LIEBHERR A904C Litronic / A904C HD Litronic Hydraulic Excavator Operation & Maintenance Manual
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LHB/en/Edition: 07 / 2011
Document identification
ORIGINAL OPERATING MANUAL
Id. number: 11140229
Edition: 07 / 2011
Valid for: A 904 C Litronic / A 904 C HD Litronic from serial
number 57189
Author: LHB - Technical documentation department
Product identification
Manufacturer: LIEBHERR Hydraulikbagger GmbH
Type: A 904 C Litronic / A 904 C HD Litronic
Type no.: 1071 / 1004
Conformity: CE
Address
Liebherr Hydraulikbagger GmbH
Liebherr-Straße 12
D - 88457 Kirchdorf / Iller
en
Operating manual
Machine for Industrial Applications
A 904 C Litronic / A 904 C HD Litronic
from serial number 57189
Operating manual
A 904 C Litronic / A 904 C HD Litronic / 11140229
MJFCIFSS
LHB/en/Edition: 07 / 2011
Machine data
Please fill in the following data when you receive your machine.
This will also be helpful when ordering spare parts.
Vehicle Id. No.:
WLHZ . . . . . . . . . . . .
Year of manufacture:
. . . .
Delivery date:
. . / . . / . .
LHB/en/Edition: 07 / 2011
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A 904 C Litronic / A 904 C HD Litronic / 11140229
MJFCIFSS
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Introduction
This operating manual has been specifically devised for machine operators and
maintenance personnel. It contains important warnings, information and tips
regarding the maintenance and proper operation of the machine. It assists you in
becoming familiar with the functions and features of the machine and helps prevent
incorrect operation.
By strictly adhering to the instructions in the operating manual, you can significantly
enhance the reliability and service life of the machine.
The operating manual is an integral part of the scope of delivery of the
machine. Ensure that a copy is at all times available in the storage
compartment in the operator's cab.
Carefully read the operating manual before starting the machine and then regularly
read it again. All persons carrying out work on or with the machine must be fully
familiar with the content of the operating manual and must adhere to the instructions.
Such work include:
– Machine operation including tooling, troubleshooting during work, general care
and cleaning, disposal of fuels and lubricants.
– Maintenance including inspection, servicing and repair.
– Transport or loading of the machine.
The machine owner must ensure that this operating manual is complemented with
the relevant statutory regulations for accident prevention and the protection of the
environment. Apart from the instructions in this operating manual and the statutory
accident prevention, health and safety regulations applicable in the country of
operation, all personnel working on or with the machine must adhere to best practice
for safe and proper operation.
Certain sections in this manual might not apply to your specific model.
Some of the figures in this operating manual might show details or equipment that
differ from those in your machine.
Some of the figures show the equipment with guards or covers removed (for better
depiction).
As our products are constantly being improved, certain changes might be made to
the equipment which are not referred to specifically in this operating manual.
Should you require additional information or if you have any queries, please contact
the LIEBHERR customer service department.
Warranty and liability
Due to the range of products (e.g. fuels, lubricants, tool attachments, spare parts)
available from other manufacturers, LIEBHERR is not in a position to assess the
compatibility of these products with its own machines. This also applies in relation to
possible effects that third-party products have on LIEBHERR products and vice
versa.
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Operating manual
A 904 C Litronic / A 904 C HD Litronic / 11140229
LHB/en/Edition: 07 / 2011
MJFCIFSS
copyright by
It is therefore the responsibility of the machine owner to assess whether third-party
products can be safely used in conjunction with the LIEBHERR machine. LIEBHERR
shall not be liable for damage to or downtimes of LIEBHERR machine caused by the
use a third-party products. Such damage is not covered by the LIEBHERR warranty.
LIEBHERR shall not be liable for damage caused by improper operation, insufficient
maintenance or non-compliance with safety instructions.
Amendments, general terms and conditions, copyright
We reserve the right to modify our products and amend the instructions in this
operating manual without prior notice.
The reproduction or publication of the content of this operating manual (including
figures) is prohibited. LIEBHERR reserves all rights in this operating manual,
including copyright.
The warranty and liability clauses of the general business terms and conditions of
LIEBHERR apply.
Operating manual
A 904 C Litronic / A 904 C HD Litronic / 11140229
LHB/en/Edition: 07 / 2011
MJFCIFSS
copyright by
Table of contents
1 Product description ....................................................................................................................................... 1-1
1.1 Design and overview ............................................................................................................................. 1-1
1.1.1 General overview ..................................................................................................................... 1-1
1.1.2 Uppercarriage........................................................................................................................... 1-2
1.1.3 Undercarriage........................................................................................................................... 1-3
1.2 Vibration emissions................................................................................................................................ 1-4
1.3 Sound emission ..................................................................................................................................... 1-5
1.4 EC Declaration of Conformity ................................................................................................................ 1-6
1.5 Technical data ....................................................................................................................................... 1-7
2 Safety notes, signs ........................................................................................................................................ 2-1
2.1 Symbols used in this operating manual ................................................................................................. 2-1
2.2 Proper use ............................................................................................................................................. 2-2
2.3 Safety instructions ................................................................................................................................. 2-2
2.3.1 General safety instructions ....................................................................................................... 2-2
2.3.2 Crushing and burn prevention .................................................................................................. 2-3
2.3.3 Fire and explosion prevention .................................................................................................. 2-4
2.4 Signs on the machine ............................................................................................................................ 2-4
2.4.1 Safety and information signs .................................................................................................... 2-4
2.4.2 ID tag ...................................................................................................................................... 2-12
3 Control, operation .......................................................................................................................................... 3-1
3.1 Operating and control elements............................................................................................................. 3-1
3.1.1 Overview of operator's platform................................................................................................ 3-1
3.1.2 Keypad ..................................................................................................................................... 3-3
3.1.3 Monitoring screen ..................................................................................................................... 3-7
3.1.4 Main screen ............................................................................................................................ 3-10
3.1.5 Information symbols on the main screen................................................................................ 3-11
3.1.6 Operator's menu ..................................................................................................................... 3-13
3.2 Control ................................................................................................................................................. 3-29
3.2.1 Entering and exiting the operator's cab .................................................................................. 3-29
3.2.2 Adjusting vertical position of the operator's cab (optional equipment) ................................... 3-31
3.2.3 Emergency lowering of the operator's cab ............................................................................. 3-33
3.2.4 Safety lever ............................................................................................................................ 3-34
3.2.5 Operator seat ......................................................................................................................... 3-35
3.2.6 Adjusting the steering column ................................................................................................ 3-38
3.2.7 Windscreen ............................................................................................................................ 3-39
3.2.8 Sun blind ................................................................................................................................ 3-40
3.2.9 Emergency exit through rear window ..................................................................................... 3-41
3.2.10 Inside lighting ......................................................................................................................... 3-41
3.2.11 Fire extinguisher (optional equipment)* .................................................................................. 3-42
3.2.12 Windshield wiper .................................................................................................................... 3-42
3.2.13 Lighting ................................................................................................................................... 3-44
3.2.14 Radio mute mode (optional equipment) ................................................................................. 3-45
3.2.15 Heating and air-conditioning system ...................................................................................... 3-45
3.3 Operation ............................................................................................................................................. 3-51
3.3.1 Safety instructions .................................................................................................................. 3-51
3.3.2 Starting machine .................................................................................................................... 3-52
3.3.3 Switching off the diesel engine ............................................................................................... 3-58
3.3.4 Starting aids ........................................................................................................................... 3-58
3.3.5 Jump start procedure ............................................................................................................. 3-61
3.3.6 Travelling operation ................................................................................................................ 3-62
3.3.7 Travel warning device (option) ............................................................................................... 3-64
3.3.8 Drive deactivation (optional extra) .......................................................................................... 3-64
Operating manual
A 904 C Litronic / A 904 C HD Litronic / 11140229
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3.3.9 Oscillating axle locking device ................................................................................................ 3-65
3.3.10 Operation of support system .................................................................................................. 3-66
3.3.11 Operation of dozer blade (optional equipment) ...................................................................... 3-68
3.4 Working with the machine .................................................................................................................... 3-68
3.4.1 Safety Instructions .................................................................................................................. 3-68
3.4.2 Sensor controlled low idle automatic ...................................................................................... 3-72
3.4.3 Working position ..................................................................................................................... 3-73
3.4.4 Operating working attachment ................................................................................................ 3-74
3.4.5 Swivelling the uppercarriage .................................................................................................. 3-75
3.4.6 Halting the uppercarriage ....................................................................................................... 3-76
3.4.7 Lowering the working attachment when diesel engine is shut off ........................................... 3-77
3.4.8 Grab control ............................................................................................................................ 3-77
3.4.9 Electronic stick cylinder shut-down function (optional equipment) ......................................... 3-78
3.4.10 Mechanical stick cylinder shut-down function ......................................................................... 3-80
3.4.11 Adjustment of attachment tool ................................................................................................ 3-83
3.4.12 Operating the attachment tool (by pedals, push buttons) ....................................................... 3-83
3.4.13 Changeover of control (optional equipment) .......................................................................... 3-86
3.4.14 Operating attachment tool (mini joystick control, optional equipment) ................................... 3-86
3.4.15 Changeover of joystick control (optional equipment) .............................................................. 3-89
3.4.16 Magnetic system (option) ....................................................................................................... 3-89
3.5 Installation and removal of attachment parts ....................................................................................... 3-90
3.5.1 Safety Instructions .................................................................................................................. 3-90
3.5.2 Installation and removal of digging tool .................................................................................. 3-92
3.5.3 Attachment of grapple to bucket stick ..................................................................................... 3-94
3.5.4 Attachment of grapple to industrial stick ................................................................................. 3-97
3.5.5 Multi-coupling system (optional equipment) ........................................................................... 3-99
3.5.6 Industrial stick with mechanical quick-change adapter (optional equipment) ....................... 3-102
3.5.7 Industrial stick with hydraulic quick-change adapter (optional equipment) ........................... 3-106
3.5.8 LIKUFIX MH 40 quick-coupling system (optional equipment) .............................................. 3-112
3.5.9 Hydraulic quick-change adapter (optional equipment) ......................................................... 3-117
3.5.10 Hydraulic quick-change adapter with LIKUFIX (optional equipment) ................................... 3-123
3.5.11 Mechanical quick-change adapter (optional equipment) ...................................................... 3-124
3.6 General working methods .................................................................................................................. 3-128
3.6.1 Tips for the proper operation of the machine preventing damage and wear ........................ 3-128
3.6.2 Preparation ........................................................................................................................... 3-130
3.6.3 Working with grapples .......................................................................................................... 3-131
3.6.4 Excavating and moving material with grapples..................................................................... 3-131
3.6.5 Loading operation ................................................................................................................. 3-132
3.6.6 Load lifting operation ............................................................................................................ 3-133
3.6.7 Use of quick-change adapter for load lifting operation ......................................................... 3-134
3.6.8 Overload warning system (optional equipment) ................................................................... 3-135
3.7 Parking and exiting machine .............................................................................................................. 3-137
3.8 Transport............................................................................................................................................ 3-137
3.8.1 Safety instructions ................................................................................................................ 3-137
3.8.2 Transportation on low-loader ................................................................................................ 3-138
3.8.3 Loading with crane ............................................................................................................... 3-139
4 Malfunctions ................................................................................................................................................... 4-1
4.1 Error code list ......................................................................................................................................... 4-1
4.2 Faults and remedies .............................................................................................................................. 4-8
4.2.1 Diesel engine and fuel system.................................................................................................. 4-8
4.2.2 Hydraulic system .................................................................................................................... 4-10
4.2.3 Travelling ................................................................................................................................ 4-11
4.2.4 Brakes .................................................................................................................................... 4-12
4.2.5 Electrical system..................................................................................................................... 4-12
4.2.6 Heating and air conditioning system....................................................................................... 4-13
4.2.7 Working attachment ................................................................................................................ 4-13
4.3 Fuses and relays.................................................................................................................................. 4-13
Operating manual
A 904 C Litronic / A 904 C HD Litronic / 11140229
LHB/en/Edition: 07 / 2011
MJFCIFSS
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4.3.1 Fuse box E50 ......................................................................................................................... 4-14
4.3.2 ESP02 printed circuit board.................................................................................................... 4-15
4.4 Emergency operation........................................................................................................................... 4-16
4.4.1 Purpose .................................................................................................................................. 4-16
4.4.2 Identifying solenoid valve ....................................................................................................... 4-17
4.4.3 Emergency mode control ....................................................................................................... 4-17
4.4.4 Emergency operation of hydraulic pump ................................................................................ 4-20
4.4.5 Emergency operation of electric stick cylinder shut-down function ........................................ 4-21
4.4.6 Emergency gear shifting......................................................................................................... 4-21
4.4.7 Towing the machine ............................................................................................................... 4-22
4.4.8 Disengaging transmission (emergency release) .................................................................... 4-23
5 Maintenance ................................................................................................................................................... 5-1
5.1 Safety instructions ................................................................................................................................. 5-1
5.1.1 General safety instructions ....................................................................................................... 5-1
5.1.2 Checking for cracks .................................................................................................................. 5-1
5.1.3 Welding .................................................................................................................................... 5-2
5.1.4 Fuels, lubricants and process chemicals .................................................................................. 5-2
5.1.5 Repair ....................................................................................................................................... 5-2
5.1.6 Electrical system ...................................................................................................................... 5-3
5.1.7 Pressure accumulator .............................................................................................................. 5-3
5.1.8 Hydraulic hoses and lines ........................................................................................................ 5-4
5.1.9 Cab protection (FOPS) ............................................................................................................. 5-5
5.2 Maintenance access doors .................................................................................................................... 5-5
5.2.1 Overview of access doors ........................................................................................................ 5-5
5.2.2 Door locking mechanism .......................................................................................................... 5-6
5.2.3 Engine hood locking mechanism.............................................................................................. 5-7
5.3 Cleaning machine .................................................................................................................................. 5-7
5.4 Care for rubber components .................................................................................................................. 5-8
5.5 Tyres ...................................................................................................................................................... 5-8
5.5.1 Checking tyre pressure ............................................................................................................ 5-8
5.5.2 Foam tyres ............................................................................................................................. 5-10
5.5.3 Checking wheel lugs for proper fit .......................................................................................... 5-10
5.6 Fuels, lubricants and process chemicals ............................................................................................. 5-10
5.6.1 General information ................................................................................................................ 5-10
5.6.2 Filling volumes, lubricating chart ............................................................................................ 5-11
5.7 Specifications for fuels, lubricants and process chemicals .................................................................. 5-15
5.7.1 Diesel fuels ............................................................................................................................. 5-15
5.7.2 Lubricating oil for the diesel engine ........................................................................................ 5-16
5.7.3 Coolants for diesel engine ...................................................................................................... 5-18
5.7.4 Hydraulic oil ............................................................................................................................ 5-21
5.7.5 Lubricants for axles and gearboxes ....................................................................................... 5-27
5.7.6 Lubricating oil for transmission ............................................................................................... 5-28
5.7.7 Grease.................................................................................................................................... 5-29
5.7.8 Lubricants and care products for electrical and mechanical components .............................. 5-29
5.8 Diesel engine ....................................................................................................................................... 5-30
5.8.1 Checking the oil level in the diesel engine ............................................................................. 5-30
5.8.2 Changing the diesel engine oil ............................................................................................... 5-30
5.8.3 Ribbed V-belt for A/C compressor and alternator installation................................................. 5-32
5.8.4 Crankcase bleeding point ....................................................................................................... 5-32
5.8.5 Grease the starter tooth ring .................................................................................................. 5-33
5.9 Cooling system .................................................................................................................................... 5-34
5.9.1 Checking and cleaning the cooling system ............................................................................ 5-34
5.9.2 Checking the coolant level ..................................................................................................... 5-34
5.9.3 Changing the coolant ............................................................................................................. 5-35
5.9.4 Checking coolant, adjusting mixing ratio ................................................................................ 5-37
5.10 Fuel system ......................................................................................................................................... 5-41
5.10.1 Refuelling ............................................................................................................................... 5-41
Operating manual
A 904 C Litronic / A 904 C HD Litronic / 11140229
LHB/en/Edition: 07 / 2011
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5.10.2 Dewatering fuel tank ............................................................................................................... 5-42
5.10.3 Emptying and cleaning fuel tank ............................................................................................. 5-43
5.10.4 Maintenance of fuel filter ........................................................................................................ 5-44
5.10.5 Bleeding fuel system .............................................................................................................. 5-46
5.11 Dry air filter........................................................................................................................................... 5-48
5.11.1 Changing the main element .................................................................................................... 5-49
5.11.2 Changing the safety element .................................................................................................. 5-50
5.11.3 Checking the filtered air line ................................................................................................... 5-50
5.12 Hydraulic system.................................................................................................................................. 5-51
5.12.1 Preparations ........................................................................................................................... 5-51
5.12.2 Checking the oil level in the hydraulic tank ............................................................................. 5-51
5.12.3 Depressurizing the hydraulic system ...................................................................................... 5-52
5.12.4 Replacing the breather filter ................................................................................................... 5-53
5.12.5 Emptying and refilling the hydraulic tank ................................................................................ 5-53
5.12.6 Return filter ............................................................................................................................. 5-54
5.12.7 Control oil filter ........................................................................................................................ 5-55
5.12.8 Control circuit .......................................................................................................................... 5-56
5.12.9 Bleeding the hydraulic pump .................................................................................................. 5-56
5.12.10 Bypass oil filter (optional equipment)...................................................................................... 5-57
5.12.11 Maintenance of hydraulic cylinders ........................................................................................ 5-58
5.12.12 Replacing hydraulic hoses ...................................................................................................... 5-59
5.13 Changing the oil on components ......................................................................................................... 5-59
5.13.1 General notes ......................................................................................................................... 5-59
5.13.2 Swin gear - oil change ............................................................................................................ 5-60
5.13.3 Transmission – oil change ...................................................................................................... 5-61
5.13.4 Steering and rigid axle - oil change ........................................................................................ 5-61
5.13.5 Wheel head – oil change ........................................................................................................ 5-62
5.13.6 Pump distributor gear - oil change .......................................................................................... 5-63
5.14 Checking brake pads for wear ............................................................................................................. 5-63
5.15 Electrical system .................................................................................................................................. 5-64
5.15.1 Notes regarding the electrical system .................................................................................... 5-64
5.15.2 Battery main switch ................................................................................................................ 5-64
5.15.3 Battery care ............................................................................................................................ 5-65
5.15.4 Slip ring body (optional equipment) ........................................................................................ 5-66
5.16 Heating and air-conditioning system.................................................................................................... 5-67
5.16.1 Recirculated and ambient air filter .......................................................................................... 5-67
5.16.2 Heating system ....................................................................................................................... 5-68
5.16.3 air-conditioning system ........................................................................................................... 5-68
5.17 Automatic lubrication of the machine ................................................................................................... 5-69
5.17.1 Semi-automatic central greasing system................................................................................ 5-69
5.17.2 Fully automatic central greasing system (optional extra)........................................................ 5-71
5.18 Manual lubrication of the machine ....................................................................................................... 5-73
5.18.1 Steering axle ........................................................................................................................... 5-73
5.18.2 Central lubrication system of steering axle (optional equipment) ........................................... 5-74
5.18.3 Digging buckets / bucket tilting device .................................................................................... 5-74
5.18.4 Attachments (optional equipment) .......................................................................................... 5-75
5.18.5 Industrial stick with mechanical quick-change adapter ........................................................... 5-76
5.18.6 Industrial stick with hydraulic quick-change adapter............................................................... 5-76
5.18.7 LIKUFIX MH 40 quick-coupling system .................................................................................. 5-77
5.18.8 Hydraulic quick change adapter ............................................................................................. 5-77
5.18.9 Mechanical quick-change adapter .......................................................................................... 5-78
5.19 Couplings of the quick-change adapter systems (optional equipment) ............................................... 5-79
5.19.1 Hydraulic coupling .................................................................................................................. 5-79
5.19.2 LIKUFIX electric coupling ....................................................................................................... 5-80
5.20 Parking and swing gear brake ............................................................................................................. 5-81
5.21 General maintenance tasks ................................................................................................................. 5-81
5.21.1 Replacing wear parts .............................................................................................................. 5-81
5.21.2 Replacing teeth on digging tool .............................................................................................. 5-81
Operating manual
A 904 C Litronic / A 904 C HD Litronic / 11140229
LHB/en/Edition: 07 / 2011
MJFCIFSS
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5.21.3 Welded parts on the machine................................................................................................. 5-83
5.22 Maintenance and inspection schedule................................................................................................. 5-84
Operating manual
A 904 C Litronic / A 904 C HD Litronic / 11140229
LHB/en/Edition: 07 / 2011
MJFCIFSS
copyright by
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This is a complete Operation & Maintenance Manual for the LIEBHERR A904C Litronic / A904C HD Litronic HYDRAULIC EXCAVATOR.
From serial number 57189.
This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical, and safe machine operation and maintenance.
Contents as follows:
- PRODUCT DESCRIPTION
- SAFETY NOTES, SIGNS
- CONTROL, OPERATION
- MALFUNCTIONS
- MAINTENANCE
Model Specification: LIEBHERR A904C Litronic / A904C HD Litronic HYDRAULIC EXCAVATOR
Language: English
Total Pages: 314
File Format: .PDF
Requirements: Adobe Reader
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