Liebherr R 9400 1257 1407 Hydraulic Excavator Operating Manual SN 26377 – 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:

The operating instructions allow the machine operator to familiarize themselves with the machine more easily and prevent malfunctions occurring due to improper operation. The observance of the operating and maintenance instructions by maintenance personnel:

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

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

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

Product description
1.1 Assembly – overview
1.1.1 Machine and construction equipment
1.2 Vibration emission
1.3 EC Declaration of Conformity
1.4 Chapter division
1.5 Page numbering

Safety instructions
2.1 General safety instructions
2.2 Safety instructions for the control cab
2.15 Maintenance safety instructions
2.5 Transport safety instructions

Control and operation
3.1 Operating and control elements
3.1.1 Overview of the control cab
3.1.2 Arrangement of joystick
3.1.3 Keyboard
3.1.4 Control board
3.1.5 Monitoring display
3.1.6 Joystick calibration
3.1.7 Monitoring cameras
3.2 Seat adjustment
3.2.2 Safety lever
3.2.3 Seat heating
3.2.4 Adjusting the auxiliary seat
3.2.5 Sunshade
3.2.6 Emergency exit
3.2.7 Interior lighting
3.2.8 Fire extinguisher
3.2.10 Field of view
3.2.11 Lighting equipment
3.2.12 Heating/air conditioning system
3.3 Starting and stopping the machine
3.3.2 Starting aids (optional)
3.3.3 Jump start procedure
3.3.4 Emergency operations
3.3.5 Board E52 for safety mode of Diesel engine and servo control
3.3.6 Driving
3.4 Working with the machine
3.4.1 Uppercarriage swing movements
3.4.2 Working position
3.4.3 Joystick functions when setting up the machine
3.4.4 Lowering the work equipment when the engine is not running
3.5 General working methods
3.5.1 Minimum impact working methods for your machine
3.5.2 Preparatory activities
3.5.3 Positioning of the machine
3.5.4 Working with the backhoe bucket
3.5.5 Working with the shovel bucket
3.6 Transport
3.6.1 Travelling procedures for mining machines
3.6.2 Excavator lifting and lashing operations

Malfunctions
4.1 Error code charts
4.1.1 General information
4.1.2 Regulating circuit
4.1.5 Coding error
4.1.6 Connection box pump transmitters
4.1.7 Joysticks
4.1.8 Error due to warning symbols in SY field
4.1.9 Heating/air conditioning system
4.2 Faults and remedies
4.2.1 Diesel engine and fuel system
4.2.2 Hydraulic system
4.2.3 Transmission
4.2.4 Electrical system
4.2.5 Heating/air-conditioning system
4.2.6 Work equipment
4.3 Fuses and relays
4.3.1 Power electrical box E1003
4.3.2 Cabin electrical box E1005
4.3.3 Heating/air-conditioning electrical box E1006

Maintenance
5.1 Servicing the machine safely
5.3 Approved anchor points
5.4 Lubricants and operating fluids
5.4.1 General information on changing lubricants and operating fluids
5.4.2 Lubricating chart
5.4.3 Service trap
5.4.4 Lubricant chart
5.4.5 Operating material chart
5.4.6 Service Trap 5-19
5.5 Lubricating and Operating Material Specifications 5-21
5.5.1 Lubricating Oil for the Diesel Engine 5-21
5.5.2 Fuel 5-21
5.5.3 Coolant 5-22
5.5.4 Hydraulic Oil Specifications for Liebherr Mining Excavators 5-22
5.5.5 Swing and Travel Gear Oils 5-28
5.5.6 Splitterbox Oil 5-30
5.5.7 Coupling Oil 5-30

5.6 Condition Monitoring with Oil Analysis 5-33
5.6.2 Oil Sampling 5-40

5.7 Diesel Engine 5-44
5.7.1 Diesel Engine 5-44
5.7.2 Diesel Engine Oil Change 5-45
5.7.4 Mounting Screws 5-48
5.7.5 Elastic Bedding 5-49

5.8 Splitterbox 5-50
5.8.1 Mounting Screws 5-50
5.8.2 Elastic Bedding 5-52
5.8.3 Air Filter 5-53

5.9 Coupling 5-54
5.9.1 Geislinger Coupling Wear Check 5-54

5.10 Cooling System 5-55
5.10.1 Checking and Cleaning the Cooling System 5-55
5.10.2 Checking the Coolant Level 5-55
5.10.3 Coolant Antifreeze and Anti-Corrosion Fluid 5-56
5.10.4 Changing the Coolant 5-56

5.11 Fuel System 5-58
5.11.2 Draining the Fuel Tank 5-59
5.11.3 Emptying and Cleaning 5-60
5.11.4 Fuel Filtering System 5-61

5.12 Compressed Air System 5-65
5.12.1 Pressure Regulator and Air Compressor 5-65
5.12.2 Air Dryer 5-66

5.13 Dry Air Filter 5-70
5.13.3 To Clean the Air Channels for the Precleaner 5-73
5.13.4 Check the Air Intake System, Hoses, Elbows, Clamps 5-73

5.14 Hydraulic System 5-74
5.14.1 Preparatory Activities 5-74
5.14.2 Checking the Oil Level in the Hydraulic Tank 5-75
5.14.3 Depressurising the Hydraulic System 5-75
5.14.4 Emptying and Refilling the Hydraulic Tank 5-76
5.14.5 Hydraulic Oil Coolers 5-78
5.14.6 Leak-Identification Lift-and-Look Filter 5-78
5.14.7 Oil Filters in PowerPack 5-80
5.14.8 High Pressure Filters on Valve Bank 5-81
5.14.9 Control Circuit 5-83
5.14.10 Hydraulic Distributor Block 5-84
5.14.11 Bleeding the Hydraulic Cylinders 5-86
5.14.12 Hydraulic Pumps Intake Hoses Removal 5-87
5-14-13 Replace the dust filter for the safety relief valves 5-88
5-14-14 Oil cooler protection filters (optional) 5-89
5-14-1177 Progressive criss-cross tightening procedure 5-94
5-15 Oil changes on components 5-95
5-15-2 Swing gears – oil change 5-96
5-15-3 Lifetime Travel gear – oil change 5-97
5-15-4 Swing gears and travel gears flushing 5-103
5-15-6 Splitterbox – oil change 5-105
5-15-7 Coupling – oil change 5-106
5-16 Hydraulic rotary connection (from SN 28066) 5-108
5-17 Track components 5-109
5-17-1 Track components mountings check 5-109
5-17-2 Check the track tension 5-111
5-17-3 Track link grease points 5-113
5-17-4 Cleaning the track components 5-116
5-18 Electrical system 5-116
5-18-1 Notes on the electrical system 5-116
5-18-2 Principal batteries switches and ECM connectors 5-117
5-18-3 Battery care 5-118
5-18-4 Electrical components location 5-119
5-18-5 Aeration devices 5-119
5-19 Heating/air conditioning 5-120
5-19-1 Heating system 5-121
5-19-2 Air-conditioning 5-122
5-19-3 Dual air-conditioning system (optional) 5-125
5-20 Maintenance chart 5-126
5-20-2 Swing ring mounting bolts 5-128
5-20-3 Travel gear mounting bolts 5-129
5-20-4 Hydraulic tank mounting bolts 5-130
5-20-5 PowerPack mounting bolts 5-131
5-20-6 Swing gears and swing motors mounting bolts 5-132
5-20-7 Hydraulic pumps mounting bolts 5-133
5-20-8 Side frames mounting bolts 5-134
5-20-9 Cabin elevation mounting bolts 5-135
5-20-10 Riser and boom assembly mounting bolts 5-136
5-23 Control and maintenance chart 5-138
5-23-1 General information 5-138
5-23-2 How to use the maintenance chart 5-139
5-23-3 Daily Maintenance Schedule – R 9400 5-140
5-23-4 250 Hours Maintenance Schedule – R 9400 5-146
5-23-5 500 Hours Maintenance Schedule – R 9400 5-153
5-23-6 1000 Hours Maintenance Schedule – R 9400 5-161
5-23-7 2000 Hours Maintenance Schedule – R 9400 5-169
6 Appendix 6-1
6-1 Visual check of the hydraulic hoses 6-1
6-1-1 Preface 6-1
6-1-2 General information 6-2
6-1-3 Components functions 6-4
6-1-4 Recommendations for hose assembly maintenance 6-5
6-2 Cleaning procedure for hydraulic circuits 6-9
6-2-1 Preface 6-9
6-2-2 General information about hydraulic oil contamination 6-9
6-2-3 General cleaning procedure
6 2 4 Working pumps circuit 6-11
6 2 5 Swing circuit 6-18
6 2 6 Cooling pumps circuit 6-22
6 2 7 T ravel motors circuit 6-32
6 2 10 Hydraulic tank
6 2 11 Restart the ma五h盂~· 6-50 6-49
6 2 12 Monitor the restarted machine
6.3 Centralized lubrication system 6-53