Professional Documents
Culture Documents
Notes regarding the electrical system 8.02.1 A 900 C-ZW EDC (F.D.) 37728-
Electical system with installation kits and 8.34.1 A 900 C-ZW EDC (F.D.) 37728-
wiring harnesses
Electical system with installation kits and 8.36.1 A 900 C-ZW EDC (F.D.) 51093-
wiring harnesses
Electical system with installation kits and 8.38.1 A 900 C-ZW EDC (F.D.) 63563-
wiring harnesses
Operating symbols on the operator's platform 8.44.1 A 900 C-ZW EDC (F.D.) 37728-
Electronically controlled working and travelling 8.60.1 A 900 C-ZW EDC (F.D.) 37728-
pedal
Calibration of the electric foot pedals 8.62.1 A 900 C-ZW EDC (F.D.) 37728-
Monitoring display from V.4.7.2 8.72.1 A 900 C-ZW EDC (F.D.) 37728-
Emergency actuation (emergency operation) 8.81.1 A 900 C-ZW EDC (F.D.) 37728-
LHB/en/Edition: 10/2013
Slip ring rotary connection 8.82.1 A 900 C-ZW EDC (F.D.) 37728-
MJFCIFSS
MJFCIFSS
Service Manual
LHB/en/Edition: 10/2013
Service Manual Overview of electrical symbols
Overview of symbols
A new software package has been used for the drawing of the electrical diagrams of machines from
models A 900 C 24677 and A 904 C 30580 .
The symbols, their designation and meaning are shown in the table below for a better understanding
of the diagrams.
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Overview of electrical symbols Service Manual
Overview of symbols
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Service Manual Overview of electrical symbols
Overview of symbols
Battery Alternator
Generator
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Overview of electrical symbols Service Manual
Overview of symbols
Time relay
(with pick-up delay)
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Service Manual Overview of electrical symbols
Overview of symbols
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Overview of electrical symbols Service Manual
Overview of symbols
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Service Manual Overview of electrical symbols
Overview of symbols
LED LED
flashing
LHB/en/Edition: 11/2007
Z diode Amplifier
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Overview of electrical symbols Service Manual
Overview of symbols
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Service Manual Overview of electrical symbols
Overview of symbols
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Overview of electrical symbols Service Manual
Overview of symbols
LHB/en/Edition: 11/2007
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Service Manual Overview of electrical symbols
Overview of symbols
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Overview of electrical symbols Service Manual
Overview of symbols
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Service Manual Notes regarding the electrical system
General notes regarding the electrical system
When switched off (position 0, see Fig. 1), the battery main switch disconnects the electric contact
(vehicle mass) to all connected components.
After switching off the diesel engine, the engine control unit remains activated for approx.
LHB/en/Edition: 02/2009
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Notes regarding the electrical system Service Manual
Battery
Special care is required in connection with machines with built-in auxiliary heater.
Only switch off the battery main switch after the afterrun time of the auxiliary heater has lapsed.
Before carrying out any work on the electrical system or performing welding work on the machine,
set the battery main switch to position (off).
Before washing the machine, cover the electrical devices (in particular the alternator, generator,
cabling, electrical components and measurement transducers) so that they are protected against
LHB/en/Edition: 02/2009
splashing water.
When cleaning the engine with a water or steam jet, ensure that the measurement transducers
(e.g. oil pressure switches) are not exposed to a direct water or steam jet.
Otherwise, water might penetrate the devices causing corrosion of the contacts, leading to
measuring failures.
Oil pressure switches cannot be designed as water-tight units due to the need for diaphragm
ventilation.
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Service Manual Notes regarding the electrical system
Battery
To ensure that the batteries work properly at all times, keep them clean.
Regularly clean the pole heads and cable terminals and apply a thick layer of acid-proof grease,
see Fig. 2.
Kinked rubber hoses of the central gas release system lead to a higher risk of explosion!
The hydrogen produced in the battery may not collect in the battery box and must be released from
the enclosure through rubber hoses. When installing the hoses of the central gas release system,
ensure that they are not kinked.
Regularly check the hoses for damage, especially after installation of the battery, see Fig. 2.
The liquid level in the cells should be about 10 to 15 mm above the upper edge of the plate. If topping
up is necessary, add only distilled water.
From time to time, check the acid density using a battery tester .
If the battery tester shows a lower value, the battery is discharged to some degree and might need
to be recharged.
LHB/en/Edition: 02/2009
When connecting an external battery, there is a risk of increased gas production in older batteries.
When jumpstarting the machine, always wear goggles and protective gloves. Ensure that there
are no naked flames near the battery and prevent sparks in the vicinity of the discharged vehicle
battery. RISK OF EXPLOSION!
Use only jump leads with adequate cross-section. Strictly adhere to the proper jumpstart
procedures.
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Notes regarding the electrical system Service Manual
Slip ring body (optional equipment)
First connect the cable to the positive pole (+) of the discharged battery and then to the positive
pole (+) of the external battery.
Then connect the second cable to the negative pole (-) of the discharged battery and subsequently
to the negative pole (-) of the external battery.
Start the engine as described above.
Before disconnecting the jump lead, set the diesel engine of the jump-started machine to the
lower idle speed.
For safety reasons, switch off all large consumers such as working headlights, uppercarriage
illumination, etc. to prevent overvoltage. Otherwise, there is a risk of damage to the electronic
equipment.
First disconnect the cable from the negative pole (-) of the external battery and then from the
negative pole (-) of the discharged battery.
Then disconnect the second cable from the positive pole (+) of the external battery and
subsequently from the positive pole (+) of the discharged battery.
Test the electrical functions of the machine.
For instructions regarding battery care and maintenance, see chapter "Battery care".
Slip ring bodies are easily damaged by humidity, as oxide layers might form on the conducting
surfaces, impairing electrical conductivity. As a consequence, the electrical consumers in the
undercarriage are insufficiently supplied with power, which can result in malfunctions.
To prevent this, we recommend carrying out the following tasks every 500 operating hours:
Unscrew the lock nuts .
LHB/en/Edition: 02/2009
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Service Manual Arrangement of components
Control elements
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Arrangement of components Service Manual
Control elements
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Service Manual Arrangement of components
H1 Monitoring display
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Arrangement of components Service Manual
S2 Keyboard
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Service Manual Arrangement of components
S2 Keyboard
This is where switched functions are being stored when the machine is shut down. When the
electrical system is switched on again, the original state is restored (as before shutdown).
For information on keyboard repairs, please refer to .
LHB/en/Edition: 11/2010
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Arrangement of components Service Manual
ZW system - control element
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Service Manual Arrangement of components
ZW system - control element
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Arrangement of components Service Manual
Control console A (type 1033)
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Service Manual Arrangement of components
Control console A (type 1384/1385)
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Arrangement of components Service Manual
Control console A (type 1384/1385)
LHB/en/Edition: 11/2010
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Service Manual Arrangement of components
Printed circuit board A 1001 (ESP-01)
LHB/en/Edition: 11/2010
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Arrangement of components Service Manual
Printed circuit board A 1001 (ESP-01)
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Service Manual Arrangement of components
Printed circuit board A 1100 (ESP-02)
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Arrangement of components Service Manual
Printed circuit board A 1100 (ESP-02)
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Service Manual Arrangement of components
Printed circuit board A 1100 (ESP-02)
pin
Plug connection to BS K333 / 6-pin
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Arrangement of components Service Manual
Universal Earthmoving Controller (UEC)
Fig. 12 in undercarriage
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Service Manual Arrangement of components
Universal Earthmoving Controller (UEC)
In the event of a complete failure of the electrical system, the software version of the UEC is not
displayed. It can however be found on the adhesive label . If the software has been upgraded since
the machine was delivered, the current version number can be found on the inside of the cover of
the electric box .
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Arrangement of components Service Manual
Relay board 2
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Service Manual Arrangement of components
Relay board 2
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Arrangement of components Service Manual
Fuse and power switch cabinet
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Service Manual Arrangement of components
Fuse and power switch cabinet
20 A Refuelling pump*
15 A Reserve K66-2
20 A Heating and a/c system terminal 30
50 A Special equipment auxiliary headlight* and motor terminal 30
50 A Engine control terminal 30
7.5 A Emergency operation terminal 15
7.5 A Engine control terminal 30
7.5 A Engine control terminal 15
7.5 A Engine control, preheating monitoring
7.5 A not assigned
25 A Stick light
50 A Automatic cut-out terminal 15/terminal 30 main circuit
Relay, optional*
Fuel pre-heating*
Relay, optional*
Relay, optional*
Relay of emergency operation / speed control
Relay for starting engine emergency operation
Main relay terminal 15
Relay of pre-heating
Auxiliary heating
Relay stick light*
Main relay ZW operation terminal 15
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Arrangement of components Service Manual
Fuse and power switch cabinet
LHB/en/Edition: 11/2010
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Service Manual Arrangement of components
D 934S/L A6 diesel engine
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Arrangement of components Service Manual
Tank and control oil unit
power control P2
H9 Horn Y66 Solenoid valve / oscillating axle support
Y3 Solenoid valve / pilot control pressure Y353 Proportional solenoid valve / travel
function
8.12.24
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Service Manual Arrangement of components
Other components
Fig. 22 HBGV block and solenoid valve on basic boom bearing block
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Arrangement of components Service Manual
Other components
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Service Manual Arrangement of components
Other components
Batteries
Battery main switch
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Arrangement of components Service Manual
Other components
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Service Manual Arrangement of components
Other components
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Arrangement of components Service Manual
Other components
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Service Manual Arrangement of components
Other components
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Arrangement of components Service Manual
Other components
LHB/en/Edition: 11/2010
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Service Manual Operating symbols on the operator's platform
Overview of symbols
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Operating symbols on the operator's platform Service Manual
Overview of symbols
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Service Manual Operating symbols on the operator's platform
Overview of symbols
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Operating symbols on the operator's platform Service Manual
Overview of symbols
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Service Manual Operating symbols on the operator's platform
Overview of symbols
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Operating symbols on the operator's platform Service Manual
Overview of symbols
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Service Manual Operating symbols on the operator's platform
Overview of symbols
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Operating symbols on the operator's platform Service Manual
Overview of symbols
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Service Manual Operating symbols on the operator's platform
Overview of symbols
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Operating symbols on the operator's platform Service Manual
Overview of symbols
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Service Manual Operating symbols on the operator's platform
Overview of symbols
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Operating symbols on the operator's platform Service Manual
Overview of symbols
LHB/en/Edition: 11/2007
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Service Manual Data logger
Function/design
The data logger records various data of the machine, (see “Logged files of data logger” on
page 5). The data on the memory card (CF2) can be read with a conventional card reader.
The data logger is installed in the right console behind the passenger seat. To protect the data
logger against unauthorised access, it is secured with a padlock.
The data logger does not have any control function and is only used for the recording of machine
data. In order to ensure continuous data logging, a memory card each must be inserted in the two
slots and of the data logger.
The logger is monitored with the button (LOG) in the right console. It indicates the operating
status of the data logger.
If the indicator light in the button is off, no data is being recorded. In this case, it is strictly
forbidden to operate the machine, (see “Operating statuses of data logger” on page 3).
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Data logger Service Manual
Function/design
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Service Manual Data logger
Function/design
The indicator light in the switch An overload occurred since the last
flashes. reset. Connect the service plug, see Fig.
9, and actuate the switch . If the
system works properly, the indicator
light is on in green.
(see “Resetting data logger” on page 8).
The indicator light in the switch No data is being logged. In this case, it
is off. is to operate the machine.
Observe the error messages, see group
8.80.
CF1 memory card with software for data logger, information on the software version and ID
number
Memory card (slot CF2) for logged data
LHB/en/Edition: 09/2012
When handing over the machine to a new owner, pass on the key. It is the responsibility of the
machine owner to manage access to the key according to standard RIS1530, version 2.
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Data logger Service Manual
Function/design
Unscrew the cover of the data logger , (see “Design of data logger” on page 2).
The memory card is now accessible and can be removed to read out the data. The memory card
remains inserted.
The LEDs indicate the operating status of the memory card and the communication status between
the memory card and the control system.
The data logger logs the data listed in the table below over a period of 100 operating hours. After
100 operating hours have lapsed, the oldest recorded data is overwritten with new data. This
ensures that the logger always stores all data of the last 100 operating hours. However, less data
is available if data has been deleted.
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Service Manual Data logger
Function/design
2 Zähler counter
3 Fahreridentifkation-Code personal number
4 Fahreridentifkation-Code personal number OK
5 Überlastabschaltung eingeschaltet RCI on
6 ZW ein rail-mode on
7 SWL zulässige max. Last (t) safe working load - SWL (t)
8 Last am Haken (t) load (t)
9 Radius (m) radius (m)
10 Höhe (vorderer Stielbolzen) (m) height (m)
11 Winkel (Unterwagen-Oberwagen (Winkel) slew angle (degree)
12 Überhöhung in mm cant (mm)
13 Überhöhung (0=Winkel, 1=mm) cant unit (==degree; 1=mm)
14 Geschwindigkeit speed
15 Anzeige der Geschwindigkeit (0=km/h; 1=mph) speed unit (0=km/h; 1=mph)
16 UL-Vorwarnung RCI-audible warning
17 UL-Abschaltung RCI-cutoff
18 UL-Überbrückung betätigt RCI-by-pass active
19 Pendelachse zu axle locked
20 Static Lifting mode ein S/L-mode on
21 Lift and Carry ein L/C-mode on
22 Digging mode D/G-mode on
23 Tandem Lift ein T/L-mode on
24 Backward stability ein backward stability on
25 Sicherheitshebel safety lever
26 Abschaltung Hub durch die backward stability stop boom due to backward stability (bs)
27 Abschaltung Drehwerk durch die backward stop slewing gear due to backward stability (bs)
stability
28 Berechnete Radlast calculated wheel load
29 Nothydraulik aktiv emergency hydraulic on
30 Schienenachsen senken lowering rail gear
31 Schienenachsen heben lifting rail gear
32 Hinterachse gesperrt Rear axle locked
33 Vorderachse gesperrt Front axle locked
34 Regeln in Automatik control automatic active
35 Automatikbetrieb aktiv automatic
36 Gefahr des Traktionsverlustes E964 traction lose E964
37 Automatik gesperrt automatic locked
38 Quittierung Kontrollleuchte Datenlogger Confirmation control lamp
LHB/en/Edition: 09/2012
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Data logger Service Manual
Function/design
The recorded data is stored on the memory card (CF2/128MB). The data is stored in several
directories and files.
The recorded data is available in text format and can thus be analysed by means of standard office
applications such as MS Excel.
When reading out data, note that the reading date does not correspond to the recording date, (see
Fig. 6 on page 6).
LHB/en/Edition: 09/2012
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Service Manual Data logger
Function/design
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Data logger Service Manual
Function/design
After reading the data, reset the status indicator (indicator light in button ) of the data logger by
pressing the button .
The service plug is connected.
Press the button .
The data logger status indicator is reset and the indicator light is lit in green, provided that the
device works properly.
LHB/en/Edition: 09/2012
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Service Manual Operator ID code
Preliminary settings (storing operator code)
Up to 10 operator ID codes can be stored in the menu. These codes must be entered through the
excavator keyboard (BBT).
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Operator ID code Service Manual
Preliminary settings (storing operator code)
If less than ten operator ID codes are to be assigned, enter the last operator ID code in all blank
fields.
Each code change must be saved separately with . To exit the program, press (see arrow).
LHB/en/Edition: 11/2010
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Service Manual Operator ID code
Preliminary settings (storing operator code)
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Operator ID code Service Manual
Preliminary settings (storing operator code)
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Service Manual Electronically controlled working and travelling pedal
Function/design
The Liebherr rail-road excavators are equipped with an electro hydraulic travel drive and the
associated components as well as with electronic working pedal sensors.
The direction and speed of travel and the working pedal functions the are controlled electronically,
while the travel drive is controlled hydraulically.
The UEC optional control system ( ) controls the travelling pedal sensor as well as the
proportional solenoid valve . It also controls the working pedal sensors and with the
accessory kit functions.
The electronically controlled working and travelling pedals consist of the following main components:
– Travelling pedal sensor on the pedal / operator's platform
– Working pedal sensors and on the pedal / operator's platform
– Switch for travel direction and switch for the storage of the travel velocity
– Proportional solenoid valve on the control oil unit
LHB/en/Edition: 12/2008
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Electronically controlled working and travelling pedal Service Manual
Functional description
Preselect the direction of travel with the switch . Depending on the position of the switch ,
(forward travel) or (reverse travel) is powered (the direction of travel is indicated on the display).
The proportional solenoid valve (pressure reducing valve) is powered through the UEC optional
control system ( ), whereby the current is determined by the pivot angle detected by the travelling
pedal sensor .
The resulting control oil pressure acts through the connection of the control oil unit and through
the actuated solenoid valve on the spool of the compact control block . The spool
is moved up or down, in proportion to the control pressure, thus feeding pressurised hydraulic oil
from the working pump to the regulating travel motor The regulating travel motor is pressurised and
drives the machine through the transmission the drive shafts and the axles.
The automotive travel function can be switched on or off in the menu. The default setting for automatic
travel is .
LHB/en/Edition: 12/2008
If the switch is not actuated, automatic travel is controlled by the UEC optional control system
( ). In this mode, the travelling pedal sensor also controls the diesel engine speed,
depending on the pivot angle of the pedal.
Advantages for travel in normal road traffic: If required, semi-speed and idling speed operation can
be controlled with the travelling pedal sensor and must thus not be constantly corrected with
the speed buttons.
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Service Manual Electronically controlled working and travelling pedal
Functional description
"Tempomat" operation is activated with the switch (right console). When this function is on, the
indicator light in the switch is lit.
When the desired speed is reached, it can be stored by briefly pressing . The current value of
the travelling pedal sensor is stored in the UEC optional control system ( ).
Both Tempomat and normal mode travel ( on) is possible in both directions of travel. In normal
on-road travel mode ( off), the Tempomat function is only available for forward travel.
The operator can now lift the foot from the travelling pedal while the machine continues to travel
at the set speed. The proportional solenoid valve is powered with a constant current from the
UEC optional control system ( ).
For safety reasons, the following events automatically deactivate the Tempomat:
– The switch is pressed again (indicator light in the switch is off).
– The travelling pedal sensor records a value that is above the saved limit.
– The direction of travel is changed.
– The wagon brake system is actuated.
– An emergency brake manoeuvre is carried out.
– The safety lever is tilted up or the servo control is switched off.
– An kit that is also controlled with the push button is switched on.
The stored value is thereby deleted.
Tempomat.
Press the push button again or actuate the brake to deactivate the set travel speed.
The set travel speed is deleted, and the vehicle velocity must again be controlled with the
travelling pedal.
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Electronically controlled working and travelling pedal Service Manual
Functional description
The travelling pedal sensor generates a voltage signal that is proportional to the actual pedal
path and that transmitted to the central control unit . Each incoming voltage signal is assigned
an output current to the proportional solenoid valve . This current is determined by means of
characteristics stored in the UEC optional control unit ( ).
The travelling pedal sensor is equipped with 2 analog outputs. The two analog outputs of the
travelling pedal sensor generate negative-sequence voltage signals, which are read,
processed, constantly compared with each other and assessed for plausibility by the UEC optional
control system ( ). If an error occurs at the travelling pedal sensor or in the cabling to the
travelling pedal sensor , the respective error code signals are generated. For details, see group
8.80.
If the UEC optional control system ( ) detects a signal from the travelling pedal sensor the
speed is set to the speed step preselected in the BBT.
To check the travelling pedal sensor , measure the voltage when the pedal is at the maximum/
minimum position and compare it with the diagram, see Fig. 4.
LHB/en/Edition: 12/2008
The electrical inputs are connected to the right working pedal sensor and the left working pedal
sensor . Depending on the activation (SF2 OFF/ON, SF3 OFF/ON or vertical-horizontal), on-
road travel, the attachment or the horizontal adjustment equipment is actuated.
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Service Manual Electronically controlled working and travelling pedal
Functional description
The UEC optional control system ( ) controls the listed proportional solenoid valves, depending
on the actual actuation.
If the continuous oil attachment (P1-S453) is activated, the road travel or vertical-horizontal
adjustment equipment functions are again released for the working pedals.
The continuous mode function is reset with the safety lever S7.
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Electronically controlled working and travelling pedal Service Manual
Functional description
LHB/en/Edition: 12/2008
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Service Manual Electronically controlled working and travelling pedal
Maintenance and repair
Regularly clean the travelling and the working pedal sensors and the electrical connections.
For functional reasons, the pedals cannot be repaired. If necessary, always replace the entire pedal.
The pedals must be calibrated during commissioning of the machine or after they have been
exchanged. Always calibrate all 3 pedal sensors (travelling pedal sensor and the two
accessory kit pedal sensors ) together, see group 8.62.
LHB/en/Edition: 12/2008
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Electronically controlled working and travelling pedal Service Manual
Maintenance and repair
LHB/en/Edition: 12/2008
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Service Manual Calibration of the electric foot pedals
Purpose of calibration
The pedals must be calibrated during commissioning of the machine and after they have been
replaced. Always calibrate all 3 foot pedals (travel pedal and 2 attachment kit pedals) together.
Fully press down the travel pedal , the left attachment pedal and the right attachment pedal
one after the other. After calibration has been activated, you must always actuate all three pedals
one after the other.
After calibration has been completed, switch off the ignition.
Exit the calibration mode.
LHB/en/Edition: 04/2009
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Calibration of the electric foot pedals Service Manual
Maintenance and repair
For functional reasons, the pedals cannot be repaired. If necessary, always replace the entire pedal.
LHB/en/Edition: 04/2009
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Service Manual ZW monitoring display (TDS01)
Function/design
From TDS01 version 2.0, the ZW monitoring display has been equipped with a service menu
facilitating diagnostics. Without service plug, only the software version can be viewed. With service
plug, the parameter values, the internal variables as well as the I/O values can be viewed and
adjusted, if necessary.
It is thus possible to call up the values of the rail guide system and to set the parameters for the
various configurations without the need for a laptop.
The program includes three different service menus:
– i-i/O
– i-parameters
– i-variables
The control buttons of the monitoring display are shown as graphic icons. The system is operated
with the keys F1 to F4.
F1 = BACK
F2/F3 = UP/DOWN
F4 = MENU
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ZW monitoring display (TDS01) Service Manual
Checking of parameters, inputs and outputs
If the ignition is started without connected service plug and the key is pressed, only the software
version is shown on the monitoring display.
In the i-i/O service menu, you can view the input and output values of the control system. These
values are converted by the UEC control system into effective values in mA and bar. For details, see
Tab. 1.
Press the F2/F3 (UP/DOWN) keys to select the i-i/O service menu and confirm by pressing the
menu key.
The I/O values are displayed.
Compare the I/O values with those in the table, see Tab. 1.
Use key F4 to page through the menu pages 1 to 9.
To exit the menu, press key F1 (BACK).
LHB/en/Edition: 05/2010
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Service Manual ZW monitoring display (TDS01)
Checking of parameters, inputs and outputs
outputs
107 32 X1.11 OUT+28; overvoltage protection output, supply
External sensors
108 32 X1.39 DIN (1) not assigned
109 32 X1:40 DIN (2); emergency-stop input; 0V/24V
110 32 X2.1 DIN (3); outrigger support, front right, pressure switch B310
111 32 X2.2 DIN (4); outrigger support, front left, pressure switch B311
112 32 X2.3 DIN (5); outrigger support, rear right, pressure switch B312
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ZW monitoring display (TDS01) Service Manual
Checking of parameters, inputs and outputs
113 32 X2.4 DIN (5); outrigger support, rear left, pressure switch B313
114 32 X2.5 DIN (7) not assigned
115 32 X2.6 DIN (8) not assigned
126 32 X1.31 Pressure sensor railcar brake system accumulator pressure
B320
127 32 X1.32 Angle sensor, front B401 0-5V
128 32 X1.33 Pressure sensor railcar brake system operating pressure
B321 0-10V
129 32 X1.34 Angle sensor, rear B402 0-5 V
130 32 X1.25 Pressure sensor rail, front right B329 1-5V
131 32 X1.26 Pressure sensor rail, front left B330 1-5V
132 32 X1.27 Pressure sensor rail, rear right B331 1-5V
133 32 X1.28 Pressure sensor rail, rear left B332 1-5V
134 32 X1.29 Pressure sensor ZW pump B322 1-5V
142 32 X2.36 PWM nominal output 1; Y430 ZW pump
143 32 X2.35 PWM nominal output 2; Y395 front bottom to P
144 32 X2.34 PWM nominal output 3; Y395 rear bottom to P
145 32 X2.33 PWM nominal output 4; Y496 rear axle pressure regulation
146 32 X2.32 PWM nominal output 5; Y398 front ring to P
147 32 X2.31 PWM nominal output 6; Y399 front bottom to T
148 32 X2.30 PWM nominal output 7; Y400 rear bottom to T
149 32 X2.29 PWM nominal output 8; Y401 rear ring to P
150 32 X2.28 PWM nominal output 9; Y215 release outrigger front left
151 32 X2.27 PWM nominal output 10; Y495 front axle pressure
regulation
154 32 X2.17 Differential lock
156 32 X2.19 Bridge +; Y216 release front right
157 32 X2.18 BRIDGE - not assigned
158 32 X2.26 Nominal output 11; Y402 front axle release
159 32 X2.25 Nominal output 12; Y403 rear axle release
160 32 X2.24 Nominal output 13, Y325-2 rear axle
emergency lowering
161 32 X2.23 Nominal output 14, Y325-1 front axle
emergency lowering
162 32 X2.22 Nominal output 15; Y350 emergency valve railcar brake
system
163 32 2.21 Nominal output 16; Y217 outrigger rear left release
LHB/en/Edition: 05/2010
164 32 2.20 Nominal output 17; Y218 outrigger rear right release
165 32 2.16 IOut1 not assigned
170 32 1.35 FIN(1); B259 speed sensor gearbox
171 32 X1.36 FIN (2) not assigned
172 32 X1.37 FIN (3) not assigned
173 32 X1.38 FIN (4) not assigned
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Service Manual ZW monitoring display (TDS01)
Checking of parameters, inputs and outputs
Call up the i-parameters service menu to view and adjust the parameter values of the rail guide
system. In this menu, you can also activate and deactivate various configurations and modes by
adjusting the relevant parameter values. This menu has been designed to assist mechanics in
identifying faults and errors.
Changes made in this menu must conform to the relevant adjustment instructions of the accessory
kits. Only 9 values can actually be adjusted (marked in the table with ) while all other settings are
protected. These values can be temporarily adjusted for testing and troubleshooting purposes. The
new settings can however not be saved.
If the ignition is switched off, the default values are applied. For details, see Tab. 2.
Press the F2/F3 (UP/DOWN) keys to select the i-parameters service menu and confirm by
pressing the menu key.
The parameter values are displayed.
Compare the parameter values with those in the table, see Tab. 2.
Use key F4 to page through the menu pages 1 to 10.
To exit the menu, press key F1 (BACK).
EP1 32 Minimum current for lowering (actuation of valves) 390 150 450
EP2 32 Maximum current for lowering (end position of valves) 600 300 700
EP3 32 Minimum pressure front axle in 1/10 bar 350 0 1200
EP4 32 Minimum pressure rear axle in 1/10 bar 350 0 1200
EP5 32 Window for minimum pressure adjustment in 1/10 bar 70 0 400
EP6 32 P amplification for lifting, position controller 50 0 1000
EP7 32 Switch-on threshold of accumulator charging function 1000 10 1000
LHB/en/Edition: 05/2010
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ZW monitoring display (TDS01) Service Manual
Checking of parameters, inputs and outputs
EP13 32 Reserve 0 0 0
EP14 32 Reserve 0 0 0
EP15 32 Level sensor rear travel gear up 100%. Digital value from 400 70 430
which "travel gear 100% up" is displayed.
EP16 32 Level sensor rear travel gear down 0%. Digital value from 110 70 430
which "travel gear 0% down" is displayed.
EP17 32 Reserve 0 0 0
EP18 32 Minimum current ring side to P 420 150 450
EP19 32 Maximum current ring side to P 650 300 700
EP20 32 Minimum current for lifting (bottom to T) 420 150 450
EP21 32 Maximum current for lifting (bottom to T) 550 300 700
EP22 32 Reserve 0 0 0
EP23 32 Reserve 0 0 0
EP24 32 Reserve 0 0 0
EP25 32 P amplification parallel lifting pressure value 15 0 500
EP26 32 P amplification minimum pressure controller 100 1 300
EP27 32 I amplification minimum pressure controller (reserve) 0 200
EP28 32 I-max for minimum pressure controller in 1/1000 1000 0 1000
EP29 32 P amplification for parallel lifting 8 0 1000
EP30 32 Data log reserve 0 0 0
EP31 32 Current ZW pump stand-by 800 0 900
EP32 32 Current ZW pump automatic 300 0 900
EP33 32 Current ZW pump maximum pressure 100 0 900
EP34 32 Current ZW pump fan performance 0% 800 0 900
EP35 32 Current ZW pump fan performance 100% 400 0 900
EP36 32 Speed-controlled reduction I lifting 550 0 900
EP37 32 Lifting value in 1/1000 for lifting in automatic mode 20 0 100
Shift value for traction increase
EP38 32 Total axle transmission ratio, e.g. 16.00*1.19=1904 1904 1000 4000 X
Axle-dependent factor for speed indication
EP39 32 Current ZW pump for maximum pressure in mA 100 100 1000
EP40 32 Current ZW pump for minimum pressure in mA 900 100 1000
EP41 32 Correction speedometer for friction wheel in % 187 1 2000 X
Axle-dependent factor for speed indication
EP42 32 Undercarriage inclination for overload available = 1 1 0 1 X
1 With inclination sensor, 0 Without inclination sensor
EP43 32 Warning threshold rail pressure 1/10 bar 150 100 230 X
Warning threshold for buzzer activation
LHB/en/Edition: 05/2010
EP44 32 Pressure limit for pressure increase in auto mode 1/10 bar 1200 800 2000
ZW pump to maximum value 100 mA
EP45 32 Current factor for parallel lifting 900 500 1000
EP46 32 Locking during swivelling 0 0 3 X
0 OFF, 1 front axle, 2 rear axle, 3 both axles
EP47 32 Window for locking in 1/10 degrees 100 30 500 X
Angle left/right when locking is activated
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Service Manual ZW monitoring display (TDS01)
Checking of parameters, inputs and outputs
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ZW monitoring display (TDS01) Service Manual
Checking of parameters, inputs and outputs
Tab. 2 Variables
Call up the i-variables service menu to view measurements, current values, internal values and
variables. This menu has been designed to assist mechanics in identifying faults and errors. For
details, see Tab. 3.
Press the F2/F3 (UP/DOWN) keys to select the i-variables service menu and confirm by pressing
the menu key.
The i-variables are displayed.
Compare the i-variables with those in the table, see Tab. 3.
Use key F4 to page through the menu pages 1 to 12.
To exit the menu, press key F1 (BACK).
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Service Manual ZW monitoring display (TDS01)
Checking of parameters, inputs and outputs
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ZW monitoring display (TDS01) Service Manual
Checking of parameters, inputs and outputs
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Service Manual ZW monitoring display (TDS01)
Checking of parameters, inputs and outputs
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ZW monitoring display (TDS01) Service Manual
Checking of parameters, inputs and outputs
LHB/en/Edition: 05/2010
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Service Manual Monitoring display from V.4.7.2
Working brake
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Monitoring display from V.4.7.2 Service Manual
Ranges of analogue indicator and check display
The LEDs lighting up on the analogue indicator show how much fuel is left in the tank.
When red LEDs light up, fuel remaining in the tank amounts to 10 - 20 %, i.e. about 50 litres
(depending on type of machine).
The indicator light lights up, if the oil pressure in the engine falls below a certain pre-set value
during operation (depends on current rpm).
Low oil pressure sets off an acoustic alarm in the operator's cab (buzzer), and the system stores the
incident under error code .
Immediately switch the engine to low idle gear.
Shut down engine immediately.
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Service Manual Monitoring display from V.4.7.2
Ranges of analogue indicator and check display
Light starts to flash whenever the direction indicator switch or hazard light have been actuated.
The indicator lamp lights up as soon as the parking brake has been engaged and/or the release
pressure of the parking brake has been undercut.
The indicator light lights up, if the accumulator pressure is too low. The brake may not be
functional any more.
Whenever this light is on, the occurrence is stored under error code . The buzzer gives two short
signals.
Shut down machine.
Set engine into low idle gear.
Move the safety lever to the top.
Check the brake system.
If there is insufficient accumulator charge pressure, the brake does not work properly.
In the event of a malfunction, move the machine from the danger area.
The indicator light lights up, if the oil flow going to the steering Servostat is insufficient.
Whenever this light is on, the occurrence is stored under error code . The buzzer gives two short
signals.
Immediately switch the engine to low idle gear.
Let engine continue in low idle for about 2 to 3 minutes.
Switch off the engine.
Check the steering pump and system.
If the oil flow rate to the steering Servostat is too low, the steering becomes stiff and can only be
operated with great force.
In the event of a malfunction, move the machine from the danger area and halt it there.
LHB/en/Edition: 12/2007
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Monitoring display from V.4.7.2 Service Manual
Menu control for screen
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Service Manual Monitoring display from V.4.7.2
Main screen
There is a light sensor at the top left of the monitoring display. It controls the brightness of the main
screen with respect to the ambient brightness. Automatic brightness control is based on the basic
setting entered with the buttons. The display will be dimmed when the environment gets darker.
The main screen appears after the machine has been switched on and will remain visible until you
press and change to the menu selection screen.
The time is displayed in the upper part of the screen. To the left, you see error messages and warning
symbols. If the system needs to display more than 2 symbols, the clock is hidden. If there is reason
to show more than 2 symbols, they will wander and disappear to the left, one symbol every 10
seconds.
For a list of the symbols shown in the SY field, refer to group 8.80.
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Monitoring display from V.4.7.2 Service Manual
Error messages - menu control
Display window EC shows the error codes of current electrical faults in the electronics of the
excavator (faults in the lines, sensors etc.). Up to seven error codes can be shown at any one time.
If there are more than seven faults, an arrow appears besides the error code window, showing where
else in the list error codes occurred. The total is shown at the bottom of the EC field.
Press buttons and/or
to scroll up or down through the error code window.
The possible error codes are listed in group 8.80.
The field INF (bottom right in the main screen) is for the display of temporary information, also in
graphic form. If there is reason to show more than three symbols, they move across the screen and
disappear to the left, one symbol every 10 seconds.
Displayed information comes in the form of graphics or text, indicating e.g. a function launched (pre-
heating etc.), important pointers and reminders (scheduled service check) and/or dangers (overload
etc.).
The possible instruction signs are listed in group 8.80.
This field, to the bottom right, displays machine operating hours, the daily operating hours counter
and the attachment selected.
The open-end spanner may appear when the ignition is engaged. It indicates that the next scheduled
service check is due.
The display usually showing the daily operating hours now shows the hours of the current service
interval. The service check symbol disappears after about 8 seconds.
The symbols next to item 1 show that there is a distinction between the Super Finish function and
accessory kit operation:
As soon as a fault condition displayed in field is confirmed as , the display returns to the main
screen window. The corresponding error output is active.
Depending on the actual occurrence (importance), there may be an acoustic signal at the same time
(buzzer), either continuously or in recurring intervals.
The symbol indicates a possibility to reset the buzzer (button ).
The possible error codes are listed in group 8.80.
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Service Manual Monitoring display from V.4.7.2
On-road travel symbols on main screen
If the error indicated is not eliminated immediately, there is a danger people get hurt or equipment
gets damaged.
Make sure all faults are dealt with without delay.
To switch of buzzer, press BACK.
The error message is acknowledged and stored.
When travelling on public roads, you must conform to the relevant statutory regulations.
Before undertaking a journey, inform yourself of the local regulations.
Find out whether your machine is approved and registered for travel on public roads.
Always strictly adhere to the regulations.
Fig. 6 On-road travel, position of working attachment, optimised centre of gravity for type 1031
The total weight of the machine is distributed unevenly onto the axles, depending on the respective
position of the uppercarriage and the working attachment.
Sometimes, the permissible maximum axle load for travel on public roads is laid down in the national
regulations.
The weight of the rear axle of type 1031 (machine with outrigger support) might exceed 12 t, provided
that the working attachment is moved as closely as possible to the uppercarriage.
The following instructions are based on a . In order to keep
the load of the rear axle below this limit, the centre of gravity must be moved forward.
LHB/en/Edition: 12/2007
This symbol is displayed, if the slewing boom is positioned in such a way that the rear
axle load is within the limits.
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Monitoring display from V.4.7.2 Service Manual
Output of information via menus in LCD screen
Display DISP 02
Keypad BBT-02
Excavator control BST-EHR / UEC
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Service Manual Monitoring display from V.4.7.2
Level 1 for operators (no dongle required for access)
Execution of the various functions requires authorisations (service level), which are organised in
various levels. This sort of organisation allows to limit access to certain functions that require a certain
degree of knowledge to those persons who know the machine and components.
The first level can be accessed by everybody. For levels 2 and 3, personnel need a dongle for
or for amplifier board containing the appropriate coding,
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Monitoring display from V.4.7.2 Service Manual
Levels 2 and 3 for mechanics and inspectors
Purge mode
Starting diesel engine in PURGE mode
(only displayed if diesel engine is off)
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Service Manual Monitoring display from V.4.7.2
Menu control
The description below refers to the menu control of the basic model. For ZW-specific menus, refer
to the service manual, (see “ZW-specific menu control” on page 11).
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Monitoring display from V.4.7.2 Service Manual
Menu control
LHB/en/Edition: 12/2007
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Service Manual Control panel
Coding plug
The control panel of the machine (called from now on) has a coding plug on connection plug
LHB/en/Edition: 04/2007
15-pin plug detects the type of machine, thanks to the hardware coding. In the absence of a valid
coding plug, the keyboard is not operational.
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Control panel Service Manual
Replacing control panel
The coding plug stores current machine data in a data memory (serial EEPROM), as listed below.
Thanks to this method, it is possible to exchange keyboards and re-enter data from the plug into the
new keyboard.
Data stored:
– Type of equipment, serial number and settings in menu
– Current operating hour
– Current operating times (screen )
– Current settings of flow limitation (internal and external values)
– Currently selected flow limitation options
– Error memory for water level )
– Error memory for water temperature
– Error memory for hydraulic oil
– Error memory for hydraulic oil temperature
– Error memory for motor oil pressure
– Confirmed service intervals / service checks
Transfer of data from the keyboard to the coding plug for storage is carried out
– automatically, every 30 minutes approx.
– It is possible, in addition, to force a copy of the data stored pressing buttons and
(see following paragraph) in order to save data to the plug, e.g. before you exchange the .
Before you replace the panel, you should read the most important parameters of the keyboard in
LHB/en/Edition: 04/2007
the display and write them down (i.e. serial no., operating hours, flow limitations, number of
operating errors E5xx in error memory etc. See menus , and ).
Before you replace the , check the data in the coding plug.
Switch off ignition. Insert green service plug into of board ( ) (see Fig. 2).
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Service Manual Control panel
Secure data in coding plug.
Switch off ignition. Insert service plug. Press and hold buttons and . Hold buttons
and, simultaneously, turn key on position.
The keyboard will now check its data against the data stored in the plug.
If the data is okay, the display will show the message .
If the keyboard and plug data do not match, the keyboard data will be automatically copied to
the plug. (LEDs of speed adjustment flash running signal).
Finally, a message will appear.
LHB/en/Edition: 04/2007
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Control panel Service Manual
Replacing keyboard S2
Be sure to switch off main power switch before you disconnect the connection plug.
Remove connection plugs from keyboard you want to remove. Plug into new keyboard. Plug in
correctly. Secure. (see Fig. 4)
Automatic transfer of data from coding plug to new keyboard
– As soon as the control is launched (self-check), the data in the EEPROM are automatically
checked. The data stored will then be automatically transferred from the plug to the new keyboard.
– Data transfer is indicated by running light signal of the speed adjustment LEDs on the keyboard.
– When finished, all the important data listed and essential for operation are available in the new
keyboard.
Checking transferred data in the new BBT:
– Call up display menu and compare data indicated with data you wrote down before replacement. LHB/en/Edition: 04/2007
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Service Manual Control panel
Replacing glow bulbs of backlit keyboard
– The backlit keyboard has six glow bulbs ( ) underneath upper part of keyboard.
– New keyboards are always supplied with two spares.
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Control panel Service Manual
Replacing glow bulbs of backlit keyboard
LHB/en/Edition: 04/2007
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Service Manual Error code list
Error code list
Malfunctions and errors are indicated by indicator lights or symbols on the monitoring display. In
certain cases, an acoustic warning signal is generated. Additional information that facilitates the
elimination of the problem is provided by error codes.
Malfunctions and errors are frequently caused by incorrect operation of the machine or improper
maintenance.
Each time you encounter a malfunction, read the relevant chapter in the operator's manual and/
or refer to the respective subgroup in the service manual.
Check the basic settings of the machine.
Identify the cause of the malfunction or error and eliminate it.
E 002 Engine oil pressure not monitored Pressure switch, short circuit, earth Check engine oil level,
E 003 Pressure switch B5 (X154/14) contact or wire break check pressure switch; replace, if
necessary
E 004 Coolant temperature not monitored Water level sensor, short circuit, Check cooling water level,
Water level sensor B3 (X135/13) earth contact or wire break check water level sensor; replace, if
E 005
necessary
E 006
E 007 Coolant temperature not monitored Temperature sensor, short circuit, Check cooler for dirt, check
E 008 Water temperature sensor earth contact or wire break temperature sensor; replace if
B2 (X135/40) necessary
E 009
E 010 Hydraulic oil level not monitored Hydraulic oil level sensor, short Check hydraulic oil level, check
E 011 Hydraulic oil level sensor circuit, earth contact or wire break hydraulic oil level sensor; replace, if
B14 (X135/31) necessary
E 012
LHB/en/Edition: 09/2012
E 013 Hydraulic oil temperature not Hydraulic oil temperature sensor, Check cooler for dirt, check hydraulic
E 014 monitored short circuit, earth contact or wire oil temperature sensor; replace if
Hydraulic oil temperature sensor break necessary
E 015 B8 (X135/21)
E 016 Pump distributor gear (if installed): Temperature sensor, short circuit, Check plug and cable connections,
E 017 gear oil temperature not monitored earth contact or wire break check temperature sensor; replace, if
Transmission temperature sensor necessary
E 018 B15 (X135/35)
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Error code list Service Manual
Error code list
E 022 Diesel engine speed not monitored; Speed sensor, short circuit, earth Switch diesel engine and hydraulic
diesel engine speed cannot be contact or wire break pump to emergency mode, see
E 023
changed through keyboard; reduced group 8.81 "Emergency operation"
E 024 hydraulic power Check speed sensor; replace, if
Diesel engine speed sensor necessary
B12 (X135/1)
E 027 Insufficient hydraulic power Cable defect at the amplifier for the Switch hydraulic pump to emergency
Power regulator solenoid performance regulation of the mode, see group 8.81 "Emergency
Y50 (X135/9 hydraulic pump operation"
E 030 Proportional solenoid valve Y451 Cable break at proportional solenoid Check solenoid valve Y347; replace,
(X135/8) not monitored; proportional valve Y514 if necessary
pressure control is not possible Check plug and cable connections;
E 033 Maximum fan speed Fan control, cable defective Check solenoid valve Y347; replace,
Fan control regulator solenoid if necessary
Y347 (EV5 X135/5) check fan control
E 036 Flow reduction for hydraulic Cable defect at the amplifier for the Do not operate flow-reduced
attachments is not working properly flow regulation of the hydraulic pump attachments, check solenoid valve
Flow reduction regulating solenoid Y51; replace, if necessary
Y51 (EV1 X135/7)
E 039 Flow reduction for hydraulic Cable defect at the amplifier for the Do not operate flow-reduced
attachments is not working properly flow regulation of the second attachments, check solenoid valve
Flow reduction regulating solenoid hydraulic pump Y52; replace, if necessary
Y52 (EV2 X135/6)
E 042 Slewing gear fine control not working Cable defect at valve Check solenoid valves; replace, if
Y451 (A 900 C - A 904 C) necessary
Monitoring of hydraulic oil cooling not Cable defect at valve Check plug and cable connections;
(EV3X135/25)
working Y53 (A 914C - A 924 C)
No power reduction at slewing gear Cable defect at valve
Y103 (A 934 C - A 954 C)
Performance regulation of hydraulic Wire break at valve
pump not working properly
E 045 Insufficient pressure for attachment Tool Control, cable defect at Check pressure control valve Y429;
pressure control valve Y414 (EV6) replace, if necessary
E 046 Separating plate over S38(SF3) can Wire break at solenoid valve Y431 Check plug and cable connections;
now longer the activated if necessary, replace solenoid valve
No kit operation Y431
E 053 Stick cannot be moved Angle sensor, short circuit, earth Check potentiometer; replace, if
E 054 Potentiometer B317 (X1/5) contact or wire break necessary Check plug and cable
E 055 connections
E 056 Fine control of slewing gear not Pressure sensor, earth contact or Check pressure switch at left servo
responding wire break control unit; replace, if necessary
E 057
Pressure sensor B335 (X1/21)
E 058
E 063 Engine power reduced Temperature sensor of intercooling Check temperature sensor; replace,
E 065 (XA/50) air, earth contact or short to plus if necessary
E 073
(XA/47)
E 074 Diesel engine cannot be started Starter, earth contact or wire break Check starter; replace, if necessary
E 075 Starter start terminal 15 (XA/29) Check plug and cable connections
E 081 In the event of a failure of both speed Speed sensor Speed1 Check speed sensor; replace, if
E 082 sensors, the engine cannot be Speed sensor Speed2 necessary
started
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Service Manual Error code list
Error code list
E 084 Failure of pre-heating and after- Cold-starting aid, short circuit, Check engine control unit, heater
heating function malfunction or wire beak flange, cable harness
E 085
E 086
E 087 Error is displayed Speed difference between Speed1 Check speed sensor; replace, if
and Speed2 necessary
E 088 Engine power reduced Fault in ambient air pressure sensor Check cabling and sensor; replace, if
necessary
E 089 Machine cannot be started Cable defect, water in fuel filter Check cabling between engine
control unit and sensor, dewater fuel
filter
E 090 Fuel temperature is not transmitted, Fuel temperature sensor, earth Check cabling between engine
engine performance is reduced contact, wire break or short to plus control unit and sensor; replace, if
E 091
(XA/52) necessary
E 098 Error is displayed Fault in cable connection D+ to PLD Check alternator and cabling to
(XA/64) electronics alternator; replace alternator, if
necessary
E 099 Alternator defective
E 100 Error is displayed Speed signal Speed1 Check speed sensor, cabling to
E 101 Speed signal Speed2 engine control unit; replace, if
necessary
E 102 Engine cannot be started Crank shaft synchronisation failed Check ignition (on/off) and speed
sensor; replace, if necessary
E 103 Error is displayed Speed sensor of cam shaft defective Check cabling to speed transducer,
E 104 No speed signal from cam shaft speed sensor; replace, if necessary
E 105 Engine cannot be started Cam shaft synchronisation failed Check speed sensor; replace, if
necessary
E 109 Error is displayed CAN1 hardware failure Check cabling, plugs and CAN
E 110 No CAN1 data (timeout) assemblies
E 111 Error is displayed Injector A1 defective Check cabling, plug and engine
control unit
E 112 Error is displayed Injector A1 BIP fault
E 113 Error is displayed Injector A2 defective
E 114 Error is displayed Injector A2 BIP fault
E 115 Error is displayed Injector A3 BIP defective
E 116 Error is displayed Injector A3 BIP fault
E 117 Error is displayed Injector A4 BIP defective
E 118 Error is displayed Injector A4 BIP fault
E 119 Error is displayed Injector B1 BIP defective Check cabling, plug and engine
E 120 Error is displayed Injector B1 BIP fault control unit
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Error code list Service Manual
Error code list
E 150 Servo pressure is not measured Wire break Check plug and cable connections;
B359 Current at pressure sensor B359 check pressure sensor B359;
<3mA replace, if necessary
E 151 Servo pressure is not measured Short circuit Check plug and cable connections;
B359 Current at pressure sensor B359 check pressure sensor B359;
>21mA replace, if necessary
E 302 Input through keyboard not possible No code plug
(X42)
E 303 Engine speed cannot be adjusted No CAN bus connection between Switch diesel engine and hydraulic
through the keyboard, hydraulic keyboard and control system (BST) pump to emergency mode, see
performance is reduced (Message might appear even if BST group 8.81 "Emergency operation"
Reduced hydraulic power in PLD excavator control is not operational, Y50 emergency operation of working
machines e.g. no power supply, etc.) pumps Y50 (only in PLD machines)
E 305 Malfunctions, e.g. of travel brake, No CAN bus connection between Switch control to emergency mode,
slewing gear brake, servo control keyboard and ESP01 printed circuit see group 8.81 "Emergency
board (message is also displayed, if operation"
ESP01 is not ready for operation) Check cable and plug connections
E 306 Malfunctions, e.g. in travel direction No CAN bus connection between Check cable and plug connections
switch, gear shifting system, keyboard and ESP02 printed circuit
oscillating axle locking mechanism, board (message is also displayed, if
accessory kits ESP02 is not ready for operation)
E 307 Throttle control not possible No CAN bus connection between Check cable and plug connections
PLD electronics A700 keyboard and PLD diesel engine
regulating unit (message is also
displayed, if PLD regulator is not
ready for operation)
E 308 No or incorrect display No CAN bus connection of keyboard Check cable and plug connections
to display, or keyboard defective Check software versions
E 309 Software incompatibility between
keyboard and display
E 311 The ZW control panel and/or the No CAN bus connection between Check cable and plug connections
main screen remain blank control system / ZW control panel, or
fault at ZW control panel
E 312 Control system failure No CAN bus connection between Check cable and plug connections
BBT and option control system
E 314 Diesel engine switches to Timeout of PLD
emergency mode
E 315 Machine cannot be moved, travel No CAN bus connection between Check cable and plug connections
function remains available UEC stroke limitation and UEC
undercarriage
E 317 Tool management not working No CAN bus connection to control Check cable and plug connections
system
E 318 Proportional control not working No CAN bus connection to control Check cable and plug connections
system (A180)
E 319 Engine speed cannot be adjusted Hardware coding does not match Switch diesel engine and hydraulic
through the keyboard, hydraulic software coding pump to emergency mode, check
E 321 performance reduced No known machine type received software versions
Code plug X42
from keyboard
LHB/en/Edition: 09/2012
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Service Manual Error code list
Error code list
E 442 Failure of idle automatic at left servo Handle sensor, short circuit, earth Deactivate idle automatic, check
control unit, engine remains at lower contact or wire break handle sensor; replace, if necessary
E 443
speed; handle sensor B19L
E 445 Failure of idle automatic at right Handle sensor, short circuit, earth Deactivate idle automatic S20,
E 446 servo control unit, engine remains at contact or wire break check handle sensor; replace, if
lower speed; handle sensor B19R necessary
E 447 Pressure for regulating travel motor Ground connection, wire break Check cable and plug connections
not monitored Cable fault at pressure sensor B144, Check pressure sensor; replace, if
current <3mA or >21mA necessary
E 450 Engine speed reduction at lowering Pressure sensor, short circuit, earth Check pressure sensor; replace, if
of attachment (pressure-free contact or wire break necessary
lowering)
Pressure sensor B145
E 454 Speed sensor for slewing gear Slewing gear speed sensor, slewing Check speed sensor; replace, if
mechanism without function; non- gear, short circuit, earth contact or necessary
E 455
compliance results in damage to wire break
slewing gear brake
Speed sensor B53
E 456 Incorrect fuel level indication Fuel sensor, short circuit, earth Visually check fuel level, check tank
Tank sensor B39 contact or wire break sensor; replace, if necessary
E 458
E 901 Overload warning system generates Pressure sensor in hoist cylinder Check pressure sensor; replace, if
warning signal and shuts down defective necessary
working attachment Pressure sensor B335
A141.X1.31
E 902 Reduced payload Failure of angle sensor B384 at Check cable and plug connections
horizontally adjustable boom Do not execute any work that
requires horizontal boom adjustment
Check angle sensor; replace, if
necessary
E 903 Failure of overload warning system Pressure sensor B318 of hoist Do not execute any work that
A141.X1.33 cylinder 1 faulty requires overload warning; check
E 904 Failure of overload warning system Pressure sensor B319 of hoist pressure sensor; replace, if
necessary
A141.X1.34 cylinder 2 faulty
E 905 Failure of overload warning system Failure of angle sensor of basic Do not execute any work that
and stroke limitation A141.X1.25 boom requires overload warning or stroke
limitation; check angle sensor;
E 906 Failure of overload warning system Angle sensor of boom faulty
and stroke limitation A141.X1.26 replace, if necessary
E 909 Failure of boom limitation Angle sensor of slewing gear faulty Do not execute any work that
A141.X1.29 requires boom limitation
E 910 Failure of boom limitation Pressure sensor of slewing gear Do not execute any work that
A141.X1.30 faulty requires boom limitation; check
pressure sensor; replace, if
necessary
E 911 Control system failure Error in EEPROM record Check control data record
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Error code list Service Manual
Error code list
E 912 Uppercarriage cannot be swivelled to No release signal to control system Check cable and plug connections
the left A141.X2.36 for swivelling to the left Check control system
E 913 Uppercarriage cannot be swivelled to No release signal to control system
the right A141.X2.35 for swivelling to the right
E 914 Hoist cylinder cannot be moved No release signal for lifting the hoist
A141.X2.34 cylinder to control system
E 915 Slewing gear fails to turn or turns Slewing gear fine control Y451 Check cable and plug connections;
only very slowly A141.X2.33 Wire break, short circuit check control output DO.4 (X2.33)
E 916 Hoist cylinder cannot be moved No release signal to control system Check cable and plug connections
A141.X2.32. for hoist cylinder preliminary shut- Check control system
down
E 917 Adjustable boom cylinder cannot be No release signal for lifting of
moved A141.X2.31. adjustable boom cylinder to control
system
E 918 Adjustable boom cylinder cannot be No release signal to control system
moved A141.X2.30 for adjustable boom cylinder
E 919 Stick cylinder cannot be moved No release signal for lifting of stick
A141.X2.29 cylinder to control system
E 920 Adjustable boom cylinder cannot be No release signal to control system
moved A141.X2.28 for adjustable boom cylinder
E 921 Super Finish does not work Super Finish solenoid valve, earth
A141.X2.27 contact or wire break
E 929 Working attachment cannot be Stroke limitation, failure in power Switch stroke limitation to
operated supply to sensors emergency mode, check cable and
plug connections
E 941 Automatic mode of rail guide system High pressure sensor at left front axle Move machine from the track, check
is switched off, manual lifting and defective A140.X1.26 B330 cable and plug connections
lowering remains possible Check sensors; replace, if necessary
E 942 High-pressure sensor at right front
axle defective A140.X1.25
E 943 High-pressure sensor at right rear
axle defective A140.X1.28
E 944 High-pressure sensor at left rear axle
defective A140.X1.27
E 945 High pressure sensor of ZW pump
defective A140.X1.29
E 946 Travel function and rail gear locked Level sensor of front rail guide Check cable and plug connections
system defective A140.X1.32 Check sensors; replace, if necessary
E 947 No angle value is sent to overload Inclination sensor defective
warning system and a less
favourable angle is applied; warning
signals are therefore triggered earlier
A140.X1.30
E 948 Travel function and rail gear locked Level sensor of rear rail guide system Check cable and plug connections
defective Check sensors; replace, if necessary
E 949 Front axle verification error Switching points of proximity switch Check cable and plug connections
are outside permissible range of Check switching point of proximity
angle sensor switch (indicator light)
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Service Manual Error code list
Error code list
E 951 Pump is fully swivelled out, even if Wire break at pump valve Check cable and plug connections
there is no need for this movement
Automatic rail guide mode is
switched off A140.X2.36
E 952 Automatic rail guide mode is Front rail guide system - wire break Move machine from the track, check
switched off at valve, at pump side (P) cable and plug connections
A140.X2.32
E 953 Rear rail guide system - wire break at
valve, at pump side (P) A140.X2.29
E 954 Valve of rear axle pressure control
A140.X2.32
E 955 Front rail guide system - wire break
at valve, at pump side (P)
A140.X2.35
E 956 Front rail guide system - wire break
at valve, at tank side (T) A140.X2.31
E 957 Rear rail guide system - wire break at
valve, at tank side (T) A140.X2.30
E 958 Rear rail guide system - wire break at
valve, at pump side (P) A140.X2.29
E 959 Valve outrigger release, front left
A140.X2.28
E 960 Valve of front axle pressure control
A140.X2.27
E 961 Is displayed, if automatic mode has One of the above faults has
been terminated due to one of the terminated the automatic mode
above faults
E 962 No CAN bus connection between CAN bus timeout to uppercarriage Check CAN bus connection
control (uppercarriage) and control control (stroke limitation) Check cables and plug connections
(undercarriage) between the control units
Check slip-ring rotary connection
E 963 ZW control panel without function CAN bus timeout TDS 01 Carry out emergency lowering
Automatic rail guide mode is manoeuvre
switched off Using the hand-operated emergency
Manual lifting and lowering is not control device, lift the rail guide axles
possible Move machine from the track, see
group 8.81
E 964 Acoustic warning signal indicating Pressure of one of the rail guide Move machine from the track; check
that machine might become derailed axles is too low traction; readjust, if necessary
With friction wheel guide system:
loss of traction or incorrect traction
settings
E 965 Machine cannot be steered properly Power supply UB1, UB2 or UB3 If necessary move machine from the
Automatic rail guide mode is interrupted Cable or fuse defective track, check cable and plug
switched off connections
Replace fuse, if necessary
E 966 Automatic rail guide mode is Reference voltage overload at angle Move machine from the track; check
switched off sensors sensors
LHB/en/Edition: 09/2012
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Error code list Service Manual
Error code list
E 970 Right AHS pedal faulty A159.X1.25 Short circuit or wire break signal 1 Check cable and plug connections
E 971 Right AHS pedal faulty A159.X1.26 Short circuit or wire break signal 2 Check cable and plug connections
E 972 Left AHS pedal faulty A159.X1.27 Short circuit or wire break signal 1 Check cable and plug connections
E 973 Left AHS pedal faulty A159.X1.28 Short circuit or wire break signal 2 Check cable and plug connections
E 974 Travelling pedal faulty A159.X1.29 Short circuit or wire break signal 1 Check cable and plug connections
E 975 Travelling pedal faulty A159.X1.30 Short circuit or wire break signal 2 Check cable and plug connections
E 976 Error is displayed Error in EEPROM Check control system
E 977 Affected functions are locked Error in I/O configuration due to Check display programming
duplicate assignment
E 978 Right AHS pedal faulty Comparison error signals 1 and 2 Check cable and plug connections
E 979 Left AHS pedal faulty Comparison error signals 1 and 2 Check cable and plug connections
E 980 Travelling pedal faulty Comparison error signals 1 and 2 Check cable and plug connections
E 981 Adjustable boom cylinder cannot be Solenoid valve, short circuit or wire Check cable and plug connections
extended A159.X2.36 break
E 982 Adjustable boom cylinder cannot be Solenoid valve Y481, short circuit or Check cable and plug connections
retracted A159.X2.35 wire break If necessary, replace solenoid valve
E 983 Failure of function "closing cylinder Solenoid valve Y482, short circuit or Check cable and plug connections
A1" A159.X2.34 wire break If necessary, replace solenoid valve
E 984 Failure of function "closing cylinder Solenoid valve Y483, short circuit or Check cable and plug connections
A2" A159.X2.33 wire break If necessary, replace solenoid valve
E 985 Failure of function "travel" Solenoid valve Y353, short circuit or Check cable and plug connections
A159.X2.32 wire break If necessary, replace solenoid valve
E 986 Left AHS pedal faulty A159.X2.31 Solenoid valve Y485, short circuit or Check cable and plug connections
wire break If necessary, replace solenoid valve
E 987 Right AHS pedal faulty A159.X2.30 Solenoid valve Y484, short circuit or Check cable and plug connections
wire break If necessary, replace solenoid valve
E 988 Failure of function "grapple turning" Solenoid valve Y23, short circuit or Check cable and plug connections
A159.X2.29 wire break If necessary, replace solenoid valve
E 989 Failure of function "grapple turning" Solenoid valve Y22, short circuit or Check cable and plug connections
A159.X2.28 wire break If necessary, replace solenoid valve
E 990 Magnet system failure A159.X2.27 Solenoid valve Y500, magnet Check cable and plug connections
system, short circuit or wire break If necessary, replace solenoid valve
E 991 Failure of function "reverse travel" Solenoid valve, magnet system, Check cable and plug connections
Y63 A159.X2.26 short circuit or wire break If necessary, replace solenoid valve
E 992 Failure of function "forward travel" Short circuit or wire break Check cable and plug connections
Y62 A159.X2.25 If necessary, replace solenoid valve
E 993 Control system switching not Solenoid valve, short circuit or wire Check cable and plug connections
possible break If necessary, replace solenoid valve
E 994 Working attachment cannot be Stroke limitation, failure in power Switch on stroke limitation
operated A159.X1.11 supply to sensors
The faults and errors listed below are indicated by symbols on the screen or by indicator lights. The
respective error codes are not shown in the EC field of the operator menu. The only way to read them
is the "list-S-Exxx" menu.
LHB/en/Edition: 09/2012
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Service Manual Error code list
Error code list
E 501 Indicator light H2 on, Oil pressure of diesel engine too Set the diesel engine to low idle
acoustic warning signal low speed and switch it off after 30
seconds
E 502 Symbol is displayed, Coolant level too low Set the diesel engine to low idle
acoustic warning signal speed and switch it off after 30
seconds; locate leak and seal it
E 503 Symbol and P2 are on at the Coolant overheating Set the diesel engine to low idle
same time, acoustic warning speed and shut it down after 30
signal seconds; check cooler for dirt; check
coolant level
E 504 Symbol is displayed, Hydraulic oil level too low Set the diesel engine to low idle
acoustic warning signal speed and shut it down after 30
seconds; locate leak and seal it; add
hydraulic oil
E 505 Symbol is displayed, Hydraulic oil overheating Set the diesel engine to low idle
acoustic warning signal speed and shut it down after 30
seconds; check cooler for dirt
E 506 Symbol is displayed, Oil temperature in pump Set the diesel engine to low idle
acoustic warning signal distribution gear too high speed and shut it down after 30
seconds; check hydraulic oil cooler
for dirt
E 509 Indicator light H24 on, Flow indication of steering Check hydraulic system of steering
acoustic warning signal system: no hydraulic oil or system; check flow indicator and
steering pump defective steering pump; replace, if necessary
E 510 Indicator light H23 on, Accumulator pressure of Load accumulator while diesel
acoustic warning signal operating brake too low engine is on; if problem persists:
(< 100 bar)
E 514 Central lubrication system: Signal to clock pulse generator Carry out intermediate lubrication
E 515 lubrication control without valve continues after the set
function, symbol is displayed monitoring time has lapsed
(clock pulse generator B51)
E 516 Diesel engine cannot be Emergency-stop EDC error,
started, or engine shut-down engine control has detected an
LHB/en/Edition: 09/2012
internal error
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Error code list Service Manual
Error code list
E 523 Symbol is displayed, Coolant overheating (7> Let machine cool down, e.g. in F
acoustic warning signal seconds); safety threshold mode; check cooler for dirt; check
exceeded coolant level
E 524 Symbol is displayed, Intercooling air overheating Check cooler for dirt
acoustic warning signal (7>seconds); safety threshold
exceeded
E 525 Symbol is displayed, Engine fault in emergency mode. Set the diesel engine to low idle
acoustic warning signal Engine was started in speed and switch it off after 30
Collective warning after error emergency mode; no connection seconds
E501, E502, etc. between engine control system
and keyboard
E 526 Symbol is displayed, Fuel temperature: warning Check radiator for dirt
acoustic warning signal threshold exceeded
E 527 Symbol is displayed, Fuel temperature: safety Set the diesel engine to low idle
acoustic warning signal threshold exceeded speed and switch it off after 30
seconds
E 528 Symbol is displayed Water in fuel filter Remove the water from the fuel filter
E 530 Diesel engine shuts down; Internal error in engine control Restart the engine; in the event of
symbol is displayed, unit failure
acoustic warning signal
E 532 Symbol is displayed Fuel pressure: warning threshold Check fuel, filter, tank
exceeded
E 533 Symbol is displayed Fuel pressure: safety threshold Set the diesel engine to low idle
exceeded speed and shut it down after 30
LHB/en/Edition: 09/2012
seconds
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Service Manual Error code list
Troubleshooting
E 597 Engine power reduced; Intercooling air temperature: Let machine cool down, e.g. in F
symbol displayed, acoustic warning threshold exceeded mode; check cooler for dirt
warning signal
This symbol, together with a buzzer warning sound, indicates that the quick-change adapter is not
properly locked.
If the symbol is displayed, immediately halt operation, unless you wish to release the adapter. If the
symbol is not displayed while the quick-change adapter is being released, also immediately stop the
procedure.
The alarm signals might be triggered if a lock bolt has inadvertently become dislodged, or by
mechanical or hydraulic damage. The alarm signals might also be caused by defects in the electrical
system (e.g. at the proximity switch or buzzer).
Only resume operation after the defective part has been repaired or replaced.
LHB/en/Edition: 09/2012
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Error code list Service Manual
Troubleshooting
Starter turns slowly Battery voltage too low Charge or replace battery
Battery connections loose or corroded Clean and tighten loose connections
Ambient temperature too low Take measures required for winter
operation
Diesel engine fails to start Fuel tank nearly/completely empty Add fuel and bleed fuel system
Underpressure in tank Remove tank lid
Fuel filter dirty Clean or change filter and bleed fuel
system; drain off fuel / clean tank
Ambient temperature below 0°C For operation and control under extreme
conditions, see operating instructions
Heater flange defective (at low Check heater flange; replace, if
temperatures) necessary
Starter failure Check line connections, service starter
Batteries flat Recharge / replace batteries
Engine starts, but stops immediately or Fuel tank empty (underpressure in tank) Add fuel and bleed fuel system
runs irregularly Fuel filter dirty Clean or change filter and bleed fuel
system (tank)
During cold season: engine oil viscosity Use an engine oil that is suitable for the
too high actual ambient temperature
Dry air filter dirty Clean or replace main filter element
Air in fuel system Bleed fuel system
Bleeder valve in fuel tank blocked Cleaning
Fuel line, pre-filter or strainer in fuel tank Clean and bleed fuel system
blocked
Fuel line kinked Check line and repair, if required
Diesel engine emits grey or black fumes Dry air filter dirty Clean or replace filter
Injection nozzles jammed or no injection
Turbo charger defective
Diesel engine constantly emits steam Water in combustion chamber
Injection too late
Heater flange defective (at low Check heater flange; replace, if
temperatures) necessary
Blue exhaust fumes Oil level too high Correct oil level
Lubricating oil in combustion chamber
Crankcase ventilation defective
Diesel engine knocking Combustion problems
Diesel engine knocking Excessive valve play
Injection nozzles damaged or
carbonised
Damaged bearing
LHB/en/Edition: 09/2012
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Service Manual Error code list
Troubleshooting
Poor diesel engine performance Fuel system defective (blockage, Visually check for leakage; replace filter
leakage)
Intercooling pressure too low Visual inspection for loose clamps,
defective seals and damaged hoses;
clean air filter
Intercooling air temperature too high Clean intercooling cooler
(power reduced by engine control unit)
Coolant temperature too high (power Check coolant level; check cooler for
reduced by engine control unit) dirt, clean if necessary; check fan and
thermostat
Fuel temperature too high (power
reduced by engine control unit)
Injection nozzles jammed or no injection
Diesel engine compression too low
Fault in electronics
Diesel engine too hot Insufficient coolant Add coolant, check for tightness
Water pump defective Repair
Thermostats fail to work Replace thermostats
Radiator dirty Clean radiator
Coolant temperature sensor defective Contact LIEBHERR customer service
Insufficient oil pressure in diesel engine Oil level too low Adjust oil level
Oil pressure indicator defective Change oil pressure switch
Immediately switch off diesel engine
Diesel engine uses too much oil Leakage in diesel engine Retighten screws; replace seals, if
required
Oil in coolant or coolant in oil Contact LIEBHERR customer service.
Unusual noises / noise at exhaust side Leakage in exhaust gas system Check / repair exhaust gas system
Unusual noises / noise from hydraulic Stop valve on hydraulic tank closed Open stop valve
pumps Hydraulic pumps take in air Check oil level in hydraulic tank, check
suction lines for leakage
Immediately switch off diesel engine
Modes E and P show poor performance No performance adjustment by means Disconnect cable at connection Y50,
of proportional solenoid valve Y50 remove cotter pin, set handle switch to
emergency position
Hydraulic oil temperature too high Radiator dirty Clean radiator
Fan or fan control defective Eliminate fault
Hydraulic oil level too low Oil loss Repair leak, replace hoses, add oil
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Error code list Service Manual
Troubleshooting
Travel function not available Safety lever moved up Move safety lever down
No direction of travel selected Select direction of travel using the travel
selection switch in the right joystick
Pressure switch of parking brake
defective
Parking brake not released Release parking brake using the switch
Parking brake cannot be released with Servo pressure OK:
the switch actuate emergency function Y6
No servo pressure:
operating brake applied Release operating brake
Slewing gear failure Servo control not working Move safety lever down
Switch on servo control
Slewing gear brake activated Move safety lever down
Release slewing gear brake
No working movement Servo control not working Move safety lever down
Switch on servo control
No servo pressure
No pump high pressure
Machine fails to travel forward or back Safety lever moved up Move the safety lever down. Release
Parking brake applied with switch parking brake with switch
No direction of travel selected Preselect direction of travel with
Operating brake applied with brake switch
pedal and retainer Release operating brake with the
retainer
Machine moves too slowly Incorrect gear ratio reduction with Select different gear ratio reduction,
switch using switch
Creeper gear activated with switch Deactivate creeper gear with switch
Travelling pedal cannot be fully pushed Clean cab floor
down Deactivate Super-Finish with
Super-Finish activated with switch switch (if installed) Switch off
(if installed) emergency control and switch machine
Emergency control activated to standard operating mode.
LHB/en/Edition: 09/2012
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Service Manual Error code list
Troubleshooting
Battery charging indicator light does not V-belt of alternator loose or broken Tighten or replace V-belt.
go off Alternator defective Replace alternator.
Batteries not sufficiently charged Batteries defective Replace batteries.
Battery connections dirty / oxidised Clean battery connections.
Cable loose or defective Connect or replace cable.
Failure of indicator light or indicating Incandescent lamp burnt out; indicating Replace defective part
instrument instrument defective
Failure of one or more instrument panel Adapters disconnected or defective; Plug in or change adapter; eliminate
functions earth connector disconnected; short cause of short circuit; replace fuse or
circuit - fuse blown reset automatic cut-out.
Diesel engine speed cannot be adjusted Low idle automatic switch actuated Touch joystick or release switch of low
through keyboard (mode and arrow idle automatic
keys) Excavator electronics for throttle control Changeover to emergency control for
not working throttle control and
No signal from speed sensor
Low idle automatic without function; Permanent sensor signal Contact LIEBHERR customer service.
speed fails to drop Switch deactivated Activate switch
Servo control cannot be activated with Fault in electrical system of excavator Activate emergency operation with
switch switch in the right joystick
Parking brake cannot be released with Caution: The servo and brake circuit can
switch now only be switched off with the safety
lever Keyboard is disabled
Slewing gear brake cannot be released
with switch
No warm air from heating system Stop valves of coolant line at diesel Open stop valve
engine closed
Engine not at operating temperature Run engine to operating temperature
Heating blower not working No power Check fuse and cable; replace if
required
Blower motor defective Replace blower motor
Low air circulation rate in operator's cab Ambient air filter / recirculated air filter Clean air intake openings; replace
dirty ambient air filter
Air outlet closed Open air outlet.
LHB/en/Edition: 09/2012
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Error code list Service Manual
Troubleshooting
Rail guide axles cannot be moved ZW system is switched off Switch on ZW system.
One rail guide axle is locked Release rail guide axle.
Hydraulic or electrical fault See error code table
Automatic rail guide mode is switched Hydraulic or electrical fault (e.g. angle See error code table
off sensor)
Manual lifting and lowering is possible
Cylinder responds to load Piston seal in cylinder defective Service cylinder.
Poor tracking, rough travelling Excessive play at bearings, bearing Replace bearing components.
points worn
Rail wheels excessively worn Replace or re-turn rail wheels (max. to
wear limit).
Poor traction, drive wheels spinning, Tyres worn Replace tyres
poor braking behaviour Load to be moved requires increased Briefly activate "lift rail guide" function
contact pressure
Impression depth of drive wheels
insufficient, despite intact tyres
Rail guide axles cannot be moved ZW system is switched off Switch on ZW system.
One rail guide axle is locked Release rail guide axle
Hydraulic or electrical fault See error code table
Automatic rail guide mode is switched Hydraulic or electrical fault (e.g. angle See error code table
off sensor)
Manual lifting and lowering is possible
Cylinder responds to load Piston seal in cylinder defective Service cylinder
Poor tracking, rough travelling Excessive play at bearings, bearing Replace bearing components
points worn
Rail wheels excessively worn Replace or re-turn rail wheels (max. to
wear limit).
Poor traction, drive wheels spinning, Tyres worn Replace tyres
poor braking behaviour Load to be moved requires increased Briefly activate "lift rail guide" function
contact pressure
Impression depth of drive wheels
insufficient, despite intact tyres
LHB/en/Edition: 09/2012
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Service Manual Emergency actuation (emergency operation)
Emergency hydraulics (optional equipment)
The fuse of the emergency hydraulics is accessible when the right access door is opened.
In certain situations, it might be necessary to restore a function that failed before the machine is
properly repaired. Depending on the type and extent of the malfunction, this might be achieved by
setting the machine to emergency mode.
In emergency mode, certain control electronics and control elements are bypassed so that certain
functions can be controlled directly. This mode allows for the temporary limited operation of the
machine.
Emergency mode is designed for use in emergency situations only.
Due to the reduced functionality of the machine in emergency mode and the associated risks, this
mode may only be used in exceptional situations.
:
– Hydraulic pump Move the machine away from the construction site or
– Slewing gear brake a dangerous position (immediate repair is required)
– Stroke limitation
– Boom limitation
LHB/en/Edition: 09/2008
– Travelling
– Emergency hydraulics
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Emergency actuation (emergency operation) Service Manual
Emergency mode control
In emergency mode, certain safety functions of the control system are disabled. This can lead to
accidents or damage to the machine.
Use the emergency mode only for the intended purpose.
Inform all persons involved in the operation and maintenance of the machine that it is in
emergency mode.
Immediately switch off the emergency mode when it is no longer required.
All repairs to the machine must be carried out without delay.
In the event of a failure of the steering electronics, certain machine components might not work
properly.
Depending on the type and extend of the malfunction, it might be possible to re-establish proper
operating conditions for the machine components:
The emergency control feature includes three functions:
– Emergency operation of diesel engine
– Emergency speed adjustment
– Emergency control of control devices
These functions may be combined with each other.
The control panel for emergency control operation is located in the rear section of the right control
console.
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Service Manual Emergency actuation (emergency operation)
Emergency operation of diesel engine
In normal operating mode, the electronic devices of the diesel engine communicate with the control
electronics of the machine. In the event of a malfunction or failure, it might not be possible to start the
diesel engine or to control it properly. In such a case, the diesel engine can be started in emergency
mode.
Press the emergency start switch to the right.
Start the diesel engine with the ignition key.
The indicator light is on.
The symbol is shown at the display.
The diesel engine runs in emergency mode.
Resetting to normal operating mode is only possible after the diesel engine has been switched off
and restarted again.
In emergency mode, communication between the diesel engine and the control electronics of the
machine might be impaired. Error messages from the diesel engine might not be displayed. In
addition, the following safety functions are disabled:
– Automatic shut-down of the diesel engine in the event of insufficient engine oil pressure
– Automatic shut-down of the diesel engine in the event of excessive coolant or intercooling air
temperature
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Emergency actuation (emergency operation) Service Manual
Emergency control of control devices
If the diesel engine has been automatically switched into emergency mode, the current engine
speed is maintained.
The emergency control of the control devices caters for the following situations:
– servo control
– Parking brake, slewing gear brake
In emergency mode, the servo control system, the parking brake and the slewing gear brake cannot
be operated with the normal switches and buttons, but only with the safety lever.
In emergency mode, the machine might make unexpected movements when the safety lever is
pushed down (instant release of slewing gear brake and parking brake). There is thus an increased
risk of accidents!
Therefore, use the emergency mode for control devices only when absolutely necessary.
In emergency mode, only complete the manoeuvres necessary to remove the machine from the
danger zone.
In the event of a failure in the pump control, the performance of the hydraulic pumps is automatically
reduced to a minimum.
For such a situation, the excavator is equipped with an emergency operation system for the hydraulic
pump.
LHB/en/Edition: 09/2008
It bypasses the control electronics so that the hydraulic pump can be operated at an only slightly
reduced output rate.
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Service Manual Emergency actuation (emergency operation)
Emergency operation of servo control
The the emergency control for the servo control system is used, if it is not possible to restore the servo
control with any other emergency mode. In this case, the respective solenoid valve must be
operated by hand.
The solenoid valve is equipped with an emergency actuating device.
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Emergency actuation (emergency operation) Service Manual
Emergency operation of slewing gear brake
The safety lever is disabled while the machine is in servo control emergency mode. If a joystick is
moved inadvertently, the machine might perform an unexpected movement. There is thus an
increased risk of accidents!
Therefore, use the emergency mode for control devices only when absolutely necessary.
In emergency mode, only complete the manoeuvres necessary to remove the machine from the
danger zone.
The emergency control for the slewing gear brake is used, if it is not possible to release the slewing
gear brake in any other emergency mode. In this case, the respective solenoid valve must be
operated by hand.
The solenoid valve is equipped with an emergency actuating device.
The slewing gear brake is immediately released when the slewing gear emergency operation is
actuated. The machine might perform an unexpected movement. There is thus an increased risk of
accidents!
Therefore, use the emergency control for the slewing gear brake only when absolutely
necessary.
In emergency mode, only complete the manoeuvres necessary to remove the machine from the
danger zone.
When the shut-down points are reached, the stroke and boom limitation disconnects the pilot control
devices of the working tool and/or slewing gear. The pilot control equipment is again released, when
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Service Manual Emergency actuation (emergency operation)
Emergency operation of stroke and boom limitation (optional equipment)
the limitation function is switched off or when the components are again within the permissible range
of movement.
In the event of a control system failure, the release signal might not be generated, so that the working
attachment or the uppercarriage cannot be moved.
In this case, the respective solenoid valves must be operated by hand. The solenoid valves are
equipped with an emergency actuating device. They is located beside the engine compartment at the
rear of the operator's cab.
The emergency operation of the stroke and boom limitation is designed for assistance when the
following functions fail:
– Control of the working attachment
– Control of the slewing gear
Fig. 8 Valve block for stroke and boom limitation, travel direction preselection
If one of the above solenoid valves fails, all other solenoid valves for boom limitation or slewing gear
movement are disabled. This means that these valves must be operated in emergency mode.
Switch off the diesel engine.
LHB/en/Edition: 09/2008
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Emergency actuation (emergency operation) Service Manual
Travel emergency mode
In the event of a failure of the control system, the travel pedal might become disabled and the
machine cannot be moved.
In this case, the respective solenoid valves must be operated by hand.
The solenoid valve determines the direction of travel is and is actuated with the travel
direction switch. It is located beside the engine compartment at the rear of the operator's cab. The
valve is attached to a bracket or integrated into the valve block of the stroke and boom limitation
system (if installed).
The solenoid valve on the control oil unit is used to switch on travel operation and is actuated
with the travel pedal.
In the event of a failure of the above solenoid valves, all other solenoid valves involved in travel
operation are automatically disabled ( and ). This means that these valves must be
operated in emergency mode.
The solenoid valves are equipped with a n emergency actuating device. The method by when the
machine can be set to travel mode depends on the cause of the failure.
LHB/en/Edition: 09/2008
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Service Manual Emergency actuation (emergency operation)
Travel emergency mode
The cable harness supplied with the machine is required for both methods. By connecting the
respective solenoid valve, the travel pedal or the travel direction switch function can be simulated.
LHB/en/Edition: 09/2008
Check pin
Forward travel
Neutral position - no travel direction selected
Reverse travel
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Emergency actuation (emergency operation) Service Manual
Travel emergency mode
The spool of the solenoid valve is extended outwards and can be shifted by hand. A check
pin is thereby moved inside the manual shift gate and indicates the current switching position.
Switch off the diesel engine.
Turn and shift the spool until the check pin is in the desired position.
The travel direction is preselected.
The solenoid valve can be shifted by means of a manual button. To do this, connect the
supplied cable harness.
Remove the plug from the solenoid valve .
Connect the plug of the cable harness.
Lay the cable so that can it be reached from the operator seat.
Connect the plug of the cable harness to the socket of the cigarette lighter (24 V).
Start the diesel engine.
Press and hold the button at the cable harness.
The machine begins to move.
Release the button.
The machine is halted.
LHB/en/Edition: 09/2008
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Service Manual Emergency actuation (emergency operation)
Travel emergency mode
The machine begins to move immediately after the travel function has been released and the travel
selection control is actuated. If there is no operator in the cab, the machine moves without a driver.
This can of course lead to serious injury or even death.
Never operate the solenoid valve manually.
Operate the cable harness with the button while seated on the operator seat (see section below).
LHB/en/Edition: 09/2008
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Emergency actuation (emergency operation) Service Manual
Emergency hydraulics (optional equipment)
The solenoid valve can be shifted by means of a manual button. To do this, connect the
supplied cable harness see Fig. 10.
Ensure that the check pin is engaged in the neutral position .
Remove both plugs from the solenoid valve.
Insert the plug of the cable harness to the solenoid valve, observing the following instructions
for the selection of the direction of travel: - reverse / - forward.
Lay the cable so that can it be reached from the operator seat.
Connect the plug of the cable harness to the socket of the cigarette lighter (24 V).
Start the diesel engine.
Press and hold the button at the cable harness.
The machine begins to move.
Release the button.
The machine is halted.
The emergency hydraulics make it possible to continue all working and travel motions of the
machines in the event the hydraulic pumps or diesel engine cut out - at least for a certain period of
time.
The emergency hydraulics are powered electrically. Their only purpose is to move the machine out
of the danger zone. Power is supplied from an on-board power system (batteries) or from some
external source.
The emergency hydraulics work only, if the diesel engine and/or generator stand still.
The batteries of the on-board power system can guarantee operation only for about 3 minutes.
When external power supplies are used, on the other hand, there is a danger of overloading the
electric motor.
Please note that the period for which you can use the emergency hydraulics depends on the
state of the batteries.
If using an external power source: Do not operate the emergency hydraulics for longer than 5
minutes in order to prevent an overload of the electric motor.
LHB/en/Edition: 09/2008
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Service Manual Emergency actuation (emergency operation)
Emergency hydraulics (optional equipment)
The control elements of the emergency hydraulics are accessible when the right access door is
opened.
Before you use the emergency hydraulics, it may be necessary to switch to a different operating
mode by actuating the block ball valve:
Hydraulic excavator All components of the machine can be actuated. The functionality of
the rail guide axles is restricted. The machine cannot be lifted from
the track.
Rail guide Only the rail guide axles can be actuated. It is possible to lift the
machine from the track.
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Emergency actuation (emergency operation) Service Manual
Emergency gear shifting
If the parking brake cannot be released, this could be due to a failure of the solenoid valve of the gear
shifting system. In this case, turn in the valve manually (emergency operation).
Towing the machine is a dangerous manoeuvre, and the responsibility for any damage in connection
with towing rests with the operator.
The machine may only be towed in exceptional situations, e.g. if the machine must be moved for
safety reasons or if it must be repaired at the workshop.
Injuries to persons or damage to equipment caused by towing of the machine are not covered by the
manufacturer's warranty.
LHB/en/Edition: 09/2008
The travel drive can be damaged, if the machine is towed over a certain distance without
disengaging the transmission.
If possible, disengage the transmission before towing the machine see 14.
Adhere to the maximum distance and speed for towing.
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Service Manual Emergency actuation (emergency operation)
Disengaging transmission (emergency release)
When the transmission is disengaged, the parking brake is disabled. The machine might roll away,
if another brake (working brake) is disabled.
When the diesel engine is off the transmission is disengaged, all brakes (working brake,
parking brake) are disabled. The machine might roll away, and the steering is stiff so that its
operation requires some force.
Before disengaging the transmission, secure the machine against rolling off (with towing rod or
chocks).
The transmission can be disengaged by pressing in grease. The respective adapter for connection
to the transmission is found in the tool box.
LHB/en/Edition: 09/2008
Fig. 16 Transmission
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Emergency actuation (emergency operation) Service Manual
Disengaging transmission (emergency release)
The transmission might be damaged, if it is disengaged for a prolonged period of time while the
machine is in motion.
Do not put the machine into gear and do not press the accelerator while the transmission is
disengaged.
Loosen the bleeder using a wrench and open it until grease escapes.
Start the diesel engine.
Release the parking brake while the working brake (pedal) remains applied.
Repeatedly shift gear .
Leave the bleeder open until no grease escapes.
Switch off the diesel engine.
Close and tighten the bleeder .
The transmission is re-engaged.
LHB/en/Edition: 09/2008
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Service Manual Slip ring rotary connection
Function
Machines with electrical equipment in the undercarriage (e.g. pressure switches, solenoid valves,
angle sensors, etc.) must be equipped with a special rotary connection for electrical power from the
uppercarriage to the undercarriage.
This slip ring rotary connection is screw-mounted to the 6x oil rotary connection.
Depending on the requirements regarding the rotary connection, a varying number of slip rings/
contact brackets and microswitches are installed.
The base flange , adapter ring and the associated slip rings are fixed to the stator of the oil
rotary connection and thus permanently fixed to the undercarriage.
The base plate with the contact bracket holder , the shim and the contact bracket is fixed
to the rotor of the oil rotary connection, and thus permanently fixed to the uppercarriage.
In order to allow for the uppercarriage to rotate on the undercarriage, the slip ring is mounted on the
base flange with the groove ball bearing .
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Slip ring rotary connection Service Manual
Description
The slip rings is mounted on the microswitch attachment and the angle sensor of the
swivel angle limitation (optional).
The hood as well as the hood pipe with the O-ring protect the slip ring against physical impact
and contamination.
LHB/en/Edition: 11/2007
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Service Manual Slip ring rotary connection
Functional description
The cable assignment of the individual slip rings/contact brackets is shown in the wiring diagram in
and the diagram below.
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Slip ring rotary connection Service Manual
Maintenance
The slip ring body is easily damaged by humidity, as an oxidant layer might form on the conducting
surfaces, impairing the conductivity. As a consequence, the electrical consumers in the
undercarriage are insufficiently supplied with current, which can result in malfunctions.
Slip ring contacts must be regularly treated with Cramolin contact spray
,
LHB/en/Edition: 11/2007
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Service Manual Slip ring rotary connection
Maintenance
For a detailed description of the configuration of the angle sensor at dismantled slip ring
rotary connection ,
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Slip ring rotary connection Service Manual
Maintenance
LHB/en/Edition: 11/2007
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Service Manual Slip ring rotary connection
Maintenance
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Slip ring rotary connection Service Manual
Maintenance
LHB/en/Edition: 11/2007
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Service Manual Resistance measurement
General instructions regarding resistance measurement
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Resistance measurement Service Manual
General instructions regarding resistance measurement
Connect the measuring cable (magnet) to a blank metal section on the rail.
If this is not possible, place an iron plate onto the rail idle wheel and attach the measuring cable
(magnet).
Connect the measuring cable (clamp) to a bright section on the attachment. Depending on the
design of the attachment, this point might be located in a different position than shown here.
To carry out the measurement correctly, adhere to the instructions in the operating manual of the
tester manufacturer and the specifications in DIN EN 50153.
Carry out the measurement and compare the results with the prescribed limit values, (see Tab. 1
on page 1).
Please note that limit values might vary from country to country.
LHB/en/Edition: 05/2009
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