Liebherr R924 Compact Excavator Full Service & Repair Manual

Technical documentation R 924 Compact Tier III MJFCIFSS copyright by Document identification Order number: 10360657 Issue: 01/2011 Valid for: R 924 Compact Tier III Author: LFR - Technical documentation department Product identification Manufacturer: LIEBHERR France S.A.S. Type: 1055 / 1056 1083 Tunnel Conformity: CE En Technical documentation Hydraulic excavator R 924 Compact Tier III

Technical documentation R 924 Compact Tier III copyright by MJFCIFSS Address Liebherr France S.A.S. 2 avenue Joseph Rey B.P. 90287 F - 68005 Colmar Cedex Book data Book number : . . . . . . . . . . . . . . . . Book owner : . . . . . . . . . . . . . . . .

Service Manual copyright by MJFCIFSS 1 General information 2 Tools 3 Technical data / Maintenance guidelines 4 Engine 5 Coupling / Splitterbox 6 Hydraulic system 7 Hydraulic components 8 Electrical system 9 Swing gear 10 Swing ring 11 Travel gear 12 Track components 13 14 15 16 Options 17 Cab / Heater / Air conditioning system 18 Central lubrication

Service Manual copyright by MJFCIFSS

Service Manual MJFCIFSS Introduction This manual contains technical data, design and functional descriptions, as well as service and set up instructions. The documents include numbers of drawings, functional diagrams, as well as detailed views of units and assemblies of LIEBHERR hydraulic excavators. This manual has been created in order to assist the customer support services, but does of course replace neither proper technical training and qualification of the user nor participation in LIEBHERR operator training courses. General basic technical information is not included in this manual. For operating instructions and information on spare parts, please refer to the separate documentation. For maintenance and reparation of the machine, follow conscientiously the safety instructions and warnings. Symbols used in this manual In this manual the description of tasks and procedures that are associated with specific dangers are accompanied by safety instructions mentioning the danger related to described work. The safety instructions are graded according to the severity of the risk, and are identified with the symbols «Danger» and «Caution», which have the following significances: These terms are identified by symbols in the operating instructions and : The symbol «Note» is destined to attract the attention of the persons having to intervene on the machine upon observations and comments concerning the procedure to be followed for operating as well for maintenance or repair works. Signification of specific punctuation marks in descriptions – This mark introduces «an entry in a list». • This mark introduces «an entry in a sublist». This mark indicates «a requirement that must be fulfilled», before going on with the procedure below. This mark identifies «an injunction to perform the mentioned action». This mark indicates «the normally expected result of a carried out action». About the contain of this Service Handbuchs This manual may not be replicated or made available to third parties without the explicit written consent of LIEBHERR, who retains all rights in this documents. All rights reserved - Printed in France. Danger! Warning referring to a danger where there is a high probability of death or serious injury to operators, unless the prescribed safety measures are taken. Caution! Warning relating to dangers that might lead to injury or machine damages, unless the prescribed safety measures are taken. Note! Comments and advices which will, if adhered to, help you to keep your excavator operating, to insure longlife to your machine and to facilitate certain procedures.

Service Manual MJFCIFSS This manual shall be amended without prior notice to reflect new technical developments and machine series. LIEBHERR reserves the right to make minor technical amendments to the machines that might not be reflected in the accompanying documentation. This manual might be complemented by additional service information sheets issued by LIEBHERR. This manual has been compiled and published by the Technical Documentation Department of LIEBHERR-FRANCE SAS 68005 Colmar cedex. We hope that the information in this documentation, aimed at improving the service of LIEBHERR excavators, is useful to you. Structuration of our Service Manuals In order to make it easy for users to find a specific sheet or information on a certain group, and to file amended and additional pages, each page is identified as follows: . The main groups are listed in the table of contents at the beginning of the book. The subgroups are listed on a subgroup index, on the first page of each main group section. This subgroup index also includes the indication of machines modells, types and serial number to which the subgroup is relevant. Example Main Group 7. = Main Group «Hydraulic components» Sub Group 12. = Sub Group «Variable Flow Hydraulic Pump - Type LPVD» Number of the Page in Sub Group 14. = Page «Adjustment for Varia- ble Flow Hydraulic Pump LPVD» 7. 12. 14

Technical documentation R 924 Compact Tier III 1.00.1 copyright by MJFCIFSS Group 1: General Information Safety instructions, Signs on the machine ..........................................................................1.10 1 Meaning of the symbols in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.1 2 Bestimmungsgemäße Verwendung. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.2 3 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.2 4 Sichere Wartung der Maschine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10.12 Tightening torques .................................................................................................................1.20 1 Tightening torques for screws with metric coarse and fine thread (Liebherr Standard WN 4037) . . . 1.20.1 2 Tightening torques of screw-in studs (Ermeto) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20.3 3 Tightening torques of swivelling connections (Ermeto) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20.4 4 Tightening torques of screw-in studs (Ermeto) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20.5 Installations for pistons and piston nuts by hydraulic cylinders ......................................1.22 1 Application and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.1 2 Requirements / description of procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.1 2.1 Tightening with assembly wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.2 2.2 Tightening with hydraulic assembly device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.4 3 Torque table - Status 02.06.2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22.7 3.1 Tightening with assembly wrench (siehe Kap. 2.1, ”Tightening with assembly wrench” auf Seite 2) . 1.22.7 3.2 Tightening with hydraulic assembly device (siehe Kap. 2.2, ”Tightening with hydraulic assembly device” auf Seite 4)1.22.9 Assembly instruction for piston rod bearings with external threads (hydraulic cylinders) .. 1.24 1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24.1 1.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24.1 2 Tightening torques for factory standard (02.07.2008) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24.3 Lubricants and operating fluids ............................................................................................1.51 1 General information on changing lubricants and operating fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.1 2 Lubricant chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.1 3 Fuels, lubricants and process chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.2 4 Diesel fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.3 4.1 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.3 4.2 Sulphur content of diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.3 4.3 Diesel fuels for operation at low temperatures (winter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.4 4.4 Diesel fuels with the LIEBHERR Particles filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.4 5 Lubricating oil for the diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.4 5.1 Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.4 5.2 Lubricating oil change intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.5

Technical documentation 1.00.2 R 924 Compact Tier III copyright by MJFCIFSS 6 Coolant for the diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.6 6.1 General recommandations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.6 6.2 Water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.6 6.3 Mixting ratio for coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.7 6.4 Permitted corrosion inhibitors / antifreeze agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.7 6.5 Permitted premixed coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.8 6.6 Permitted corrosion inhibitors without antifreeze agent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.8 7 Hydraulic liquids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.9 7.1 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.9 7.2 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.10 7.3 Warm-up instruction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.11 7.4 Biodegradable hydraulic oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.11 7.5 Monitoring, filter change and oil change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.12 7.6 Instructions for the reduction of the contamination of the hydraulic oil in machines used for dust in- tensive applications1.51.13 8 Lubricating grease and other lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.51.14

Technical documentation R 924 Compact Tier III Meaning of the symbols in this manual 1.10.1 Safety instructions, Signs on the machine copyright by MJFCIFSS Group 1: General Information 1.10: Safety instructions, Signs on the machine Working with the machine holds dangers to which you as the owner, machine operator or maintenance expert could be exposed. If you regularly read and note the safety information, however, you can prevent danger and accidents. This is particularly true for those who are only occasionally in con- tact with the machine, eg. for maintenance work. The following information comprises safety regulations which, if followed conscientiously, will guarantee your safety and that of other persons, as well as avoiding damage to the machine. Following these precautions does not release you from the responsibility to take note of safety regulations which apply on site or of guidelines given by legal bodies or professional associations. For EU countries, guideline 89 / 655 / EEC contains the minimum safety information applicable to the owner. 1 Meaning of the symbols in this manual Work processes and actions that could cause danger are accompanied by safety informations in these operating instructions. These safety informations describe various dangers which are emphasized by the terms Danger, Caution and Note. These terms are identified by symbols in the operating instructions and have the following meaning: – This symbol identifies a listing. • This symbol identifies a sub-listing. This symbol signifies the following: “The precondition must be fulfilled”. The machine operator or the maintenance personnel must first fulfil the precondition described, i e. the machine must be brought into a particular work position in order to be able to carry out the actions subsequently described. This symbol identifies an action. The machine operator or the maintenance personnel should be active at this location and carry out the action described. This symbol means “Carry out an activity". If the machine operator or maintenance personnel have carried out the activities described in an action, the result of this action will be described here. Danger! Warning relating to a danger that carries with it a high risk of death or serious injury if the appropriate preventative measures are not taken. Caution! Warning relating to dangers that could result in physical injury and/or damage to the machine if the appropriate preventative measures are not taken. Note! This symbol identifies user tips and operating and maintenance procedures whose use will guarantee a high degree of user-friendliness and longevity to the machine or which will considerably simplify working procedures.

Safety instructions, Signs on the machine Technical documentation Bestimmungsgemäße Verwendung 1.10.2 R 924 Compact Tier III copyright by MJFCIFSS Following these notes does not relieve you of responsibility for following additional rules and guidelines! Additional points that should be noted are: – the safety regulations which apply on site, – statutory road traffic regulations, – the guidelines provided by professional associations. 2 Bestimmungsgemäße Verwendung – Der Hydraulikbagger ist eine Maschine mit Arbeitseinrichtung (z. B. Tieflöffel, Greifer, Lade- schaufel) zum Lösen, Aufnehmen, Transportieren und Abschütten von Erdreich, Gestein und an- deren Materialien, wobei der Transport des Ladeguts vorwiegend ohne Verfahren der Maschine erfolgt. Das Verfahren der Maschine mit Ladegut hat unter Beachtung der sicherheitstechnischen Maßgaben (siehe Abschnitt “Hinweise für ein sicheres Arbeiten”) zu erfolgen. – Maschinen im Hebezeugeinsatz unterliegen besonderen Bedingungen und müssen mit den vor- geschriebenen Sicherheitseinrichtungen versehen sein (siehe Abschnitt “Hebezeugeinsatz“). – Maschinen im Untertageeinsatz (Untertagebergbau und Tunnelbau) in nicht explosionsgefährde- ter Umgebung müssen mit Technologien zur Abgasreduzierung (z.B. Dieselpartikelfilter) ausges- tattet sein. Einzelstaatliche Anforderungen sind hierbei zu beachten. – Besondere Einsätze erfordern spezielle Ausrüstungen und eventuell spezielle Sicherheitseinrich- tungen. Diese Ausrüstungen dürfen nur nach Genehmigung und den Maßgaben des Grundg- eräteherstellers angebaut und benutzt werden. – Eine andere oder darüber hinausgehende Benutzung wie z.B. der Transport von Personen oder das Arbeiten in explosionsgefährdeter sowie kontaminierter Umgebung gilt als nicht bestim- mungsgemäß. Für hieraus resultierende Schäden haftet der Hersteller nicht. Das Risiko trägt al- lein der Anwender. – Die Beachtung der Betriebsanleitung und die Einhaltung der Inspektions- und Wartungsanleitun- gen gehört ebenfalls zur bestimmungsgemäßen Verwendung. 3 Safety Instructions General safety instructions – Please familiarize yourself with the operating instructions before starting up the machine. – Ensure that you have obtained, read and understood any additional instructions relating to special accessories for the machine. – Only specifically authorized persons may operate, maintain or repair the machine. The legal minimum age is to be adhered to. – Only employ trained or appropriately instructed personnel. Clearly establish which personnel are responsible for operating, setting up, maintaining and repairing the machine. Give personnel the power to refuse to carry out unsafe instructions by third parties. This also applies in relation to traffic regulations. – Only permit apprentices and personnel who are in training or who have only general training to operate on the machine under the constant supervision of an experienced member of staff. – As far as possible, monitor personnel to ensure that they are adhering to safe working practices, are aware of risks and are observing the operating instructions. – Always wear safe work clothes when you are working on or with the machine. Avoid wearing rings, wrist watches, ties, scarves, open jackets, baggy clothing etc... There is a risk of injury from, for example, getting caught up or being drawn in. – For specific jobs wear individual protective equipment (protective goggles, safety helmets, safety shoes and gloves, reflective vests and ear protection etc...).. – Ensure that you obtain information on any special safety regulations for the job site from the site foreman.

Liebherr R924 Compact Excavator Full Service & Repair Manual

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