LFR/en/Edition: 5 / 2006
Document identification
Order number: 10024216
Edition: 5 / 2006
Valid for: R 924B Litronic from serial number 10343
Author: LFR - Technical documentation department
Product identification
Manufacturer: LIEBHERR France SAS
Type: R 924B Litronic
Type no.: 761 / 967 / 968 / 969
Conformity: CE
Address
Liebherr France SAS
2 avenue Joseph Rey
B.P. 90287 F - 68005 Colmar Cedex
en
Operating instructions
Hydraulic excavator / Material handler
R 924B Litronic
from serial number 10343
1 - 2
Operating instructions
R 924B Litronic / 10024216
MJFCIFSS
LFR/en/Edition: 5 / 2006
Machine data
Please fill in the following data when you receive your machine.
This will also be of use to you when ordering replacement parts.
Vehicle ident. number:
WLHZ . . . . . ZK . . . . . .
Construction year:
. . . .
First start-up date:
. . / . . / . .
Operating instructions
R 924 B Li. Compact / 10286595
MJFCIFSS
LFR/en/edition: 05 / 2006
Preface
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 per-
sonnel:
– 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 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 which differ to your machine.
– In some illustrations, protective devices and covers have been removed in the in-
terests of better presentation.
– Improvements, which are always being incorporated into our machines, may re-
sult in changes to your machine which are not yet indicated in these operating in-
structions.
However, should you require any further explanations or information, LIEBHERR's
technical documentation, sales school and customer service departments are avail-
Operating instructions
R 924 B Li. Compact / 10286595
MJFCIFSS
LFR/en/edition: 05 / 2006
able 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 deal-
erships, such as guarantee commitments, service contracts etc. without prior notice
in the event that replacement parts other than original LIEBHERR parts or parts pur-
chased from LIEBHERR are used for maintenance or repair work.
Modifications, conditions, copyright
We reserve the right to make modifications without prior notice in the course of tech-
nical developments.
The information and illustrations contained in these operating instructions may nei-
ther be copied and distributed, nor used for the purposes of competition. All rights
are expressly reserved in accordance with copyright laws.
The warranty and liability conditions of LIEBHERR’s general business conditions will
not be enlarged upon through the above information.
Operating instructions
R 924B Litronic / 10024216
MJFCIFSS
LFR/en/Edition: 5 / 2006
Content
1 Product description ....................................................................................................................................... 1-1
1.1 Assembly - overview .............................................................................................................................. 1-1
1.1.1 Machine with backhoe attachment .............................................................................................. 1-1
1.1.2 Uppercarriage .............................................................................................................................. 1-2
1.1.3 Undercarriage .............................................................................................................................. 1-3
1.2 Technical data ....................................................................................................................................... 1-3
2 Safety information, signs .............................................................................................................................. 2-1
2.1 Symbols in the operating instructions .................................................................................................... 2-1
2.2 Use in accordance with the regulations ................................................................................................. 2-2
2.3 Safety instructions ................................................................................................................................. 2-2
2.3.1 General safety instructions .......................................................................................................... 2-2
2.3.2 Avoidance of crushing and burns ................................................................................................ 2-3
2.3.3 Avoidance of fire and explosions ................................................................................................. 2-4
2.4 Signs on the machine ............................................................................................................................ 2-5
2.4.1 Introduction .................................................................................................................................. 2-5
2.4.2 Arrangement of signage .............................................................................................................. 2-6
2.4.3 Explanation of signage ................................................................................................................ 2-7
2.4.4 Nameplates on the machine ...................................................................................................... 2-11
3 Control and operation ................................................................................................................................... 3-1
3.1 Operating and control elements............................................................................................................. 3-1
3.1.1 Overview of the operator’s standing position............................................................................... 3-1
3.1.2 Arrangement of joystick ............................................................................................................... 3-3
3.1.3 Keypad ........................................................................................................................................ 3-4
3.1.4 Monitoring display........................................................................................................................ 3-8
3.1.5 Main screen ............................................................................................................................... 3-11
3.2 Access and equipment of the cab........................................................................................................ 3-27
3.2.1 Safely getting up........................................................................................................................ 3-27
3.2.2 Safely getting down. .................................................................................................................. 3-28
3.2.3 Entering or leaving the cab ........................................................................................................ 3-29
3.2.4 Height adjustable cab (optional extra) ....................................................................................... 3-31
3.2.5 Safety lever................................................................................................................................ 3-33
3.2.6 Operator’s seat .......................................................................................................................... 3-34
3.2.7 Windscreen................................................................................................................................ 3-38
3.2.8 Sun visor.................................................................................................................................... 3-38
3.2.9 Sun visor on left door glass (optional extra) .............................................................................. 3-38
3.2.10Interior lighting - Safety hammer ............................................................................................... 3-39
3.2.11Fire extinguisher*....................................................................................................................... 3-39
3.2.12Windscreen wiper ...................................................................................................................... 3-40
3.2.13Lighting ...................................................................................................................................... 3-42
3.2.14Heater and air conditioner ......................................................................................................... 3-43
3.3 Operation ............................................................................................................................................. 3-47
3.3.1 Safety instructions ..................................................................................................................... 3-47
3.3.2 Stopping the machine safely ..................................................................................................... 3-48
3.3.3 Starting / stopping the machine ................................................................................................. 3-48
3.3.4 Delay engine cut-out 5 min. (option).......................................................................................... 3-54
3.3.5 indicatorStarting aids ................................................................................................................. 3-56
3.3.6 Jump start procedure................................................................................................................. 3-58
3.3.7 Emergency operations............................................................................................................... 3-58
3.3.8 Driving ....................................................................................................................................... 3-61
3.3.9 Drive warning device (optional extra) ........................................................................................ 3-64
3.3.10Towing the machine .................................................................................................................. 3-64
3.4 Working with the machine.................................................................................................................... 3-65
Operating instructions
R 924B Litronic / 10024216
MJFCIFSS
LFR/en/Edition: 5 / 2006
3.4.1 Safely getting up or down. ......................................................................................................... 3-65
3.4.2 Working safely with the machine ............................................................................................... 3-66
3.4.3 Low idle automatic ..................................................................................................................... 3-70
3.4.4 Operating the swing gear........................................................................................................... 3-71
3.4.5 Working position ........................................................................................................................ 3-74
3.4.6 Joystick functions when setting up the machine ........................................................................ 3-74
3.4.7 Lowering the work equipment when the engine is not running .................................................. 3-76
3.4.8 Turning, rotating, bolting and unbolting the add-on unit ............................................................ 3-77
3.4.9 Add-on kits AHS 1, AHS 11 and AHS 12 (optional extra).......................................................... 3-78
3.4.10Add-on kits Tool Control AHS 1, AHS 11 and AHS 12 (optional extra) ..................................... 3-81
3.4.11Foot pedals travel control with add on kits AHS (optional extra) ............................................... 3-83
3.4.12Adjust boom to side ................................................................................................................... 3-84
3.4.13Adjust boom to side (Tool Control) ............................................................................................ 3-86
3.4.14Priority commutation with add-on kit AHS 12 (optional) ............................................................ 3-89
3.4.15Transferring controls (optional extra) ......................................................................................... 3-91
3.4.16Transferring controls PCSA - LH (optional extra) ...................................................................... 3-92
3.4.17Transferring controls PCSA - J.Deere (optional extra) .............................................................. 3-93
3.4.18Transferring AHS controls (optional extra) ................................................................................ 3-94
3.4.19Special control (option) .............................................................................................................. 3-95
3.4.20Mechanical stanchion cylinder shut-down (option) .................................................................... 3-95
3.4.21Overload warning device ........................................................................................................... 3-98
3.4.22Overload warning device ........................................................................................................... 3-99
3.5 Attaching and dismounting equipment parts ...................................................................................... 3-104
3.5.1 Attaching and removing equipment parts safely ...................................................................... 3-104
3.5.2 Removing and installing equipment bolts safely ...................................................................... 3-104
3.5.3 Attaching and dismounting the bucket ..................................................................................... 3-105
3.5.4 Attaching and dismounting the bucket with improved sealing ................................................. 3-107
3.5.5 Attaching and dismounting the grab on stick ........................................................................... 3-110
3.5.6 Attaching and dismounting the grab on stick ........................................................................... 3-113
3.5.7 Attaching and dismounting the grab on the industrial stanchion ............................................. 3-115
3.5.8 Attaching and dismounting the stick to the boom .................................................................... 3-118
3.5.9 Mechanical quick-change adapter (optional extra) .................................................................. 3-120
3.5.10Hydraulic quick-change adapter (optional extra) ..................................................................... 3-125
3.5.11LIKUFIX – hydraulic coupling system (optional extra) ............................................................. 3-131
3.6 General working methods .................................................................................................................. 3-134
3.6.1 Minimum impact working methods for your machine............................................................... 3-134
3.6.2 Preparatory activities ............................................................................................................... 3-134
3.6.3 Working with the backhoe bucket ............................................................................................ 3-135
3.6.4 Loading the transport vehicle................................................................................................... 3-137
3.6.5 Working with the clamshell bucket (construction equipment) .................................................. 3-138
3.6.6 Hoisting work ........................................................................................................................... 3-140
3.6.7 Working with the hydraulic hammer......................................................................................... 3-140
3.6.8 Working with the grapple (industrial equipment)...................................................................... 3-142
3.6.9 Skimming ................................................................................................................................. 3-143
3.7 Transport............................................................................................................................................ 3-144
3.7.1 Transporting the machine safely.............................................................................................. 3-144
3.7.2 Transporting the machine on a low loader............................................................................... 3-145
3.7.3 Loading the machine with a crane ........................................................................................... 3-147
4 Malfunctions ................................................................................................................................................... 4-1
4.1 Error code charts ................................................................................................................................... 4-2
4.1.1 Sensors........................................................................................................................................ 4-2
4.1.2 Regulating circuit ......................................................................................................................... 4-3
4.1.3 Stanchion cylinder shut-down (only for machines which handle material or for machines with op-
tional extras)4-3
4.1.4 Keypad......................................................................................................................................... 4-3
4.1.5 Display ......................................................................................................................................... 4-4
4.1.6 Coding error ................................................................................................................................. 4-4
Operating instructions
R 924B Litronic / 10024216
MJFCIFSS
LFR/en/Edition: 5 / 2006
4.1.7 Other errors ................................................................................................................................. 4-5
4.1.8 Error due to warning symbols in SY field..................................................................................... 4-5
4.2 Faults and remedies .............................................................................................................................. 4-6
4.2.1 Diesel engine and fuel system..................................................................................................... 4-6
4.2.2 Hydraulic system ......................................................................................................................... 4-7
4.2.3 Transmission ............................................................................................................................... 4-8
4.2.4 Electrical system.......................................................................................................................... 4-8
4.2.5 Heating/air-conditioning system .................................................................................................. 4-9
4.2.6 Work equipment .......................................................................................................................... 4-9
4.3 Fuses and relays ................................................................................................................................... 4-9
4.3.1 Fuse box E50 .............................................................................................................................. 4-9
4.3.2 ESP02 board ............................................................................................................................. 4-11
4.3.3 A1001 board .............................................................................................................................. 4-13
5 Maintenance ................................................................................................................................................... 5-1
5.1 Servicing the machine safely ................................................................................................................. 5-1
5.1.1 General safety instructions .......................................................................................................... 5-1
5.1.2 Cleaning ...................................................................................................................................... 5-1
5.1.3 Crack testing................................................................................................................................ 5-2
5.1.4 Welding, drilling, firing and grinding work .................................................................................... 5-3
5.1.5 Process materials ........................................................................................................................ 5-3
5.1.6 Repair work ................................................................................................................................. 5-3
5.1.7 Electrical system.......................................................................................................................... 5-4
5.1.8 Hydraulic accumulator ................................................................................................................. 5-5
5.1.9 Hydraulic hoses and sheathed cables......................................................................................... 5-5
5.2 Maintenance access doors .................................................................................................................... 5-6
5.2.1 Overview of access doors ........................................................................................................... 5-6
5.2.2 Door lock ..................................................................................................................................... 5-7
5.2.3 Engine hood lock ......................................................................................................................... 5-8
5.3 Lubricating and operating materials....................................................................................................... 5-8
5.3.1 General information on changing lubricating and operating materials ........................................ 5-8
5.3.2 Lubrication chart ........................................................................................................................ 5-10
5.3.3 Lubricant chart ........................................................................................................................... 5-11
5.3.4 Operating material chart ............................................................................................................ 5-12
5.4 Lubricating and operating material specifications ................................................................................ 5-12
5.4.1 Lubrication oil for the diesel engine ........................................................................................... 5-12
5.4.2 Fuel............................................................................................................................................ 5-13
5.4.3 Transmission oil......................................................................................................................... 5-18
5.4.4 Lubricating grease and other lubricants .................................................................................... 5-18
5.4.5 Coolant ...................................................................................................................................... 5-18
5.5 Diesel engine ....................................................................................................................................... 5-25
5.5.1 Checking the oil level in the diesel engine................................................................................. 5-25
5.5.2 Changing the diesel engine oil .................................................................................................. 5-25
5.5.3 Ribbed V-belt for the A/C compressor and alternator installation.............................................. 5-26
5.5.4 Oil separator .............................................................................................................................. 5-27
5.6 Cooling system .................................................................................................................................... 5-28
5.6.1 Checking and cleaning the cooling system ............................................................................... 5-28
5.6.2 Checking the coolant level ......................................................................................................... 5-29
5.6.3 Coolant antifreeze and anti-corrosion fluid ................................................................................ 5-29
5.6.4 Changing water filters ................................................................................................................ 5-29
5.6.5 Changing the coolant................................................................................................................. 5-30
5.6.6 Reversible fan drive (option)...................................................................................................... 5-33
5.7 Fuel system ......................................................................................................................................... 5-34
5.7.1 Refuelling................................................................................................................................... 5-34
5.7.2 Electrical refuelling pump (optional extra) ................................................................................. 5-35
5.7.3 Draining the fuel tank................................................................................................................. 5-36
5.7.4 Emptying and cleaning the fuel tank.......................................................................................... 5-36
5.7.5 Draining and changing fuel filter cartridges ............................................................................... 5-37
Operating instructions
R 924B Litronic / 10024216
MJFCIFSS
LFR/en/Edition: 5 / 2006
5.7.6 Venting the fuel system ............................................................................................................. 5-38
5.8 Dry air filter........................................................................................................................................... 5-39
5.8.1 Changing the main element ....................................................................................................... 5-39
5.8.2 Changing the safety element ..................................................................................................... 5-40
5.8.3 Monitoring the filtered air line..................................................................................................... 5-41
5.9 Hydraulic system.................................................................................................................................. 5-41
5.9.1 Preparatory activities ................................................................................................................. 5-42
5.9.2 Checking the oil level in the hydraulic tank ................................................................................ 5-42
5.9.3 Depressurizing the hydraulic system ......................................................................................... 5-43
5.9.4 Emptying and refilling the hydraulic tank ................................................................................... 5-44
5.9.5 Return-line filter ......................................................................................................................... 5-45
5.9.6 Control oil filter ........................................................................................................................... 5-46
5.9.7 Control circuit ............................................................................................................................. 5-47
5.9.8 Bleeding the hydraulic pump ..................................................................................................... 5-47
5.9.9 Bleeding the hydraulic cylinders ................................................................................................ 5-47
5.9.10Bleeding the hydraulic cylinders ................................................................................................ 5-48
5.9.11Bypass oil filter for hydraulic circuit (option) .............................................................................. 5-50
5.9.12Return oil filter for hydraulic hammer (option)............................................................................ 5-51
5.9.13Servicing the hydraulic cylinder ................................................................................................. 5-53
5.9.14Replacing hydraulic hoses ......................................................................................................... 5-54
5.10 Oil changes on components ................................................................................................................ 5-55
5.10.1General information ................................................................................................................... 5-55
5.10.2Slewing gear transmission – oil change .................................................................................... 5-56
5.10.3Travelling gear - changing the oil............................................................................................... 5-57
5.11 Running gear ....................................................................................................................................... 5-57
5.11.1Checking the running gear component mountings .................................................................... 5-58
5.11.2Monitoring the crawler tension ................................................................................................... 5-58
5.11.3Retensioning the crawler ........................................................................................................... 5-59
5.11.4Releasing the crawler tension.................................................................................................... 5-59
5.11.5Cleaning the running gear ......................................................................................................... 5-60
5.12 Electrical system .................................................................................................................................. 5-60
5.12.1Notes on the electrical system................................................................................................... 5-60
5.12.2Main battery switch .................................................................................................................... 5-61
5.12.3Battery care ............................................................................................................................... 5-62
5.12.4Slip ring assembly (optional extra)............................................................................................. 5-63
5.13 Heating/air-conditioning system........................................................................................................... 5-63
5.13.1Recirculated and fresh air filters ................................................................................................ 5-64
5.13.2Heating system .......................................................................................................................... 5-65
5.13.3Air-conditioning system.............................................................................................................. 5-65
5.14 Greasing the machine .......................................................................................................................... 5-67
5.14.1Changes in the lubrication circuit ............................................................................................... 5-67
5.14.2Centralised lubrication system for uppercarriage and attachment............................................. 5-68
5.14.3Standard manual lubrication ...................................................................................................... 5-70
5.14.4Semi-automatic greasing (optional extra) .................................................................................. 5-72
5.14.5Automatic greasing (optional extra) ........................................................................................... 5-74
5.14.6Greasing buckets / shovel tilting device..................................................................................... 5-75
5.14.7Greasing the grab (optional extra) ............................................................................................. 5-76
5.15 Quick-change systems......................................................................................................................... 5-77
5.15.1Greasing the mechanical quick-change adapter (optional extra) .............................................. 5-77
5.15.2Hydraulic quick-change adapter (optional extra) ....................................................................... 5-77
5.15.3LIKUFIX (optional extra) ............................................................................................................ 5-79
5.15.4Checking and maintenance of quick change coupler ................................................................ 5-80
5.16 Drive unit brakes and swing gear brakes ............................................................................................. 5-81
5.17 General maintenance points ................................................................................................................ 5-81
5.17.1Replacing working parts ............................................................................................................ 5-81
5.17.2Replacing the teeth on the bucket ............................................................................................. 5-82
5.17.3Welding work on the machine.................................................................................................... 5-83
5.18 Control and maintenance chart ............................................................................................................ 5-84
LFR/en/Edition: 5 / 2006
1 Product description
1.1 Assembly - overview
This section comprises an overview of the machine and descriptions of the compo-
nents shown.
1.1.1 Machine with backhoe attachment
Fig. 1-1 Machine with backhoe attachment
100 Uppercarriage 310 Boom cylinder 330 Bucket
200 Undercarriage 320 Stiel 340 Bucket cylinder
300 Boom 320 Stiel cylinder
Product description
1 - 2
Operating instructions
Assembly - overview
R 924B Litronic / 10024216
MJFCIFSS
LFR/en/Edition: 5 / 2006
1.1.2 Uppercarriage
Fig. 1-2 Uppercarriage
500 Diesel engine 6220 Control panel, left
530 Dry air filter 6230 Control panel, right
560 Radiator 7100 Hydraulic oil and fuel tank
700 Swing gear 7300 Hydraulic pump
1000 Rotary connection 7600 Control valve block
6000 Control cab 8700 Cab
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Liebherr R924b Litronic Hydraulic Excavator Complete Workshop Service Repair Manual
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Description
Thank you for considering this comprehensive Service Repair Workshop Manual for the Liebherr R924b Litronic Hydraulic Excavator.
This manual is an invaluable resource covering every Service & Repair Procedure, designed to save you significant costs by enabling you to perform your own repairs. It provides easy-to-follow, step-by-step instructions and detailed illustrations for all servicing and repairs, making any job manageable.
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