moves the previous one back by one place. After 30 seconds, the display
returns automatically to standard display (speed stage and RPM), or it can be
changed manually to standard display by pressing the scroll key for 3 seconds.
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60 Starter switch
“STOP” position
Contact position
Start position
Park position
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The machine stops immediately when the emergency off button is pressed.
– The attachment can still be moved.
68 Radio
– The operation of the radio is described in the separate radio operating manual.
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Tab. 10
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3.2 Operation
3.2.1 Entry
Always enter and leave the machine using the ascending aids provided.
Clean the steps and tracks before access and check them for proper condition.
Always enter and leave the operator's cab through the left-hand operator's cab
door.
Familiarize yourself with the emergency exit on the right-hand side. See section
“Emergency exit”.
WARNING
Risk of injury due to falling or jumping off the machine!
u To enter and leave, use only the steps, ladders and handrails provided.
u Never jump off the machine.
WARNING
Risk of injury due to unintended movements of the machine!
u When entering or exiting, never use the control levers or joysticks as handholds.
u Enter and leave the machine at the front left over the push frame and the tracks.
Enter and leave the machine always through the left operator's cab door.
The right operator's cab door is intended as an emergency exit and may therefore
only be used in emergency situations.
Before operating the machine, check if the operator's cab can be exited without
restrictions through the right operator's cab door.
u Open the operator's cab door: Turn the lever 1 on the door lock upward.
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u Before leaving the operator's cab, move the safety lever 1 up.
w The indicator light travel gear brake lights up.
Door latch
The fully opened operator's cab doors are held in this position by the door latch 1.
Operator's seat
The seat suspension can be adjusted individually to the body weight of the oper-
ator.
The adjustment is made when the operator's seat is occupied and the machine is
at a standstill by turning the lever 4.
The adjustment is made with lever 7 and lever 8 on the right side of the operator's
seat.
u Lift lever 7 and lever 8 at the same time.
u Bring the seat to the desired height and release both levers.
The lumbar supports in the backrest can be adjusted individually. Two lumbar
supports are located in the backrest: One in the upper and one in the lower area of
the backrest.
The adjustment is made via button 1 and 2.
3.2.6 Seatbelt
WARNING
Risk of injury if seatbelt is not worn!
If the seatbelt is not correctly worn, then an accident with severe injuries can result
if the machine is suddenly slowed down or stopped!
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DANGER
Risk of injury if seatbelt is not worn!
If the seatbelt is not correctly worn, then an accident with severe injuries can result
if the machine tips or rolls over!
u Always wear the seatbelt before operating the machine.
u Check the condition, function and attachment of the belt regularly. Replace
damaged parts immediately.
u Wear the seatbelt in such a way that the belt is not twisted.
u Hold the belt buckle with the right hand and pull the belt slowly from the belt
retainer.
Note
If the belt is pulled out too quickly, then the belt retainer blocks the belt.
u Pull the belt out slowly.
u Hold the latch lock with the left hand and pull the belt over the body at lap
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height.
u Insert the latch into the latch lock and check if the latch lock is engaged by
pulling on the latch.
u Release the belt: Push the lock on the latch lock downward
3.2.7 Armrests
The height and the horizontal position of the armrests can be adjusted individually.
u Adjust the height: Loosen the handle 1, adjust the height and the horizontal
position and affix.
u Adjust the incline: Loosen the handle 2, adjust the incline and affix.
The operator's cab can only be heated if the Diesel engine is at operating tempera-
ture and the shut off valves 1 are open.
The shut off valves are located on the left front on the Diesel engine.
Blower stages:
Stage 0 - position OFF
Stage 1 - weak airflow
Stage 2 - medium airflow
Stage 3 - strong airflow
u Switch the blower knob 1 to the desired stage.
w The air is blown via vents into the operator’s cab.
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On damp days, the air conditioning system can dehumidify the air in the cab.
The temperature in the cab becomes more comfortable and the windows will not
fog up.
The air conditioning system works only if the Diesel engine is running.
u Start the Diesel engine.
u Turn the air conditioner master switch in the roof console on.
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The temperature in the operator’s cab is lowered by turning the knob in counter-
clockwise direction.
Due to the integrated de-icing protection, the evaporator will not ice up.
(Optional equipment)
The sliding windows installed in the operator's cab can be opened by pulling on the
hand and locked in several positions.
u Press the push button on the window handle and bring the sliding window into
the desired position.
window window
2 Switch Window wiper system left 5 Switch Intermittent control and
door window washer system
3 Switch Window wiper system right 6 Knob Intermittent control
door
The timing for intermittent wipe is set in three stages with the knob 6.
u Set the knob to the desired intermittent stage.
Note
u Always store the Operating instructions in the machine!
The back-up alarm sounds if the travel joystick is moved into position for “reverse
travel”.
Personnel near the machine is warned by the alarm.
The back-up alarm is located in the rear of the machine. The sound level is set
automatically.
Before operating the machine, deflect the travel joystick to position for "reverse
travel" to check the function of the back-up alarm.
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WARNING
Danger of accidents if machine moves in reverse.
When backing up, personnel near the machine can be overlooked.
u Always check personally that no one is being endangered when the machine is
moved, even though a back-up alarm is installed.
3.2.18 LiDAT
(Optional)
LiDAT is a data transmission and positioning system for Liebherr machines and
machines of other manufacturers. Based on the latest data transmission tech-
nology, LiDAT supplies information for localization as well as for operation of
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machines, thus enabling efficient management, optimized job planning and moni-
toring from a distance.
With LiDAT all important machine data can be viewed at any time. The data is
updated several times a day, depending on the subscription, and can be called up
at any time with a web browser. Especially important information, such as leaving
the machine in a predefined zone or messages for certain operating conditions and
job parameters can also be called up.
3) Optional
3.3 Operation
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u Close all service doors, flaps and hoods and lock them, if possible.
DANGER
During refueling, there is a danger of fire and explosion!
u Do not smoke and avoid open flames when refueling.
u Refuel only when the Diesel engine is turned off.
u Make sure to observe the safety guidelines for refueling. (For more information
see: 2.4 Safety guidelines, page 40)
Note
u To avoid condensation in the fuel tank, add fuel after completion of work or after
a shift change, if possible.
DANGER
During refueling, there is a danger of fire and explosion!
u Do not smoke and avoid open flames when refueling.
u Refuel only when the Diesel engine is turned off.
u Make sure to observe the safety guidelines for refueling. (For more information
see: 2.4 Safety guidelines, page 40)
NOTICE
If the machine is refueled without the suction basket, foreign particles can be
drawn in by the refueling pump!
The refueling pump can be thereby damaged.
u Always refuel with the suction basket on the suction hose.
u Place the suction hose 2 with the installed suction basket 8 into the fuel barrel.
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The shut off valve prevents Diesel fuel discharge from the refueling pump.
NOTICE
The refueling pump is turned on when the shut off valve is closed!
When the shut off valve is closed, the refueling pump can run dry and therefore be
damaged.
u Do not operate the refueling pump with closed shut off valve.
u Before turning the refueling pump on, open the shut off valve.
u Open the shut off valve 4 on the connection of the refueling pump.
The refueling procedure can be interrupted at any time by turning off the switch 6
(red).
NOTICE
Danger of refueling pump damage if it runs dry!
u Make sure that the fuel level does not drop below the intake level of the intake
hose.
u Place the control section into the retainer and secure it to prevent it from falling
out by moving the lever 6 down.
u Drain the fuel completely from the suction hose 2.
u Roll the suction hose 2 up and place it in the storage compartment. Close off
the connections with the blind couplings.
u Close the storage compartment.
Note
Pay attention to the temperature application range for the lubricants filled in the
machine!
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u Fill the machine with lubricants and service fluids according to the temperature
at the jobsite.
DANGER
It is strictly prohibited for personnel to ride along on the machine!
u Never use the blade or the bucket as a working platform or to transport
personnel.
u Personally make sure that no one is endangered by moving the machine.
Note
The machine is equipped with a hydrostatic travel drive.
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Starting preparations
Make sure that the machine is first in operating position. (For more information see:
3.3.1 Operate the machine daily , page 88)
WARNING
A defective safety lever can lead to severe accidents!
If the Diesel engine can be started even though the safety lever is in the down
position:
u Turn the Diesel engine off immediately.
u Remedy the defect immediately.
u Turn the throttle control to the stop to the left. Set the throttle control to idling.
NOTICE
Danger of damage of the Diesel engine!
If the cold Diesel engine is subjected to a full load, the Diesel engine can be
damaged.
u Let the Diesel engine warm up.
u After the starting procedure, leave the throttle control at low idle and wait until
the Diesel engine is warm before subjecting it to a full load.
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Note
u When the Diesel engine is warm and high ambient temperatures are present,
the indicator light Preheat system blinks: Start the Diesel engine without
preheating.
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u Do not try to start the engine for longer than maximum 10 seconds without a
break.
Troubleshooting
The Diesel engine does not start?
u Reset the starter switch to zero position.
u Repeat the starting procedure after waiting for 120 seconds.
If the engine does not start after two starting procedures:
u Find the cause with the troubleshooting chart and remedy it. (For more informa-
tion see: 4 Operating problems, page 159)
u Release the starter switch as soon as the engine is running. The starter switch
returns by itself to operating position.
u Do not put a full load on the engine until after a short warm up period.
Troubleshooting
The indicator lights do not turn off?
u Turn the engine off immediately and remedy the problem. (For more information
see: 4 Operating problems, page 159)
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WARNING
Danger of explosion due to frozen batteries!
Do not charge batteries if they are frozen.
u Let the batteries warm up to approx. 16 °C before recharging.
WARNING
When using ether based starting aids to start Diesel engines with preheat systems,
there is a danger of explosion!
u Do not use ether based starting aids.
NOTICE
The cold Diesel engine is subjected to a full load!
If the cold Diesel engine is subjected to a full load, the Diesel engine can be
damaged.
u Let the Diesel engine warm up.
u After the starting procedure, leave the throttle control at low idle and wait until
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Note
The electronic system runs through a self-check.
u Deflect the travel joystick only after the indicator light Electronic lights up.
NOTICE
If the Diesel engine is operated without a load, then it will not reach the required
operating temperature and the piston rings and cylinder bushings will not run in
optimally.
u Turn the Diesel engine off when the machine is not operated.
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u Turn the throttle control to the stop to the right: Set the throttle control to full
load.
w The machine is now ready to drive.
Note
u Work with the machine always at full engine rpm.
u Work with reduced engine rpm only in certain cases.
WARNING
Danger of accidents due to loss of control over the machine!
When driving carelessly downhill, the drive train can overspeed.
u Drive downhill at low travel speed and maximum 4 km/h .
u Move the switch on the travel joystick before driving on slopes to position “I” .
u Set the rpm to full load.
u Reduce the travel speed to keep the engine rpm under 2100 rpm .
Note
To optimally utilize the machine power:
u Carry out heavy pull work with the machine only in low speed range - rocker
switch position I, as well as maximum 2 km/h .
u Press the button 1 or button 2 on the travel joystick and set the desired speed.
w The speed is increased or decreased.
Adjustable speeds
The speed ranges for the travel speed cannot overlap through the fine adjustment.
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For example, if the forward travel speed is set in speed range “III” to 7 km/h, then
the speed in travel speed range “II” cannot be set higher than 7 km/h.
u Press the button 1 or button 2 on the travel joystick and set the desired speed.
w The travel speed is shown in the LC display and blinks, as long it was not
saved. As soon as the speed no longer blinks, it has been automatically
saved.
3.3.5 Travel
Driving forward
Driving backward
Steering
In addition to driving forward and backward, any desired steering movement with
variable speeds is possible.
If the travel joystick is deflected by 80%, then the chain on the inside of the curve
stops, the outer chain turns in the preselected speed. From 80% deflection on, the
chain on the inside of the curve turns in the opposite direction as the chain on the
outside of the curve. The further the travel joystick is deflected, the faster the chain
on the inside of the curve will turn in the opposite direction. The machine counter-
rotates.
u Counterrotation: Deflect the travel joystick more than 80%.
3.3.6 Braking
NOTICE
The speed reduction pedal is pressed down past the noticeable resistance, this
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CAUTION
Danger of accident due to careless breaking of the machine!
Pressing the speed reduction pedal all the way down causes the machine to stop
abruptly.
u Always wear the seatbelt before operating the machine.
NOTICE
The track of the machine is frozen to the ground!
If the machine is ripped loose forcefully, significant damage can occur.
u Carefully heat the track pads to release the machine.
u Park the machine on wooden boards if the temperatures are below freezing.
NOTICE
Danger of damaging the Diesel engine, especially in case of turbocharged engines!
If the engine is turned off suddenly, the turbocharger continues to run for some time
without oil supply.
u Do not suddenly turn the Diesel engine off from full load rpm.
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u Turn the starter switch to neutral position and pull the key off.
w All indicator lights turn off.
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Troubleshooting
The Diesel engine cannot be turned off with the starter switch?
Due to a problem in the Diesel engine control unit it can happen that the Diesel
engine cannot be turned off via the starter switch.
u Pull the main fuse 1 (Safety automat F1) to turn the Diesel engine off.
u Then return the main fuse 1 to operating position.
Troubleshooting
The Diesel engine cannot be turned off with the starter switch?
If the Diesel engine still cannot be turned off with the starter switch?
u Contact Liebherr Service immediately.
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WARNING
Risk of injury if seatbelt is not worn!
Pressing the emergency off button while the machine is traveling causes the
machine to stop abruptly. If the seatbelt is not worn it can result in an accident with
the most severe injuries!
u Always wear the seatbelt before operating the machine.
Continue operation
u Set the travel joystick in neutral position.
u Lift the emergency off button until it engages.
u Deflect the travel joystick into the desired direction.
DANGER
Severe danger of accidents for maintenance personnel if a second person tampers
on the machine without authorization!
u Secure the machine to prevent unauthorized access by a second person!
NOTICE
Danger of damage to the fan blade as well as the Diesel engine and the cooler!
If the maximum fording depth is exceeded, the fan and as a result the cooler and
the Diesel engine will be destroyed.
u Do not exceed the maximum fording depth (lower edge of the carrier roller).
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WARNING
Danger of accidents due to raised components and loads!
Falling components or loads can result in severe bodily injuries or even death.
u Never work under raised components and loads if they are not properly
supported or laying on the ground.
Blade release
The blade release makes it possible to place the dozer blade with its own weight
on the ground and allows it to move freely according to the ground unevenness.
DANGER
Danger of accidents due to quickly dropping working attachment!
By activating the blade release, the raised working attachment drops quickly.
Persons within the danger zone are severely injured or crushed.
u It is prohibited to remain in the danger zone of the machine.
NOTICE
Risk of damage to the working attachment!
Do not activate the blade release function if the attachment is completely raised.
u Lower the dozer blade to approximately 30 cm off the ground before the blade
release is activated.
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u Move the blade control lever to the front past the pressure point all the way to
the stop and release.
w The blade control lever is held in this position by magnetic force.
w The blade falls freely to the ground and adapts to the ground conditions.
u To deactivate the blade release: move the blade control lever backward into
neutral position.
NOTICE
Tilt cylinder and strut not pinned in the same cutting angle position.
The full tilt path is not available.
u Always pin the tilt cylinder and strut on the left and right in the same position.
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Tab. 11
u On the strut remove the retaining screw and the ring and knock out the pin.
WARNING
Bores are aligned using fingers without tools.
Danger of crushing fingers and hands.
u Use suitable tools.
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u Align the strut with a suitable tool and install the pin from the inside to the
outside.
u On the tilt cylinder, remove the retaining screw and the ring and knock out the
pin.
WARNING
Bores are aligned using fingers without tools.
Danger of crushing fingers and hands.
u Use suitable tools.
The cutting angle position must be pegged in the same position on both sides.
u Start the machine and move the tilt cylinder in the desired direction until the pin
can be installed.
u Align the strut with a suitable tool and install the pin from the inside to the
outside.
u Affix the pin with ring and retaining screw.
WARNING
Danger of accidents due to raised components and loads!
Falling components or loads can result in severe bodily injuries or even death.
u Never work under raised components and loads, if they are not properly
supported or laying on the ground.
CAUTION
Danger of injury when working with rear winches without protective grill!
When working with rear winches, the cable can break and be thrown into the oper-
ator's cab.
u For rear winch operation, secure the operator's platform with a protective grill.
3.4.1 Grading
To strip material, different working methods can be selected, depending on the
ground build up.
u Slowly lower the blade while driving forward and take up material over the entire
dozing distance.
Note
The chains start to slip.
u Lift the blade slightly.
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u Lower the blade while driving forward and fill the blade at the start of the
grading distance.
Dozing in tracks
Dozing in tracks is predominantly used for transport of large amounts of material
over longer distances.
u Establish a working face with a minimum dimension of the track length at the
height of the desired level.
u Starting from this level, move the material in for the fine grade.
Note
Track imprints on the surface of the fine grade.
u Using the blade release, remove the track imprints by pulling them off back-
ward.
u Remove track imprints: Pull the working surface off backward with the blade
release turned on.
Parallel operation
If two crawler tractors are used simultaneously to move larger amounts of loose
material, then use them in parallel operation.
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u Operate both machines with the blades as close to each other as possible.
w This working method significantly increases the total output.
Making ditches
u Move against the tree with the raised blade in 30 cm to 40 cm and push it over.
u Continue to lift the blade while moving forward.
Felling trees
DANGER
Danger of accident due to toppling tree.
u As soon as the tree starts to fall, move back immediately.
u Do not drive on the rootstock.
u Slowly move toward the tree in the direction you want the tree to fall, with the
blade raised.
u Move back as soon as the tree starts to fall.
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Removing rootstocks
CAUTION
Rootstocks exceed the ground clearance of the machine.
u When driving on the terrain, pay attention to rootstocks and rock deposits which
exceed the ground clearance of the machine.
u Move on the rootstock with the blade below level and rip it out of the ground by
driving forward and simultaneously lifting the blade.
u Bury the removed material as deep as possible below the desired ground level.
3.4.6 Ripping
Generally the ground should be ripped as deep as possible.
For natural soil layers, we recommend to proceed in layers. To obtain the desired
depth, rip the same track several times.
The distance of the tracks depends on the desired size the material is to be cut in
to.
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In ripping application, make sure that both tracks are laying on the ground with the
full track length, if possible. If necessary, prepare the site accordingly.
NOTICE
Use a multi-tooth ripper to rip difficult to rip material!
Risk of damaging the ripper!
u Rip difficult to rip material or material which breaks into large pieces only with
one ripper tooth.
NOTICE
The machine is moved backward or turned when the ripper teeth are in the ground.
Risk of damaging the ripper!
u Do not turn the machine or move backward when the ripper teeth are in the
ground.
u Lower the ripper while driving forward and rip the ground.
WARNING
Danger of accident due to suspended or raised load!
Suspended or falling loads can result in severe bodily injuries or even death.
u Never step under a suspended load.
u Approach the boom only from the side.
u Before lifting attachment parts, determine their weight and have the necessary
lifting gear available. See section “Technical data”. (For more information see:
1 Product description, page 15)
In the anchor points of the attachment, wear-resistant bearing shells are installed.
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NOTICE
The bearing shells are incorrectly installed!
The attachment cannot be installed correctly.
u At installation, always insert the bearing shells on the correct side.
u Insert the screws 1 at installation of the half shells from the bottom.
w The nuts 2 are on the piston rod.
3.5.3 Install and remove the push frame with the straight
blade
Design overview
u Install the trunion on the left and right on the track roller frame.
u Install the left half of the push frame with half shells on the left trunion.
u Install the right half of the push frame with half shells on the right trunion.
u Preassemble the center bearing and set it on the left half of the push frame.
u Connect the right half of the push frame with screws and bars on the center
bearing.
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u Lift the push frame with a lifting device on the front and support it on the left,
right and center to the height of the pivot points on the straight blade.
u Insert the half shells with inserted screws on the blade side on the straight
blade.
Note
u Affix the half shells with a short piece of wood on the straight blade.
u Install the center retainer on the push frame and on the straight blade.
u Fold the transport retainer for the hoist cylinders down and tighten.
u Start the machine as described.
u Carefully extend the hoist cylinder and install with half shells on the straight
blade.
u Relieve the tank pretension: Back the breather screw 1 on the hydraulic tank
out by two turns.
WARNING
The hydraulic system is under high pressure!
When releasing pressurized hydraulic lines and hoses, hydraulic oil can emerge
under high pressure and cause severe injuries.
u Do not remove any lines, hoses, connector pieces as long as the hydraulic
system is under pressure.
u With the Diesel engine turned off and the ignition turned on, actuate all func-
tions again to relieve the pressure in the hydraulic lines.
Note
The tilt lines are mixed up at installation.
Tilting does not function as described in the Operating instructions.
u Install the tilt lines correctly.
u Insert the half shell with inserted screws on the blade side on the straight blade.
Note
u Affix the half shells with a short piece of wood on the straight blade.
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u Carefully extend the tilt cylinder and install on the straight blade.
u Install the strut on the straight blade.
Note
u Remove the attachment in reverse order.
u For extended storage, protect the parts from corrosion.
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3.6 Transport
The ramp incline angle - W - may not be more than maximum 30°.
u Have a suitable ramp ready to drive onto the loading surface.
u Before driving on the ramp, clean the chains to remove any ice and mud.
u Make sure that guides are always positioned to the side of the machine!
u Start the Diesel engine. (For more information see: 3.3.3 Start the Diesel
engine, page 96) (For more information see: 3.3.5 Travel, page 107)
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DANGER
Danger of accidents due to careless driving!
Careless driving increases the dangers of accidents for loading personnel, the
guide as well as for the operator of the machine.
u When loading the machine, always drive carefully!
Drive onto the ramp only in low speed range position “I” .
u Select low speed range: Set the rocker switch to position “I” .
u Start the machine out carefully. (For more information see: 3.3 Operation,
page 88)
DANGER
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NOTICE
Ropes or chains are routed over sharp edges!
Ropes or chains will be damaged.
u Cover sharp edges or corners with an edge protector before rigging.
u Fasten every corner of the machine with chains or ropes on the transport
vehicle.
u Front: Use the outside or inside of the track pads for rigging.
u Side: Use the inside of the track pads for rigging.
u Rear: Use the outside of the track pads for rigging. If the trailer hitch is installed,
use it for rigging.
u Secure the machine to prevent it from slipping: Place the wedges 2 in front and
behind the track on both sides.
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WARNING
Danger of accident due to suspended or falling load!
Suspended or falling loads can result in severe bodily injuries or even death.
u Never step under a suspended load.
u Approach a raised load only from the side.
Note
u The lifting points are marked with the sign 3.
Note
u The lifting points are marked with the sign 3.
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Towing safety
WARNING
Danger of accidents due to improper towing!
Improper towing a disabled machine can result in severe injuries or death.
u
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For towing, observe all specified safety guidelines and the following recommenda-
tions:
– Keep the angle of the towing cable in relation to the machine to a minimum. The
angle should never deviate by more than 30°from the machine length axle.
– Start out and move the machine slowly and evenly. If the machine is moved
unevenly, the towing cable or the rod can be overloaded and break off.
– When towing on slopes, the towing machine must be at least the same size as
the one being towed. Power, weight and brake force of the towing machine
must be adequate to keep both machines under control. (For more information
see: 2.4.9 Safety guidelines for towing the machine, page 45)
The following fastening point on the front of the machine is provided for towing.
Note
u The machine can only be towed if the electrical system is fully functioning.
Fig. 249: Remove the cover plate for the main frame
u Short circuit connections “ML1 to ML2” and “MR1 to MR2” with the hydraulic
lines.
Note
u The angle fittings must be connected on connections “ML1” and “MR1” .
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u Remove the fitting 1 with union nut and the conical cap from the brake
adapter 2.
u Open the battery compartment door.
u Remove the hose from connection “B” and close off with the fitting 1 of the
brake adapter.
u Remove the brake adapter 2 from the cartridge holder 3 and connect on
connection “B”.
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u Insert a new air pressure cartridge into the cartridge holder 3 and screw the
cartridge holder onto the brake adapter.
w Pressurized air flows into the brake circuit.
u Check the position of the emergency off button 61: Raise the emergency off
button.
Note
u For the towing procedure, the emergency off button 61 must be in operating
position.
Fig. 259: Press the towing button and the scroll key
u Press button Towing mode 70 and the scroll key 53 simultaneously within 10
seconds.
w The word “TOWING” is shown blinking in the LC display.
w The towing mode is activated.
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WARNING
Uncontrolled rolling off of the machine due to released brakes!
u Carry out the towing procedure by taking the specified safety guidelines into
account.
NOTICE
The oil motors are driven with insufficient lubrication!
Oil motor damage due to running dry. Observe the towing time and total distance.
u Do not tow the machine for longer than 10 minutes and faster than 2 km/h and
not for a longer total distance of more than 200 m.
Note
u If the indicator light Travel gear brake does not turn off, then the towing proce-
dure must be repeated from inserting the air pressure cartridge. The pressure in
the system is no longer sufficient to vent the brake.
CAUTION
The hydraulic system is under pressure!
When opening the hydraulic fittings or hoses, there is a danger of injury due to the
hydraulic oil, which is under high pressure.
u Before removing the brake adapter, relieve the hydraulic pressure in the
system: Move the travel joystick several times in forward and backward direc-
tion.
u Carefully remove the brake adapter.
u Before putting the machine back into service, check if the parts installed for the
towing procedure have been removed and if the machine is in series condition
again.
WARNING
Danger of accidents due to incorrect or careless procedure when starting with
auxiliary batteries!
When connecting auxiliary batteries, increased gas formation can occur on old
batteries. This can result in an explosion.
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u Avoid open flames and any spark formation in the battery area.
u Wear safety glasses and protective gloves during the auxiliary jump start proce-
dure.
u Use only auxiliary start cables with sufficient diameter.
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Note
Taking care of problems with the “Service code charts”?
u Contact Liebherr Service.
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defective
Diesel engine emits black smoke Injector nozzles get stuck or do not Visit Liebherr Service
disperse
Turbocharger defective (insufficient Visit Liebherr Service
charge pressure)
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The main fuse 1 and the fuse for the intake air preheating 2 are located on the right
hand side of the machine in the battery compartment.
Tab. 12
Note
u If the safety fuse is triggered, it is important to find the cause of the overload
and remedy the problem before turning the safety fuse back on.
u Establish the power supply for the machine: Press the button on the automatic
safety fuse.
the compartment.
Access to the fuses is provided by removing the screws and the cover.
u Remove the screws 1 and remove the cover 2.
u Depending on the electrical problem, check the following chart – Fuse listing for
the fuse.
u Pull the affected fuse and replace it with a new fuse (Amperage depending on
placement).
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Troubleshooting
The bulb does not light up?
The fuse is defective.
u Change the fuse.
4) Optional equipment
Tab. 13
4) Optional equipment
Tab. 14
Fuse in radio
The radio is secured with a separate fuse.
Tab. 15
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4) Optional equipment
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Confirm tasks
Additional labelling
On handover
Assistance required
All 1000 h
All 2000 h
See page
All 8-10 h
All 500 h
All 50 h
Additional labelling
T Annually before the winter ² If necessary
Other intervals
Confirm tasks
Additional labelling
On handover
Assistance required
All 1000 h
All 2000 h
See page
All 8-10 h
All 500 h
All 50 h
m3000h Hydraulic tank - Change the hydraulic oil (Liebherr). Pay attention 259
to the notes for oil analysis and dust intensive application! (For
more information see: 5.3.5 Hydraulic oil, page 186)
m Hydraulic tank - Change the hydraulic oil (from other manufac- 259
turers). Pay attention to the notes for oil analysis and dust inten-
sive application! (For more information see: 5.3.5 Hydraulic oil,
page 186)
m m m Drain water and sediments in the hydraulic tank (but at least every 261
6 months), when using an “environmentally friendly hydraulic
medium ” - weekly
Confirm tasks
Additional labelling
On handover
Assistance required
All 1000 h
All 2000 h
See page
All 8-10 h
All 500 h
All 50 h
compressor
m m m Check condition, moisture and fill of dryer unit (replace the dryer, if
necessary, evacuate the system and refill)
m m m Clean the water drain valves
m Check the electrical lines for chafing and plug connections for tight
seating
Have the air conditioning system checked by an HVAC technician
(1 x a year)
Additional labelling
T Annually before the winter ² If necessary
Other intervals
Confirm tasks
Additional labelling
On handover
Assistance required
All 1000 h
All 2000 h
See page
All 8-10 h
All 500 h
All 50 h
o n m m m Check the blade center position and mounting (and at every instal- 304
lation)
m m m Check the equipment for accidental damage
m m m Check the bearing points of the working attachment for play and
wear
n m m m Check the mounting screws and bolt retainers of the attachment 304
for tight seating
tensioner
Liebherr Universal grease Arctic
Tab. 16
Tab. 17
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Symbol Meaning
Diesel engine
Hydraulic
Splitterbox
Travel gear
Axle bearing
Lubrication point
Grease
For oil change intervals, pay attention to the notes in the oper-
ating instructions.
Specification
Diesel fuels must meet the minimum requirements of the following specifications.
Approved specifications:
– DIN EN 590
– ASTM D 975-89a - 1D and 2D
Note
u Get a written confirmation from the supplier.
NOTICE
Danger of damage to the injection system due to incorrect fuel!
Adding petroleum or normal gasoline causes damage to the injection system.
u Do not add petroleum, normal gasoline or other additives to the Diesel fuel.
If the ambient temperature drops below -20 °C:
u Use a starter aid (such as a fuel filter heater).
If the machine is utilized in arctic climates:
u Use special Diesel fuels, which provide sufficient flow behavior.
Description Specification
ACEA - classification (Association des E4, E6, E7
Constructeurs Europeens de l'Automobile)
Caution: Use of particle filter permis-
sible only with E6
API classification (American Petroleum CH-4, CI-4
Institute)
Caution: note the reduced oil change
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intervals
The selection of the SAE classification provides no information about the quality of
a lube oil.
Excessive viscosity can cause starting problems, insufficient viscosity can
endanger the lubricating efficiency.
The temperature ranges given in the chart are reference values, which can be
exceeded or fallen below for short periods.
The following Diesel engine oils are recommended for an ambient temperature of
-20 °C to 45 °C:
Liebherr Motor oil 10W-40, Specification ACEA E4
Liebherr Motor oil 10W-40 low ash Specification ACEA E6
The following Diesel engine oils are recommended for an ambient temperature of
-30 °C to 30 °C:
Liebherr Motor oil 5W-30, Specification ACEA E4
– Operating temperature
If aggravating factors are present, then the oil and filter change must be carried out
according to the following chart.
Oil specifi-
Aggravating factor
cation
E6
Operating conditions Sulfur content in fuel Interval
up to 0.005% 500 hB)
Climate normal to -10 °C above 0.005% to 0.05% 250 hB)
above 0.0501% to 0.1% 125 hB)
up to 0.005% 250 hB)
General recommendations
The cooling system only functions reliably if it is under pretension pressure. For
that reason, it is essential that it is kept clean and tight, that the cooler lock and
working valves function correctly and that the required coolant level is retained.
Antifreeze fluids with corrosion inhibitors approved by Liebherr ensure sufficient
cold, corrosion and cavitation protection, they do not affect the seals and hoses
and do not foam.
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Sea water, brackish water, brine and industrial wastewater are not suitable.
NOTICE
Ratio of antifreeze fluid with corrosion inhibitor in coolant too high!
Diesel engine overheats and can be damaged.
u Do not use more than 60% antifreeze fluid with corrosion inhibitor.
Note
Improper mixing of various products can impair the properties of the coolant and
damage the cooling system.
u Use only approved products, do not mix different products.
u Never mix silicate containing and silicate free products.
If the Liebherr antifreeze with corrosion inhibitor is not available locally:
u Consult with Liebherr Service; use products according to the “Coolant specifica-
tion for Liebherr Diesel engines”.
Mix = prepared mix (50% water and 50% antifreeze fluid with corrosion inhibitor)
Note
Improper mixing of various products can impair the properties of the coolant and
damage the cooling system.
u Use only approved products, do not mix different products.
u Never mix silicate containing and silicate free products.
If the Liebherr antifreeze with corrosion inhibitor is not available locally:
u Consult with Liebherr Service; use products according to the “Coolant specifica-
tion for Liebherr Diesel engines”.
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Note
Improper mixing of various products can impair the properties of the coolant and
damage the cooling system.
u Use only approved products, do not mix different products.
u Never mix silicate containing and silicate free products.
If the Liebherr antifreeze with corrosion inhibitor is not available locally:
u Consult with Liebherr Service; use products according to the “Coolant specifica-
tion for Liebherr Diesel engines”.
u Drain the entire coolant before changing from corrosion inhibitor - antifreeze to
corrosion inhibitor and vice versa.
Fig. 283: Liebherr Hydraulic oil, temperature dependent selection of viscosity clas-
sification
A Ambient temperature C Operating range
B Cold start range with warm up
guideline
Liebherr Hydraulic Plus and Liebherr Hydraulic Plus Arctic are suitable for bio
as well as for long term use.
If Liebherr oils are not available locally, then engine oils according to the following
paragraph "Engine oil as hydraulic oil" must be used (after consultation with Lieb-
herr Service).
Fig. 284: Engine oil for use as hydraulic oil, temperature dependent selection of
viscosity classification 9)
A Ambient temperature 1 Single-grade oils
B Cold start range with warm up 2 Multi-grade oils
guideline
C Operating range
Warm up specification
The black bar B marks the ambient temperatures, which are up to 20 °C below the
operating range C.
If a cold start is made at ambient temperatures within range B, the following warm
up specification for hydraulic oil applies:
1. After starting, set the Diesel engine to medium rpm (to no more than maximum
half of the highest rpm).
2. Carefully actuate the working hydraulic. Actuate the hydraulic cylinder and
move it to stop for a short period.
3. After approx. 5 minutes actuate the travel hydraulic too. Total warm up period
is approx. 10 minutes.
If the cold start is made at even lower ambient temperatures, the following warm up
procedure applies: Warm up the hydraulic tank first before starting the engine.
Then start the warm up specification with Pt. 1.
NOTICE
Improper mixing of hydraulic oils!
Mixing biodegradable hydraulic oils on ester basis or with mineral oils can cause
aggressive reactions. Damage to the hydraulic system will be the result.
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Liebherr recommends the following hydraulic oils for the machine, depending on
the temperature range: Liebherr Hydraulic Plus or Liebherr Hydraulic Plus
Arctic.
When using these hydraulic oils, an auxiliary flow filtration system is not necessa-
rily required.
If these oils are not available locally, then only oils based on fully saturated
synthetic ester (HEES) may be used (after consultation with Liebherr Service).
When using synthetic ester based oils, we recommend that hydraulic hoses are
changed after 4000 operating hours or no later than after four years of use.
Plant-based oils are not permissible for use due to their insufficient temperature
properties.
Polyglycoles can be used due to their paint and sealing incompatibility in special
cases, but only after consultation with Liebherr Service.
When using third party products, we recommend to check with the manufacturer
first to ensure that the above stated specifications are met by this third party
product.
Oil change
Note
Liebherr recommends operation with regular oil analysis.
u For additional information, see: Oil analysis
A) If the result of the oil analysis is positive, then oil may be used for a longer period. If the result of the oil analysis
is negative, then the oil must be changed immediately.
B) PAO = Poly-alpha-olefin
C) Combination is not permissible
Bio use means that the use of biodegradable or environmentally friendly hydraulic
oil is specified at the jobsite of the machine.
If a machine is operated less than 1000 hours per year, then an oil sample must be
taken once a year. Hydraulic oil with longer use in the machine should be changed
at least after four years (mineral oils and fully saturated synthetic ester) as well as
no later than after six years (Liebherr Plus oils).
If a machine is not in use for longer than six month without a break, then an oil
analysis is required before putting the machine back into service.
Oil analysis
Liebherr recommends to have the oil analyzed regularly by OELCHECK and to
carry out the oil change according to the lab report:
– yellow set for biodegradable hydraulic oils
– green set for mineral oils
The frequency of taking the oil sample depends on the application conditions.
A) PAO = Poly-alpha-olefin
B) Combination is not permissible
Filter change
The frequency for changing the filter depends on the application conditions.
Quality
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If Liebherr oils are not available locally, then oils according to the specification must
be used instead (after consulting with the respective Service Dept.).
Viscosity
Quality
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If Liebherr oils are not available locally, then oils according to the specification must
be used instead (after consulting with the respective Service Dept.).
Viscosity
Use the same oil quality and viscosity as in the hydraulic system.
Use the same oil quality and viscosity as in the hydraulic system.
The grease is used for automatic or manual lubrication of the machine. The grease
gets to the lube points via the central lubrication system or via grease fittings.
Example:
– Pins, axles and screws
– Attached tools
Note
The grease must be well deliverable within the entire ambient temperature range!
u Use only approved grease products.
u For retrofit central lubrication systems, pay attention to the specifications for
deliverability of grease products.
Area of appli-
Specification Identification
cation
Standard
Soap based (Lithium complex) KP 2 K (DIN 51502)
version
NLGI grade: 2 (DIN 51818)
VKA welding load: ≥ 2300 N (DIN 51350 / 4 — ASTM D 2596)
Low tempera-
Soap based (Lithium complex) KP 1 K (DIN 51502)
ture
NLGI grade: 1(DIN 51818 / ASTM D 2596)
VKA welding load: ≥ 2300 N (DIN 51350 / 4 — ASTM D 2596)
Liebherr grease
Liebherr recommends the following grease products to obtain optimum lubrication
results and additional protection from corrosion.
Area of appli-
Recommended lubricant Specification Identification
cation
Standard Liebherr Universalfett 9900 Soap based KPF 2 N — 25 (DIN 51502)
version (Lithium complex)
NLGI grade: 2 (DIN 51818)
VKA welding load: ≥ 5500 N (DIN 51350 /
4)
with vapor phase corrosion protection
Low tempera- Liebherr Universalfett Arctic Soap based KPFHC 1 N — 60 (DIN 51502)
ture (Lithium complex)
NLGI grade: 1 (DIN 51818)
VKA welding load: ≥ 5500 N (DIN 51350 /
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4)
The temperature application ranges for Liebherr grease have been determined as
follows:
NOTICE
Unsuitable solid lubricants!
Solid lubricants (such as graphite) can plug up or damage the central lubrication
system.
u Use grease according to above chart.
Lubricate hinges and joints without grease fittings with engine oil.
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WARNING
Turning and hot engine parts!
When touching hot or turning engine parts, severe injuries can occur.
u Do not touch hot exhaust lines and engine parts.
u Do not wear ties, scarves, open jackets and loose clothing.
Hydraulic system
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Take an oil sample: On the breather screw on the hydraulic tank, via the manual
suction pump
u Take an oil sample on the respective location.
Diesel engine
With the manual suction pump via the oil dipstick tube.
When changing the oil from the emerging oil flow.
u Take an oil sample on the respective location.
Splitterbox
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With the manual suction pump via the oil dipstick tube on the splitterbox.
When changing the oil from the emerging oil flow.
u Take an oil sample on the respective location.
Travel gear
With a manual suction pump via the oil filler port on the travel gear.
u Take an oil sample on the respective location.
Cooling system
Make sure that the cooling system has cooled off.
CAUTION
At or near operating temperature, the engine cooling system is hot and under pres-
sure!
Danger of scalding when opening the cooler cap when the engine cooling system
is hot.
u Open the cap of the filler neck of the expansion tank only when the engine has
cooled off.
u Open the cap of the expansion tank only after it is cool enough to touch. Turn
the cap carefully to relieve the pressure.
u Make sure to avoid skin contact with the coolant, observe the manufacturer's
guidelines.
u In case of an accidental splash, flush eyes or skin immediately with plenty of
water.
Oil analysis
An oil analysis should include at least the following data:
Method Determination of
Atomic Emission Spectroscopy Wear metals, additives, contaminants iron,
(AES) chromium, tin, aluminum, nickel, copper, lead,
molybdenum, silver, silicium, callum, calcium,
magnesium, borax, zinc, phosphorus, barium
FT Infrared spectroscopy (FT-IR), Oil condition and contaminants: Oil oxidation,
glycol, water, nitrates, fuel, carbon
Viscosity Viscosity test Viscosity at 40°C and 100°C:
Viscosity index Information for lubricity and
mixture
Analex PQ-Index Magnetic metal wear debris: Statement
regarding the quantity of collected magnetize-
able iron abrasion in oil larger than 5 microns
Liebherr recommends that regular oil analyses be carried out by the company
OELCHECK and that oil changes are performed on the basis of the lab report (see
also Service and product information).
A kit of sample bottles, removal hose, sample documentation and mailing bags are
available from Liebherr under the following Id. No.:
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WARNING
If there is no visual contact with the operator, there is severe risk of accidents for
the maintenance staff!
u Never move unnoticed into the danger zone of the machine.
u Before entering the danger zone, establish contact with the operator.
WARNING
Turning engine parts!
Clothing, hair or limbs can be caught by the fan blade or the V-belt and be pulled
in. Severe injuries may be the result.
u Open the engine compartment doors only when the engine is not running.
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WARNING
Falling engine compartment door due to defective gas cylinder!
u Before starting to work underneath the door, check if the completely opened
door position is ensured by the gas cylinder.
u Open the door: Fold the handle outward, turn by 90° and fold the door up.
w The engine compartment door is held in this position by a gas cylinder.
If the function is not ensured:
u Find the cause and remedy it immediately.
CAUTION
During the entire working procedure, pay attention to good stability.
u If the placement location is unsuitable, there is a danger of injury due to falling
covers.
CAUTION
During the entire working procedure, pay attention to good stability.
u If the placement location is unsuitable, there is a danger of injury due to falling
covers.
DANGER
Danger of crushing between operator's platform and machine!
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u Fasten suitable load lifting equipment (belt, chain, etc.) to the fastening points
provided on the operator's platform.
u Use a lifting device (crane) to lift the operator's platform to the end position.
(Intermediate positions are prohibited!).
WARNING
Danger of accident!
u Remaining in the danger area is prohibited.
u Use pins to secure the support leg at the location provided (bore).
u Secure the pin with a cotter pin to prevent it slipping out.
u Lower the operator's platform slightly until the load lifting equipment hangs
loosely.
u If necessary, the load lifting equipment can be unhooked.
DANGER
Danger of crushing between operator's platform and machine!
Personnel remaining under the unsecured operator's platform can be crushed
between the operator's platform and the machine.
u Lower the operator's platform only when the machine is at a standstill.
u When raising and lowering the operator's platform, make sure that there are no
persons within the tilt range.
u Install the retaining pin.
u Do not start or drive the machine with tilted operator's platform.
u Leave the safety lever in the up position.
DANGER
Danger of injury due to unsecured operator's platform!
u Lower the operator's platform and secure with screws.
u Attach the operator's platform with 5 hex head screws each per side.
u The machine is ready to operate.
DANGER
Danger of crushing between operator's platform and machine!
Personnel remaining under the unsecured operator's platform can be crushed
between the operator's platform and the machine.
u Raise the operator's platform only when the machine is at a standstill.
u When raising and lowering the operator's platform, make sure that there are no
persons within the tilt range.
u Place the safety support bar.
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u Actuate the hydraulic hand pump until the piston has reached the end position
(intermediate positions are prohibited!).
u Turn the mechanical support plate on the hydraulic cylinder in clockwise direc-
tion by 90°.
w Handle on the support plate is positioned laterally to the travel direction of
the machine.
u Actuate the hand pump until the safety support bar is placed on the support
plate.
DANGER
Danger of crushing between operator's platform and machine
Personnel remaining under the unsecured operator's platform can be crushed
between the operator's platform and the machine.
u Lower the operator's platform only when the machine is at a standstill.
u When raising and lowering the operator's platform, make sure that there are no
persons within the tilt range.
u Place the safety support bar.
u Do not start or drive the machine with tilted operator's platform.
u Leave the safety lever in the up position.
u Relieve the safety support bar with a slight thumb pressure and turn the support
plate by the handle in counterclockwise direction by 90° to the front.
w Handle on the support plate is in travel direction on the front.
DANGER
Danger of injury due to unsecured operator's platform.
u Lower the operator's platform and attach it with screws before starting the
Diesel engine.
u Attach the operator's platform with 5 hex head screws each per side.
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WARNING
Work under raised working attachment!
If personnel remains under a raised and non-supported working attachment,
personnel can be crushed.
u Before carrying out any maintenance work, lower the working attachment.
u Turn the engine off and actuate all functions to relieve the pressure in all lines.
u Leave the safety lever in the up position.
u Support the working attachment properly, if necessary.
u Clean the grease nipple and lubricate all lubricating points according to the
lubrication chart.
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WARNING
Restricted space conditions and heavy weight of belly pans!
Danger of injury due to difficult removal.
u Use suitable lifting devices to remove the belly pans.
u In case of strong material deposits in the belly pan area, remove the belly pans
and clean them.
CAUTION
Hot oil!
When draining hot engine oil, there is a danger of scalding.
u Avoid skin contact with engine oil.
u When changing the oil, wear protective gloves.
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u Add fresh oil via the filler neck to the “MAX” mark on the dipstick.
u Clean the filler cap, set it on the oil filler neck and tighten.
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Note
u When changing the oil filter cartridges, protect the V-belt from emerging oil.
u After the oil filter change, remove all traces of oil from the Diesel engine, even
behind the vibration damper, to avoid subsequent diagnosis of a radial shaft
seal ring leak.
u Loosen the oil filter cartridges 1 with the filter wrench and unscrew the filter.
u Clean the sealing surfaces on the filter bracket.
u Remove the old filter seal and its remains completely.
u Lubricate the rubber seal rings on the new filter cartridges thinly with engine oil.
u Screw on the new oil filter cartridges, until the seal ring is seated on the filter
bracket
When the seal ring is seated on the filter bracket:
u Tighten the oil filter cartridge by 3/4 to 1 turn (tightening torque 20 Nm - 5 Nm).
u Start the Diesel engine.
w The indicator light Diesel engine problem turns off shortly after start.
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u Turn the engine off, check the oil filters for leaks and check the oil level.
u If necessary, correct the oil level.
Diesel engine
NOTICE
Moisture infiltrates electrical components!
Infiltrating moisture causes contact corrosion and failure of test function.
u Do not expose electrical test sensors, such as oil pressure switches to a direct
jet of water or steam.
u Check the V-belt and tension pulley for proper condition and play (for example
for profile wear of belt pulleys, damage of tension pulley).
Note
u Replace damaged parts immediately.
u Insert a ratchet with 12.5 mm, into the square hole 2 of the tension device 1.
u Swing the tension device 1 back against the spring force in counterclockwise
direction to the stop and remove the V-belt.
u Check the V-belt and tension pulley for proper condition and play (for example
for profile wear of belt pulleys, damage of tension pulley, kicked out bearings).
Note
u Replace damaged parts immediately.
u Place the new V-belt, with the tension device 1 swung back, on all belt pulleys
and the tension pulley.
u Bring the tension device 1 again to the tensioned position.
Note
u Pay attention to leaky fuel lines!
5.7.7 Check the supply and exhaust lines for mounting and
leaks
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u Check the intake lines between turbocharger, charge air cooler and engine for
leaks and mounting.
u Check the exhaust lines between engine and turbocharger, particle filter, muffler
and exhaust manifold for leaks and mounting.
The oil separator is installed on the flywheel side on the right hand side of the
Diesel engine.
Make sure that the following prerequisites are met:
q The machine is in maintenance position.
q The right engine compartment door is open.
q An original Liebherr oil separator filter insert is available.
u Pull the oil separator filter insert out and dispose of it in an environmentally
friendly manner.
u Insert the new oil separator filter insert and push it in to the stop.
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u Turn the oil separator cap to close true to side and tighten by hand to the stop.
u Check the control unit mounting for damage and tight seating.
Troubleshooting
Is the control unit mounting damaged?
u Do not start the Diesel engine.
u Replace all bearings.
u Check all sensors and cable connections for tight seating and condition.
u Check all cables and wiring harness to ensure they are not damaged and that
they are routed to prevent them from rubbing and chafing and that they are
attached properly.
Troubleshooting
Are cable connections, wiring harness or sensors damaged?
u Do not start the Diesel engine.
u Replace defective parts.
Troubleshooting
If a distortion of the vibration damper is found:
u Do not start the engine.
u Replace the vibration damper.
5.7.12 Check the engine mount, oil pan and engine brackets
u Check the oil pan for tight seating, retighten the screws if necessary.
u Check the Diesel engine brackets and engine mount for condition and tight
seating, retighten the screws if necessary.
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The coolant expansion tank with the filler neck is located in the engine compart-
ment.
Access to the filler neck is provided via a flap in the engine cover.
Make sure that the following prerequisites are met:
q The machine is in maintenance position.
q The right engine compartment door is open.
With the Diesel engine turned off, the coolant must be visible in the sight gauge.
When the Diesel engine is warm, the coolant level may also be somewhat higher.
At or near operating temperature, the engine cooling system is hot and under pres-
sure!
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CAUTION
At or near operating temperature, the cooling system is hot and under pressure!
Danger of scalding due to splashing hot coolant.
u Open the cap of the filler neck of the expansion tank only when the engine has
cooled off.
u Open the cap of the expansion tank only after it is cool enough to touch. Turn
the cap carefully to relieve the pressure.
u Never add coolant when the engine is hot.
u Turn the cap 2 a little in counterclockwise direction to relieve the pressure, then
open it.
CAUTION
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u Add coolant.
w Add coolant to the center of sight gauge.
u Set the cap 2 on the expansion tank and tighten.
u Close the flap on the engine hood.
The coolant must contain all year round at least a concentration of antifreeze fluid
of 50 % per volume, but not more than 60 % per volume. A coolant with 50 % anti-
freeze concentration corresponds to a freeze protection up to approx. -37 °C.
Make sure that the following prerequisites are met:
q The machine is in maintenance position.
q The engine compartment door is open.
q A testing tool is available.
CAUTION
Near operating temperature, the coolant system is hot and is under pressure!
Danger of scalding due to splashing hot coolant.
u Open the cap of the filler neck of the expansion tank only when the engine has
cooled off.
u Open the cap of the expansion tank only after it is cool enough to touch. Turn
the cap carefully to relieve the pressure.
u Never add coolant when the engine is hot.
NOTICE
If the corrosion inhibitor / antifreeze fluid concentration is too high, then the cooling
action is reduced.
Danger of damage to the Diesel engine!
u Do not use more than 60 % corrosion inhibitor - antifreeze fluid.
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Use of DCA 4
u Take a coolant sample and analyze with the test kit CC 2602 M by Fleetguard.
u If the analysis does not provide a DCA 4 concentration between 0.6-1.06 units
per liter, then the mixing ratio must be corrected, check the manufacturer's
instructions.
Test procedure
u Clean the cover and the prism carefully.
u Place 1-2 drops of test fluid on the prism.
w The liquid distributes when the lid is closed.
u Look through the lens 2 against a light background and adjust the scale clearly.
u Adjust the sharpness by turning the lens 2.
u Read the Brix values on the blue dividing line in the lens 2.
CAUTION
At or near operating temperature, the cooling system is hot and under pressure!
Danger of scalding due to splashing hot coolant.
u Open the cap of the filler neck of the expansion tank only when the engine has
cooled off.
u Open the cap of the expansion tank only after it is cool enough to touch. Then
turn the cap carefully to relieve the pressure.
u Never add coolant when the engine is hot.
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u Turn the cap on the filler neck a little in counterclockwise direction to relieve the
pressure, then open it.
CAUTION
Coolant can cause eye injuries and allergic skin reactions.
u Avoid skin contact with coolant.
u Observe the manufacturer's guidelines.
u When mixing coolant, wear rubber gloves and safety glasses.
u In case of an accidental splash, flush eyes or skin immediately with plenty of
water.
Add coolant
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u Add premixed coolant via the filler neck 2 to the center of the sight gauge.
u Set the cap on the expansion tank and tighten.
u Close the engine compartment doors.
u Set the heater knob to “warm”. Start the Diesel engine and let it run to warm up.
u Check the coolant level again and correct, if necessary.
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WARNING
Diesel fuel is easily flammable!
Danger of fire and explosion.
u Do not smoke.
u Avoid open flames.
u Work only when the Diesel engine is turned off and cooled off.
The fuel prefilter with water separator, water level sensor and integrated manual
refueling pump are located on the right Diesel engine side.
The shut off valve is accessible via the right engine compartment door.
Make sure that the following prerequisites are met:
q The machine is in maintenance position.
q A sufficiently sized container is available.
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u Fill the new filter cartridge with clean fuel and screw it on until the seal ring is
seated on the filter head.
u Continue to tighten the filter cartridge by hand by 1/2 turn.
u Reestablish the electrical connections, close the breather screw 6 and open the
shut off valve for the fuel system.
u Bleed the fuel system.
u Release the filter cartridge 1 with the strap wrench or similar tool and remove.
u Dispose of the old filter cartridge.
u Clean the filter base and make sure that the threaded adapter is seated tightly
in the filter base.
u Lubricate the seal ring 2 on the new filter cartridge with clean fuel.
NOTICE
Contamination of fuel system!
u Fill the new filter cartridge only via the outer small openings.
u Make sure that no contaminants get into the filter cartridge via the large
opening.
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The shut off valve is accessible via the right engine compartment door.
Access to the drain valve is possible on the rear of the machine after removing the
cover plate
Make sure that the following prerequisites are met:
q The machine is in maintenance position.
q A sufficiently sized container is available.
WARNING
Raised attachment and restricted space conditions!
u Support the working attachment properly or place it on the ground.
u Never work under the raised working attachment.
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u Remove the hex head screws 1 and remove the cover plate.
u Unscrew the cap on the drain valve on the underside of the fuel tank.
u Install the drain hose on the drain valve.
u Drain condensation and sediments into a suitable container until clean fuel
emerges.
u Remove the drain hose and install the cap on the drain valve and tighten.
u Install the cover plate with hex head screws.
u Open the shut off valve for the fuel system.
WARNING
Raised attachment and restricted space conditions!
u Support the working attachment properly or place it on the ground.
u Never work under the raised working attachment.
u Access to the drain valve is possible on the rear of the machine after removing
the cover plate
u Remove the hex head screws 1 and remove the cover plate.
u Unscrew the cap on the drain valve on the underside of the Diesel fuel tank.
u Place a container with sufficient capacity under the drain valve.
u Install the drain hose on the drain valve.
u Drain fuel into a suitable container.
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u Remove the drain hose and install the cap on the drain valve and tighten.
u Install the cover plate with hex head screws.
u Check the O-ring on the cleaning cover and replace it, if needed.
u Clean the fuel tank.
u Install the cleaning cover with O - ring.
u Refill the fuel tank.
u Open the shut off valve for the fuel system.
NOTICE
Fuel lines are opened.
Danger of damage to the fuel system and the Diesel engine!
u To bleed the fuel filter, do not open any fuel injection lines or fittings.
u Open only the breather screw on the filter head of the fine filter.
by 2-3 threads.
u Actuate the hand pump 2.
If fuel without air bubbles emerges on the breather screw:
u Retighten the breather screw 1.
u Continue to actuate the hand pump until you can feel a stronger resistance.
u Start the Diesel engine.
If the Diesel engine does not start:
u Repeat the bleeding procedure.
Fig. 385: Breather screw on the filter head of the fuel prefilter
u Release the breather screw 3 on the filter head of the fuel prefilter and back it
out by 2-3 threads.
u Actuate the hand pump 2.
If fuel without air bubbles emerges on the breather screw:
u Retighten the breather screw 3.
u Continue to actuate the hand pump until you can feel a stronger resistance.
Fig. 386: Breather screw on the filter head of the fuel fine filter
u Release the breather screw 1 on the filter head of the fuel fine filter and back it
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u Release the breather screw 4 on the crankcase and back it out by 2-3 threads.
u Actuate the hand pump 2.
If fuel without air bubbles emerges on the breather screw:
u Retighten the breather screw 4.
u Continue to actuate the hand pump until you can feel a stronger resistance.
Note
u Mark the injector lines every time you open them. After opening them three
times (marks), replace the injector lines.
u Loosen the injector lines of the cylinders 1 and 6 on the pressure pipe fitting
(nozzle side). (Make sure that it does not turn along!).
u Actuate the hand pump 2.
Tab. 40
u Continue to actuate the hand pump until you can feel a stronger resistance.
u Start the Diesel engine.
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Troubleshooting
The Diesel engine is not running?
u Wait for at least 1 minute and then start the Diesel engine again in “bleeding
mode”.
If the Diesel engine still does not start:
u Contact Liebherr Service.
(Optional equipment)
Make sure that the following prerequisites are met:
q The machine is in maintenance position.
q A sufficiently sized container is available.
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u Open the mounting clamps 1 on the service cover and remove the cover.
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NOTICE
Clean the main filter element!
Main filter element is damaged.
u Do not clean the main filter element.
NOTICE
Dust is drawn in via the intake line!
This may damage the diesel engine.
u Never use compressed air to clean the filter housing.
u Ensure highest possible levels of cleanliness.
Replace the safety element 3 with every third change of the main filter element.
The safety element must not be cleaned!
Clean the filter housing before removing the safety element as described.
u Replace the safety element 3.
NOTICE
Dust is drawn in via the intake line!
The diesel engine may be damaged as a result.
u Never operate the machine without an air filter.
u Install the safety element and the main filter element. Ensure correct seating.
u Clean the service cover and fit it on to the filter housing in the correct position.
The mounting clamps cannot be closed without force until the service cover is
touching the filter housing all around the circumference
u Close the mounting clamps.
Troubleshooting
The filter cover cannot be locked.
u The filter cover is not installed the correct way round.
u The recess on the filter cover must match the notch on the filter.
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5.11.1 Check the oil level in the hydraulic tank and add oil
WARNING
The hydraulic system is under high pressure!
When releasing pressurized hydraulic lines and hoses, hydraulic oil can emerge
under high pressure and cause severe injuries.
u Do not remove any lines, hoses, connector pieces as long as the hydraulic
system is under pressure.
u With the Diesel engine turned off and the ignition turned on, actuate all func-
tions again to relieve the pressure in the hydraulic lines.
u Relieve the tank pretension: Back the breather screw 1 on the hydraulic tank
out by two turns.
Note
u Add hydraulic oil only via the return filter.
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u Check the O-ring 4 on the return filter cover and replace it, if necessary.
Note
u The sealing action of the return filter cover is not improved by tightening it more.
The return filter cover is sealed radially.
u Insert the filter cover with the magnetic rod and attach with screws.
u Close the breather screw on the hydraulic tank.
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u Relieve the tank pretension: Back the breather screw 1 on the hydraulic tank
out by two turns.
u Loosen the screws 2 on the filter cover and slowly lift the filter cover with the
magnetic rod.
u Turn the return filter cover to open.
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u Check the O-ring 4 on the return filter cover and replace it, if necessary.
Note
u The sealing action of the return filter cover is not improved by tightening it more.
The return filter cover is sealed radially.
u Insert the filter cover with the magnetic rod and attach with screws.
u Close the breather screw on the hydraulic tank.
u Relieve the tank pretension: Back the breather screw 1 on the hydraulic tank
out by two turns.
u Loosen the screws 2 on the filter cover and slowly lift the filter cover with the
magnetic rod.
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Note
u The sealing action of the return filter cover is not improved by tightening it more.
The return filter cover is sealed radially.
The replenishing circuit filter is installed between the operator's cab and the bulk-
head.
Make sure that the following prerequisites are met:
q The machine is in maintenance position.
q An original Liebherr oil filter cartridge is available.
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u Lubricate the rubber seal ring on the new filter cartridge thinly with engine oil.
u Install a new filter cartridge on the filter bracket and tighten by hand.
u Install the cover.
Note
u See also section “Safe maintenance of hydraulic hoses and hose lines” (For
more information see: 2.4.14 Safety notes for maintenance of hydraulic hoses
and hose lines, page 48) .
NOTICE
Do not check the machine for leaks with bare hands.
A fine stream of fluid under high pressure can cause severe injuries.
u Use protective gloves.
NOTICE
Careless treatment damages the cooler fins!
Danger of damage to the cooling system.
u Do not use hard objects or excessive water pressure for cleaning
u Relieve the tank pretension: Back the breather screw 1 out by two turns.
u Unscrew the cap on the drain valve on the underside of the hydraulic tank.
u Install the drain hose on the drain valve.
u Drain hydraulic oil into a suitable container.
u Remove the drain hose and install the cap on the drain valve and tighten.
Note
u Add hydraulic oil only via the return filter.
u Loosen the screws on the filter cover and slowly lift the filter cover with the
magnetic rod.
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u Relieve tank pretension: Back the breather screw 1 on the hydraulic tank out by
two turns.
u Remove the cap on the drain valve on the underside of the hydraulic tank.
u Install the drain hose on the drain valve.
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u Drain condensation and sediments into a suitable container until clean hydraulic
oil emerges.
u Remove the drain hose and install the cap on the drain valve and tighten.
u Check the oil level in the hydraulic tank and add oil, if necessary.
5.12 Splitterbox
The dipstick 2 and the oil filler tube 3 are in the engine compartment on the right
hand side of the engine.
Make sure that the following prerequisites are met:
q The machine is in maintenance position.
q The right engine compartment door is open.
The oil level must be between the “MIN” and “MAX” marks.
u Pull out the dipstick 3, wipe it off and reinsert it.
u Pull the dipstick 3 out again and check the oil level.
If the oil level is too low:
u Remove the oil filler cap 2 from the oil filler tube 1 and add oil.
u Clean the oil filler cap 2.
u Set the oil filler cap 2 on the oil filler neck 1 and tighten.
WARNING
Restricted space conditions and heavy weight of belly pans!
Danger of injury due to difficult removal.
u Use suitable lifting devices to remove the belly pans.
u In case of heavy material deposits in the belly pan area, the belly pans must be
removed and cleaned.
u Remove the oil filler cap 2 on the oil filler neck.
u Remove the cap on the drain valve on the gear housing.
u Install the oil drain hose on the oil drain valve 1 and let the oil drain into a suit-
able container.
u Remove the oil drain hose and reinstall the cap on the oil drain valve.
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u Add fresh oil via the oil filler neck to the “MAX” mark on the dipstick.
u Clean the oil filler cap, set it on the oil filler neck and tighten.
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WARNING
Batteries emit explosive gases. Battery acid has strong caustic properties.
u Do not smoke and avoid open flames when handling batteries as well as during
battery maintenance and charging.
WARNING
Spark formation when using incorrect brushes!
When cleaning the terminals with incorrect brushes, there is a danger of spark
formation and subsequent gas explosion.
u Use the special terminal brush.
u Clean the connector terminals and the connector clamps with a suitable
terminal brush.
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WARNING
Danger of explosion due to frozen batteries!
Do not charge batteries if they are frozen.
u Let the batteries warm up to approx. 16 °C before recharging.
u Loosen the spring bar and pull the bulb base out.
u Remove the bulb from the base and replace it with a new one.
Note
u Do not touch the new halogen bulb with bare hands.
Note
u Do not touch the new bulb with bare hands.
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During repair work, close the shut off valve on the engine block.
u Close the shut off valves.
w The warm water supply to the heat exchanger is interrupted.
Note
u Operate the heater to ensure that the coolant fluid contains sufficient antifreeze
fluid. See section “Check the antifreeze concentration in the coolant”.
Proper function of the entire air conditioning system is only ensured if the mainte-
nance tasks are carried out completely, diligently and properly by qualified
personnel.
Only trained air conditioning mechanics may access and repair the coolant circuit.
The air conditioning system must be serviced once a year, if possible before the
start of the summer season in a HVAC service station, otherwise any warranty
becomes void.
DANGER
Danger of injury due to turning engine parts!
Turning and moving engine parts, such as fan blades or V-belts pose a danger of
injuries!
u Open the engine compartment doors only when the Diesel engine is not
running.
u Check the compressor carrier and compressor supports for cracks and breaks,
check the screws for completeness and tight seating.
u Check the compressor for leaks.
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Note
u The moisture content in the system must be checked regularly, otherwise the air
conditioning system can be destroyed due to acidification.
The dryer is installed on the rear on the operator's cab roof in the evaporator unit
and can be checked through the protective grill.
CAUTION
Danger of injury due to fall from the machine.
u A suitable access aid is required for inspection.
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u Check the refrigerant quantity: The refrigerant must flow without air bubbles
through the sight gauge when the Diesel engine is running and lift the white
floater ball.
u Check the color of the indicator pearl.
If the orange ball in the sight gauge turns colorless:
u Replace the dryer.
u Remove the protective grill and remove the recirculating air filter 2.
u Reinstall a new recirculating air filter and attach the protective grill with the
knurled screws.
The recirculated air filter is located behind the operator’s seat, on the floor of the
operator’s platform.
The drain valve can be cleaned via the intake channel on the operator’s platform.
The bore for the water discharge is below the insulated air conditioner hose.
Note
u If necessary use a short piece of wire or a flexible shaft for cleaning.
Check and clean the drain valve on the fresh air filter
The access to the cab fresh air filter is on the front in the operator’s cab below the
compartment for the documentation.
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Note
u If necessary use a short piece of wire or a flexible shaft for cleaning.
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NOTICE
Wire or other objects are wound around the travel gear!
Any objects wound around the travel gear can be pushed into the gaps and subse-
quently damage the seals.
u Remove any wound up objects.
u Check the travel gear housing and remove any wound up objects, if present.
The oil level must be at the height of the oil filler port.
u Clean the area of the oil filler plug 2.
u Remove both oil filler plugs 2 with a socket wrench.
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Note
u Observe the tightening torque of 120 Nm.
u Clean the area of the oil filler and oil drain plug.
u Place a container under the oil drain plug 1.
u Remove both oil filler plugs 2.
u Remove the oil drain plug 1.
u Let the oil flow into the container.
u Check the oil for mechanical contamination.
u Clean the oil drain plug 1 and reinstall.
Note
u Observe the tightening torque of 120 Nm.
To be able to drain the gear oil completely from the gear, the oil on the inside of the
gear must also be drained form the gear housing.
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Note
u Observe the tightening torques of 120 Nm.
u Add oil via the oil filler plug 2 of the gear until the lower edge of the filler port.
u Clean the oil filler plug 2 and reinsert.
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Note
u Observe the tightening torque of 120 Nm.
Fig. 455: Indicator lights Travel gear duo cone (slipring) area
If the oil level is too low, the indicator lights Travel gear duo cone (slipring) area 45
or 46 light up in the instrument panel.
If an indicator light lights up:
u Park the machine.
u Check the affected travel gear externally for leaks.
u Contact Liebherr Service.
Note
u For continued operation in the meantime, bring the oil level to normal level.
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The required equipment to flush the duo cone (slipring) area is available from your
Liebherr dealer.
u Check if both containers are under the drain plugs on the duo cone (slipring)
area and if the drain plugs are open.
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WARNING
Danger of accidents if Diesel engine is running!
u During the oil change, leave the emergency off button in actuated position.
u During the oil change, leave the safety lever in the up position.
u Remove the flushing line from the right connection 1 and close the connection 1
with fitting and union nut.
u On connection 2, remove the fitting and union nut and connect the flushing line.
Note
u Carry out the flushing procedure at the left duo cone (slipring) area also.
u After the flushing procedure, install the left and right drain plugs 1.
Note
u Observe the tightening torque of 40 Nm.
Note
u Observe the tightening torque of 40 Nm.
u Remove the flushing line from fill connection 4 and connect on fill connection 3.
u Close the fill connection 4 off with fitting and union nut.
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u Start the Diesel engine again at low idle rpm and let it run until the reservoir is
filled to the lower edge of the filler port.
w The duo cone (slipring) area oil reservoir is overfilled.
u Turn the Diesel engine off.
u Remove the flushing line and close the connection 3 off with fitting and union
nut.
u Install the cap on connection 5.
u Close the battery compartment door.
u Check the oil level in the hydraulic tank and add oil, if necessary.
u Operate the machine for a short period and recheck the oil level.
u Add oil to the duo cone (slipring) reservoir, if necessary.
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5.16.1 Checking the nuts and bolts of the travel gear compo-
nents are firmly seated
Made by BERCO
Size Tightening torque
3/4” - 16 UNF 630 +/- 20 Nm
7/8” - 14 UNF 850 +/- 10 Nm
M24 x 1.5 1020 +/- 30 Nm
M27 x 2 1913 +/- 49 Nm
1” - 14 UNF 1400 +/- 30 Nm
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Made by INTERTRAC
Size Tightening torque
3/4” - 16 UNF 640 +/- 30 Nm
Made by BERCO
Size Tightening torque
3/4” - 16 UNF 270 +/- 30 Nm + 120° 15)
7/8” - 14 UNF 350 +/- 35 Nm + 120° 15)
M24 x 1.5 400 +/- 35 Nm + 120° 15)
M27 x 2 785 Nm + 120° 15)
1” - 14 UNF 550 +/- 40 Nm + 120° 15)
Made by INTERTRAC
Size Tightening torque
3/4” - 16 UNF 320 +/- 15 Nm + 120° 15)
The normal clearance between the track roller frame and the side guide is 1 mm to
2 mm, the height clearance of rubber springs is approx. 3 mm. The clearance is
increased due to wear of the wear bars, guide rails and guide plates. When the
maximum permissible values are reached, the respective clearance must be read-
justed or the worn parts must be replaced.
Tab. 46
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Tab. 47
The difference between the number of shims on the inside and the outside may
never be more than 1 shim.
If the clearance is too large:
u Remove shims on the inside and / or outside.
If no more shims exist:
u Replace the guide plates.
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u Lift the idler: Drive on a wooden block (maximum height 200 mm).
w The claws touch on the guide rails.
u Measure the height clearance between the wear bars and the bearing bracket.
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DANGER
Danger to life when removing the chain tensioner spring!
The chain tensioner spring is pretensioned, even though the chain tension is
relieved.
During removal or repair, the chain tensioner spring can jump out and cause very
severe injuries.
u The chain tensioner spring may only be replaced or repaired by authorized and
trained expert personnel.
Check the chain tension regularly and retension the chain, if necessary, otherwise
the track wear increases. The conditions must be identical to the working condi-
tions!
An incorrectly tensioned spring results in high chain wear.
Since deposits on track and chains are less in rocky ground than in cohesive
ground, the adjustment of the chains must be made according to the application
conditions.
Before checking the chain tension, do not remove any material, which has built up
during work on the track components.
NOTICE
Strong wear on tooth segments!
If the tooth segments on the travel gear are worn too much, then the chain can
jump over.
u Check the tooth segments regularly for wear.
u Measure the distance between the lower edge of the measuring stick and the
grouser.
The chain under working conditions should have a sag of 30 mm to 40 mm
between carrier roller and idler or between carrier roller and sprocket.
NOTICE
The chain is tensioned too much!
Excessively tensioned chains increase dirt build up and wear.
u Adjust the chain tension to the specified sag dimension by taking the working
conditions into account.
NOTICE
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u Connect the manual grease gun to the fitting on the chain tension cylinder.
u Press in grease until the specified sag dimension (30 mm to 40 mm) is
obtained.
u Attach the cover with hex head screws 1.
WARNING
Danger of injury when releasing the grease fitting on the chain tension cylinder!
When releasing the grease fitting, the chain can suddenly sag and crush body
parts. Splashing grease can cause severe injuries.
u Wear protective gloves and safety glasses and keep the head away from the
track roller frame.
u Release the chain tension. (For more information see: 5.16.3 Check and adjust
the chain tension , page 293)
Do not close the grease fitting 1 to allow the grease, which is being pushed back to
emerge on the ring nut.
u Slowly move the machine with the idler against a wooden block until the idler is
pushed back completely.
u Set the master link on the center of the sprocket: Move the machine forward or
backward.
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u Secure the chain to prevent it from rolling off: Place a wooden block in front of
the idler and behind the sprocket.
u Spray the lock on the master link with penetrating oil and support the infiltration
of the penetrating oil by hitting the master link lightly with a hammer.
u Place the chain true to side on the ground behind the old chain (Travel direc-
tion forward 1).
u Connect the new chain with the old chain with a wire.
u Align the chain to the track and drive the machine carefully to the end of the
new chain.
u Release the new chain from the old chain and attach it on the sprocket with the
wire.
u Carefully drive the machine forward until the chain is positioned on top on the
sprocket.
u Secure the chain in front of the idler and behind the sprocket with a wooden
block.
u Connect the master links, place the track pad and tighten the bolts with the
specified tightening torque.
u Tension the chain.
Do not close the grease fitting 1 to allow the grease, which is being pushed back to
emerge on the ring nut.
u Slowly move the machine with the idler against a wooden block until the idler is
pushed back completely.
The chain link pins can be recognized on the tapered pin edge or on the counter-
sink.
u Set the chain link pins to 1/3 the height of the sprocket: Move the machine
forward or backward.
u Secure the chain to prevent it from rolling off: Place a wooden block in front of
the idler and behind the sprocket.
WARNING
When removing or inserting tempered link pins with a sledge hammer, metal
splinters can split off.
Danger of injury due to splitting off material on the chain link pin or the tool!
u Wear safety glasses and protective clothing.
u Use a hydraulic press.
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Press the knurled pins out from the inside to the outside and press them in from
the outside to the inside. Knurled edge on the outside.
When knocking the link pins out, hold the opposite side of the chain band to
counter.
u Press the link pins out or knock them out with a suitable tool.
u Remove any spacer rings which were inserted and lay them aside.
u Place the chain on the ground by carefully driving forward.
u Drive the machine backward on the placed down chain.
u Place the chain true to side on the ground behind the old chain (Travel direc-
tion forward 1).
u Connect the new chain with the old chain with the link pin.
u Align the chain to the track and drive the machine carefully to the end of the
new chain.
u Release the new chain from the old chain and attach it on the sprocket with the
wire.
u Carefully drive the machine forward until the chain is positioned on top on the
sprocket.
u Remove the wire on the chain and on the sprocket.
u Bring the chain over the carrier roller and the idler by driving it forward carefully.
u Drive the machine forward until two track pads are still in front of the idler.
u Secure the chain in front of the idler and behind the sprocket with a wooden
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block.
u Reinsert the spacer rings, which were removed when the chain was removed.
When knocking the link pins in, hold the opposite side of the chain band to counter.
u Press or knock the link pins in from the outside to the inside.
u Tension the chain.
The left and right axle bearings are filled with oil. Check the oil quantity according
to the data in the maintenance and inspection schedule.
The oil in the axle bearings does not need to be changed. The oil is only used as
corrosion protection.
Make sure that the following prerequisites are met:
q The machine is in maintenance position.
q The correct oil quality according to the data in chapter “Lubricants and Service
items” is available.
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The center equalizer bar bearing is equipped with a grease fitting and must be
greased as specified in the data in the Maintenance and Inspection schedule.
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5.17.1 Check the cutting edges, end bits and ripper tips for
wear
To avoid damage on the blade or the tooth adapters of the ripper, replace the
cutting edges as well as the teeth before the wear limit is reached.
Removal
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WARNING
Danger of injury due to falling attachment!
Never work under the raised attachment.
u Lower the ripper to the ground or support it properly.
WARNING
Danger of injury due to material splitting off when knocking out the pin.
u Wear protective goggles and protective gloves.
u There may be no persons within the danger zone.
NOTICE
During high pressure cleaning, electrical components, such as electronic boxes,
refueling pump, test value sensor and electrical parts in the cab can be damaged!
u Do not expose the electrical components to a direct jet of water or steam.
NOTICE
During high pressure cleaning [more than 1379 kPa (13.8 bar)] freshly painted
surfaces can be damaged!
u After delivery of the machine, the paint should air dry for at least 30 days before
cleaning the machine or parts of the machine with high pressure cleaners!
u Use only low pressure cleaners to wash the machine until the 30 days are up!
NOTICE
Danger of Diesel engine damage with associated electrical components due to
moisture infiltration!
u Do not expose electrical components, such as starter, alternator, test value
sensor and oil pressure switches to a direct jet of water or steam.
NOTICE
Danger of damaging oil lubricated track components due to destruction of seal!
When cleaning the track with high pressure cleaners, the sealing plugs of the track
components can be pushed into the oil chambers.
u Do not spray directly on the sealing plugs with the high pressure cleaner. Keep
a distance of approx. 40 cm.
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A
Accident prevention sign 30
Activate the parking brake 110, 112
Activating blade release 118
3 Actuating the tilt cylinder 119
Add coolant 224, 232
30 LC display 56
Add Diesel fuel 90
31 Warning light Operator's cab 57
Add Diesel fuel with the refueling pump 91
33 Coolant temperature display 58
Additional designations 26
34 Fuel display 58
Additional rules and guidelines 26
35 Operating hour meter 58
Adjustable speeds 105
Adjust the backrest 72, 74
4 Adjust the ergonomic seat position individually 71, 73
Adjust the lumbar support 75
40 Indicator light Battery charge 58
Adjust the mirror 90
41 Indicator light Pump replenishing pressure 58
Adjust the operator's seat horizontally 71, 73
42 Indicator light Fan control 59
Adjust the seat height 71, 74
43 Indicator light Electronic 59
Adjust the seat surface incline 74
44 Indicator light Hydraulic oil temperature 59
Adjust the seat suspension 72, 75
45 Indicator light Travel gear - duo cone (slipring)
Adjust the throttle control 97
area, left 60
After driving on the loading surface 144
46 Indicator light Travel gear - duo cone (slipring)
After the towing procedure 156
area, right 60
Air conditioning system 80, 270
47 Indicator light Preheat system 60
Air conditioning system full power 82
48 Indicator light Parking brake 60
Air filter system 173, 248
49 Indicator light Air filter contamination 60
Align the machine to the attachment 141
Approved antifreeze fluids with corrosion inhibitor
5 185
Approved corrosion inhibitors without antifreeze
50 Indicator light Return filter 61
protection 185
52 Horn button 62
Approved premixed antifreeze fluids with corrosion
53 Scroll key 62
inhibitor 185
54 Indicator light Diesel engine problem 61
Armrests 78
55 Switch Windshield wiper, front 63
56 Switch Windshield wiper, rear 63
57 Switch Windshield wiper, left door 63
58 Switch Windshield wiper, right door 63
B
Back up warning device 86
59 Switch Windshield wiper - intermittent / washer
Battery sign 32
system 63
Biodegradable hydraulic oils 188
Blade release 118
6 Bleed the fuel filter 242
Bleed the fuel filter and the fuel system 242
60 Starter switch 64
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Check the cooling system 226 Correct the antifreeze concentration 227
Check the cutting edges, end bits and ripper tips for Correct the windshield wiper position 213
wear 304 Cutting angle position 120
Check the cutting edges and end bits for wear 304
Check the Diesel engine arrangement for leaks and
condition 219 D
Check the electrical system of the Diesel engine 222 Designation of warning notes 25
Check the engine mount, oil pan and engine Design overview 15, 134
brackets 223 Destined use 26
Check the engine oil level 214 Diesel engine 160, 172, 197, 214, 218
Check the fluid level and the battery terminals 265
Diesel engine: Check all sensors and cable Fuse chart in central electric housing 167
connections for tight seating and condition 222 Fuse chart in the roof console 169
Diesel engine: Check the arrangement and belly pans Fuse in radio 169
for contamination and clean 217 Fuses in central electric housing 165
Diesel engine arrangement and belly pans 218
Diesel fuels 180
Diesel fuels at low temperatures (winter G
operation) 181 General data 180
Disconnect the auxiliary battery 158 General recommendations 183
Display Hydraulic oil temperature 66 General safety instructions 40
Door latch 70 Grading 125
Door lock 69 Grease and other lubricants 193
Downhill travel sign 30 Grease for automatic grease central lubrication
Dozer blade - Emergency lowering 118 system 195
Dozing in tracks 126
Dozing with full blade 125
Drain the coolant 231 H
Drain the fuel filter condensation 234 Hand, arm and whole body vibration emission 17
Drain the fuel water separator condensation 246 Hand - arm vibrations 17
Drain the oil 303 Heater, ventilation 78
Drain water and sediments in the fuel tank 238 Heater, ventilation, air conditioning system 174, 269
Drain water and sediments in the hydraulic tank 261 Heating system 164
Drive gear 175, 277 High sulfur content in Diesel fuel 180
Drive onto the loading surface 142 Hydraulic oil 186
Driving backward 107 Hydraulic oil level indicator 67
Driving forward 107 Hydraulic system 163, 173, 196, 251
Driving straight ahead 107
I
E Increasing blade volume 125
Electrical system 163, 174, 265 Index 309
Electrical window wiper and window washer system Information for vibration emission 17
84 Inside mirror 83
Embedding removed material 130 Install and remove the attachment 132
Emergency exit 68 Install and remove the push frame with the straight
Emergency operations 149 blade 134
Empty and clean the fuel tank 239 Installation guidelines for installation and removal of
Empty the fuel tank 239 attachment parts 132
Engine oil as hydraulic oil 187 Install the bearing shells of the attachment 132
Engine standstill sign 28 Install the center bearing 136
Entry 68 Install the hoist cylinder 138
Equipment and attachment parts 50 Install the left half of the push frame 135
Install the right half of the push frame 135
Install the straight blade 137
F Install the tilt cylinder and strut 138
Fasten the seatbelt 77 Install the trunion 135
Felling trees 129 Interior cab lighting and reading light 83
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Sign Coolant 38 Travel gear - Duo cone (slipring) seal area 279
Sign Emergency exit 37 Travel operation 101
Sign Lubrication chart 36 Travel speed fine adjustment 105
Sign MIN/MAX Hydraulic tank 34 Turning to the left 108
Sign Noise protection 35 Turning to the right 108
Sign Ripper 37 Turn the air conditioning system on 81
Sign Rops - Fops 33 Turn the battery master switch off 114, 201
Signs on the machine 26 Turn the battery master switch on 88
Sign Splash water 34 Turn the Diesel engine off 112
Sign Stop-lift point 36 Turn the electrical system off 204
Sign Travel hydraulics 35 Turn the heater on and off 79
Sign Window washer fluid 36 Type plates 39
Sign Working hydraulics 38
Sliding window 82
Software bleeding mode 245 U
Sound emission 18 Use of corrosion inhibitor without antifreeze fluid 229
Specification 180 Use of DCA 4 229
Speed ranges - basic setting 104 Use of other water-soluble corrosion inhibitors 229
Splitterbox 174, 197, 262 Use of the machine in low or high ambient
Starting preparations 96 temperatures 95
Starting preparations in freezing temperatures 101 Using several machines simultaneously 127
Start the Diesel engine 96, 99
Stay clear warning sign 28
Steering 107 V
Stop the machine 155 Viscosity 192, 193
Stop the travel drive 115
Stop the travel drive and continue with the emergency
off button 115 W
Warm up specification 188
Water (Fresh water) 183
T Wet cleaning the machine 306
Take oil samples 196 Whole body vibrations 17
Take the machine out of service 111 Wipe the window 84
Taking oil samples and oil analysis 196 Working attachment 175, 304
Taking the machine out of service 308 Working equipment 164
Technical data 17 Working in water 116
Technical description 15 Working with the attachment 117
Tension the chain 295 Work methods 125
Test procedure 229 Work with optional equipment 123
Tightening torque for cutting edges, end bits and
adapters 23
Tightening torques 19
Tightening torques for countersunk screws 21
Tightening torques for hex head screws 19
Tightening torques for sprocket segment bolts 289
Tightening torques for track pad bolts 289
Tightening torques for track pad bolts (re-check) 288
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