Liebherr Hydraulic Excavator Material handler R 904 C-Litronic & Tool Control Operating Instructions Manual SN 112305 – PDF DOWNLOAD

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

They contain:

— The technical data.

— The safety requirements.

— The operating instructions.

— The maintenance instructions.

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

Work with or on the machine includes, for example:

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

— Maintenance, including maintenance, inspection, and repair work.

— Transportation or loading the machine.

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

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

— Increases reliability in use.

— Extends the service life of your machine.

— Reduces repair costs and downtime.

The operating instructions belong with the machine. Place a copy in an easily reached position on the cab storage shelf.

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

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

— Some illustrations in these operating instructions may depict details and working devices that differ from your machine. — In some illustrations, protective devices and covers have been removed in the interests of better presentation. — Improvements, which are always being incorporated into our machines, may result in changes to your machine that are not yet indicated in these operating instructions.

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

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

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

Liebherr Hydraulic Excavator Material handler R 904 C-Litronic & Tool Control Operating Instructions Manual SN 112305 – PDF DOWNLOAD
1 Product desCriptioNcciii crn cnr renner err er ena Rae een enn ne eae

ASSEMDIY – OVEIVIEW
111 Machine and construction equipment a
112 Machine for transferring material
113 UPPEI CAITIAGE o
114 Chassis w
TECHNICAI ATA

2 Safety INStIUCHIONS crn rr rr rer ee en anne nan eae 2-1

Symbols in the handDOOKScooiii eee
Use in accordance with the regulations i
Safety INSIIUCTIONS coi eee ee eee eee berets
Servicing the Machine Safelycoo iii eee

Signs on the machine
251 INIPOAUCTION oii eee eee eee bette bette eee eee ernie
252 Arrangement Of SIGNAGEoooviiiiiit eee
253 Explanation of signage
254 Nameplates on the Machinecooiiiiiiiii eee

Operating and control @IEMENTSiiiiiiii eee eee ees
311 Overview of the operator’s standing position i
312 Arrangement Of JOYSTICKooiiiii ieee
Bu13 KEYPAA oe eens
314 Monitoring screen
315 Main screencccooeeeeee
Access and equipment of the cab
321 Entering or leavingthe cabccccooiniiiis
322 Height and inclination adjustable cab (optional extra) i
323 SAFELY IEVET cco eee 3-31
324 OPEIALOr’S SEAL outta 3-32
325 Windscreen –
328 SUNSHAE eit eee ere tenets een ae eterna enna ee
327 Emergency eXit — rear WINOOWcoiiiiiiiiiiiiieie ieee cesta ese ere see 3-37
328 Interior lighting –
329 Fire exXtiNQUISNEI™oii i eee eee eee 3-38
B210WINASCIEEN WIPET icici eee teeta eee eae 3-38
3211Lighting coco
3212The heater and air conditioner
3213Additional standstill heater (Option)
3214 Pressurisation de cabine (option) 3-52
Operation i
331 Starting / stopping the MaChiNecciiiiiiii ee 3-55
332 Anti-theft device with code key (OPtoN)ccooviiiiii ee 3-57
333 Immobilizer with electronic ignition key (option) –
334 Delay engine cut-out 5 Min (OPLION)cccciiiiiiiiiiei ieee 3-63
335 indicatorStarting aids
336 Jump start procedure i
337 EMErgenCy OPEIAtIONScccuiiiiiiiii iterate seers 3-67
338 Travel TUNCHONSooii ee eee eee eae 3-69
339 Drive warning device (optional extra)
Recovering, towing the machine 3-74
341 Pre-requisite —
342 Process PreCONISALIONSccuiiiiiiit ities reteset eee 3-75

R 904 C-Litronic & Tool Control option / 1004676

343 Other PreCONISATIONS cocoon eens 3-76
344 With clevis type eylet available w
Working with the machine

351 Low idle automatic i
352 Operating the SWING EATcoi iii eee ees
353 WOrKIiNG POSITION coisas
354 Working attachment control i
355 Lowering the working attachment with the engine shutdown 3-87
356 Turning, rotating, bolting and unbolting the add-on unitcccoc iii 3-88
357 Magnetic system (special equipment) –
358 Add-on kits AHS 1, AHS 11 and AHS 12 (optional extra)ccccocniiiiininiii cen 3-90
359 Add-on kits Tool Control AHS 1, AHS 11 and AHS 12 (optional extra)cccccooniieiinnne 3-92
3510Foot pedals travel control with add on kits AHS (optional extra)3-95
3511Adjust BOOM 10 Sideooviiiiiiiiii cc3-95
3512Adjust boom to side (Tool Control)ccccccooviiinininene3-98
3513Priority commutation with add-on kit AHS 12 (optional)
3514 Transferring controls (optional extra)ccccevinnne
3515Transferring controls PCSA – LH (optional extra)cccccoiiiiiiiii cen 3-103
3516transferring controls PCSA – JDeere (optional extra)ccceeiiiiiiiiiiiiiee cen 3-104
3517 Transferring AHS controls (optional extra)
3518Special control (OPHION)coiiii ieee
3519Special controls Fuchs (optional @Xtra)ccooiiiiiiie iii
35200ption oil flow reduction for long working attachment
3521 Dozer blade (option or serial according to machine type)
3522Boom vertical stroke limitation (Option)
3523Mechanical stanchion cylinder shut-down (option)
3524 Low pressure protection for boom cylinders
3525Electronic stanchion cylinder shut-down
35260verload warning device (Option)
35270verload warning device
3528Mowing BUCKET (OPTION)ii iii eee eee
Attaching and dismounting equIPMENt PAScoiiiiiiiiiii rece
361 Attaching and dismounting the bucket
362 Attaching and dismounting the grab on the shovel arm

363 Attaching and dismounting the grab on the industrial stanchionccooo 3-136
364 Mechanical quick-change adapter (optional extra)
365 Hydraulic quick-change adapter (optional extra)cccciiiiiiiiiiiii cee
366 LIKUFIX — hydraulic coupling system (optional extra)cccceeoiiiiieii iii 3-149
367 Control of the swivel rotator (option)cccccovuee
General working methodsccocoiiiiiiii
371 Minimum impact working methods for your machine
372 Preparatory activitiescccceoniiiieiiinii
373 Using a backhoe bucket
374 Loading a transport VENICEocoiiiiiii cree
375 SKIMMING coo eeee eee eee e betes b ete e ee sb estes eee nae een eee
376 Using a clamshell bucket (earthmoving attachment)
377 Using a multiple tine grapple (industrial attachment)cccooiiii
378 Using an hydraulic hammerccoiiiiiiiiii eee eee
TranSPOrtoooiieiie cee
381 Transporting the machine on a low loader
382 Loading the machine with @ craneccoooiiii ee 3-166

1, 10 To (5 4-1

41

EFrOr COO ChEAIS «ooo eee eee 4-2
11 SBNSOIS ooo h teehee heehee ease eas 4-2
412 RequIating CIFCUILcooiiitii icici 4-3
413 Stanchion cylinder shut-down (only for machines which handle material or for machines with

optional extras)4-3

R 904 C-Litronic & Tool Control option / 10046768

LFR/en/Edition: 01 / 2008
LFR/en/Edition: 01 / 2008

Operating instructions

414 KEYPAD oe ee hee eee eee eres 4-3
415 Display 4-4
416 Coding error 4-4
417 Other errorscccoovvvvvioiiiiic ee 4-4
418 Error due to warning symbols in SY field 4-5
La TU] ET Lg (a CT T= To [L= TUSURRTRRR
421 Diesel engine and fuel system a
422 Hydraulic SYSTEIM cco ees
423 TFANSIMISSION eit eee teeter teeth beet ebb tees b ent eee bebe eens
424 Electrical system a
425 WOTK @QUIPIMENT cotter eee beter
426 Heating/air-conditioning SYSTEMcooiiiiiii ieee ees 4-9
43 Fusesandrelayscccoovieninnnne
431 Fusebox E50 ree
LC P= mT 0 o To T= (oO PRRR
Lo 1: T12(=T Ty Uo 5-1
51 Servicing the Machine Safelyccoiiiii ieee 5-1
52 Maintenance @CCESS HOOKSiiii iii ieee eee eee betes b teeth eaten eerie 5-7
521 OVEIVIEW Of @CCESS TOOTS uit eee eesti eats ae estes sree ee eteesnee eae ee anne annas 5-7
522 Doorlockcocveeinnnnnnn5-8
523 Engine hood lock5-8
53 Lubricating and operating materialscccoooniiiiiii5-9
531 General information on changing lubricating and operating materials5-9
532 Lubrication Char i
533 LUBFCANT Char eee
534 Operating material Chart cco eee eee
54 Lubricating and operating material specifications
541 Lubrication oil for the diesel engineccccoiiiiiiiiii ee
LI = UT SOTO UROPRI
543 Hydraulic oil
544 TransSmiSSION Oloooiiiiiii ieee eee eee eee
545 Lubricating grease and other IUBMCANTScooiiiiiiiic eee
546 Coolantccooiiiiiiiii
55 Dieselenginecocoeiiiiiiiiiiiiiciie
551 Checking the oil level in the diesel engine
552 Changing the diesel engine Oilocooiiiiniinci
553 Ribbed V-belt for the A/C compressor and alternator installation5-25
554 Ol SEPAIALOTeiitiieieee eet eee tebe eee ete
56 LIEBHERR particles filter (In Option)ocoiiiiiii eee
561 Drain the condensation watter:
562 Watter separator MaiNteNaNCE:coouiiiiiiii ieee eee eee 5-28
57 C00lNG SYSTEM Leite eee eee ee eee eee 5-28
571 Checking and cleaning the cooling system 5-28
572 Checking the coolant level 5-29
573 Coolant antifreeze and anti-corrosion fluid5-29
574 Changing water filterscccccoovivinnnnn 5-30
575 Changing the coolant 5-30
576 Reversible fan drive (option) 5-33
58 Fuelsystemcoooeiiniiinin5-34
581 Refuellingcccooooiiniiiiiiie5-34
582 Electrical refuelling pump (optional @XIra)ccoooiiiiiiiiiiiii eee 5-35
583 Draining the fuel tank
584 Emptying and cleaning the fuel tank w
585 Draining and changing fuel filter cartridgesccoooviiiiiiiiiii eee 5-37
586 Venting the fuel SYSTEMcooiiiii eee 5-38
59 Dry air filter

591 Changing the main element

R 904 C-Litronic & Tool Control option / 1004676

592 Changing the safety element cores 5-40
593 Monitoring the filtered air line i

Hydraulic systemccccecinnn i
5101 Preparatory activitiesccccoovieivinnnns5-42
5102Checking the oil level in the hydraulic tankccccoiii 5-42
5103Depressurizing the hydraulic Systemccooiiiiiii ee

5104Emptying and refilling the hydraulic tank ee
B5A05REtUMN-IING FET
5108C0NTr0l
5107Control circuit I
5108Bleeding the hydraulic PUMP
5109Bleeding the hydraulic CYliNAErscooii iii
51010Unscrew the intake hose to the pump
51011 Vent filter on the hydraulic tank
51012Bleeding the hydraulic cylinders
51013Bypass oil filter for hydraulic circuit (option)
51014Return oil filter for hydraulic hammer (option) ee
51015Servicing the hydraulic CYNEcoiiiiiii ees 5-53
51016Replacing hydraulic NOSESoiiiii ieee eee ee eee eases 5-54
Qil changes on components i
5111General iNfOrMationoooi iii eee ees

5112Slewing gear transmission — Oil Changecccciiiiii iii 5-56
5113 Travelling gear – changing the oil
The track COMPONENTSoouiiiii ieee eee eee trees eens
5121 Checking the track COMPONENTScciiiiiiiiii eee eee
5122Monitoring the track chain tension
5123Retensioning the track chain
5124Releasing the track chain tension
5125Greaser extension replacement

5126Cleaning the running carriage5-62
ElECHHCAl SYSTEM eee eee eee eee 5-63
5131Notes on the electrical Systemcooiiiiiiii eee 5-63
5132Main battery switch i

BAB BBAIEIY CATE oie eee eee ees

5134Slip ring assembly (Optional @XIra)cooii iii 5-65
Heating/air-conditioning system –

5141 Recirculated and fresh air fIREersoooi iii 5-66
514 2HEATING SYSIEIM Leite eee 5-67
5143 Air-conditioning system5-67
Greasing the machine5-69

5151 Changes in the lubrication circuit

5152Centralised lubrication system for uppercarriage and attachment 5-70
5153Standard manual lubrication2
5154Semi-automatic greasing (optional @XIra)
5155Automatic greasing (Optional @XIra)

5156Greasing buckets / shovel tilting device —

5157Greasing the grab (optional @XIra)coi iii

QUICK-CRANGE SYSTEMS otic eect

5161 Greasing the mechanical quick-change adapter (optional extra)5-79
5162Hydraulic quick-change adapter (optional extra)
5163LIKUFIX (optional extra
5164Checking and maintenance of quick change coupler5-82
Drive unit brakes and swing gear brakescccoe5-83
General maintenance points5-83
5181 Replacing working parts5-83
5182Replacing the teeth on the bucket5-84
5183Welding work on the Machine ee 5-85