LUBRICATING CHART – GREASE

Lubricating chart – Grease (legend)

All other greasing points are supplied with grease by the central lubricating system.

Filling quantities - Grease

INSPECTION PLAN - OIL

Inspection plan – Oil (legend)

14 see "LUBRICANTS" section

15 Oil change interval depends on the quality of the engine oil filled in, see section "LUBRICANTS"

16 Oil change interval prolongation is possible if oil analisis is carried out regularly and with agreement of the engine manufacturer.

17 Change hydraulic oil every 5000 OH unless the oil is analyzed at regular intervals, but not later than every 3 years.

Filling quantities - oil

Filling quantities - other

Lubricants

Notes on the selection of oils and greases

Original CGM HMS oils and greases

Besides regular and careful maintenance, the quality of the oils and greases used in the machine has a decisive influence on high performance, reliability and long service life of a machine and of its units and assemblies.

The lubricants tables in the CGM HMS Operating Instructions contain specifications for the oils and greases that are approved for use in CGM HMS machines. These oils and greases are especially adapted to CGM HMS machines and their units and assemblies.

Other oils and greases which do not fulfil the requirements of the specifications can be the cause of premature wear or of damage to and failures of machine units and assemblies.

For this reason, CGM HMS only approves the use of the specified oils and greases. All other qualities are not approved.

Alternative oils and greases

The oils and greases filled into the machine must meet at least the specifications mentioned in the lubricants tables of the CGM HMS Operating Instructions.

In the event of damage to the machine or to its units and assemblies caused by the use of alternative oils and greases that are not compatible with CGM HMS specifications, CGM HMS does not assume any responsibility and does not accept any warranty claims.

Avoid mixing of different hydraulic fluids

The machine has been run in at the factory with BM Long Term Hydraulic Fluid HSS (Part-No. 2482971). CGM HMS recommends using this high-grade hydraulic fluid also in operation as it has been made especially for use in these machines to which it is also perfectly adapted.

If oil analyses are performed regularly and with positive results, the BM Long Term Hydraulic Fluid can remain in the machine for up to 10 000 operating hours.

If an alternative hydraulic fluid is to be used, it must fulfil the same specifications. Please note that the change interval for alternative fluids is fixed at 5 000 operating hours.

There is an increased risk of damage to hydraulic components, if different hydraulic fluids are mixed during topping up as well as when changing over to a fluid of a different type or from another manufacturer.

For topping up, it is therefore necessary to use only same hydraulic fluid as the one that is already in the hydraulic system.

When changing over to an alternative hydraulic fluid, please observe that there is always a small amount of old fluid remaining in the hydraulic system even after the system has been emptied. The mixing of this residual amount of old fluid with the new alternative fluid reduces the properties of the fluid dramatically and can cause damage to components of the hydraulic system in operation.

To avoid this result, the change-over to the alternative fluid must be performed in strict compliance with the manufacturer's prescriptions. The manufacturer must confirm that his hydraulic fluid is compatible with the BM Long Term Hydraulic Fluid. The remaining amount of old fluid must not exceed 2% of the total volume. This can only be achieved by repeated flushing with the total fluid volume.

If the remaining amount of fluid exceeds 2% of the total volume, the fluid becomes a detrimental "mixed fluid".

The operation of the system with mixed fluids must by all means be avoided.

CGM HMS assumes no warranty for damage caused as a result of the machine having been operated with consumables of inappropriate specification or with mixed fluids.

I. Oil for combustion engines

II. Oils for hydraulic system (selection)

III.a Oils for pump transfer gearbox and travel gearbox

III.b Oils for swing gearbox

V. Greases for bearings and swing rings (Central lubrication system)

Grease for idlers, track rollers and support rollers (Lifetime lubrication)

Coolant for use on all combustion engines

Servicing Work

Hose line for oil and cooling liquid changes

Collect escaping oil and cooling liquid and discard without polluting the environment.

Carry out oil changes when the machine is at operating temperature; warm oil drains away more easily.

The engine, hydraulic oil reservoir and the slewing gearbox are equipped with special oil drain valves (1, Fig. 3-11:).

These plugs permit to carry out oil changes in a clean and non-polluting way.

Carry out oil changes as follows:

 Place a recipient for waste oil under the drain opening (choose the capacity of the recipient in acc. with the "Refilling quantities - Oil" table).

 Choose the proper draining hose from the tool kit.

 Unscrew protective cap from oil drain valve.

 Screw on draining hose (2); the valve opens and the oil drains away.

 After the oil has drained away unscrew draining hose; the valve closes automatically.

 Screw protective cap back in place.

ENGINE Engine - Safety instructions

Read and observe: "Inspection and Servicing –Safety Instructions" and the engine operating instructions.

Exhaust gases from diesel engines and some of their constituents may cause cancer, birth defects and other reproductive harm.

Start and operate combustion engines only on well-ventilated premises.

In closed rooms, exhaust gases must be evacuated to the outside.

Do not work on the exhaust system an do not make any modifications to it.

Attention, ETHER

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Risk of injury from hot or rotating parts of the engine.

Shut off engines and allow to cool down. Secure the machine as described in the "Securing the machine" section.

Protect the skin from potentially harmful contact with engine oil. Wear protective gloves and firm working clothing.

Checking the V-belt tension Retensioning the alternator/fan belt

Checking and adjusting the valve clearance

These and other servicing works are described in the engine manufacturer's operating instructions.

Checking the engine oil level / Topping up

Fig. 3-12:

 Park the machine on a horizontal surface and protect it against rolling away.

 Shut off the engine.

 Withdraw dipstick (1, Fig. 3-12:).

 Wipe dipstick clean with a clean and lintfree cloth and re-insert.

 Withdraw oil dipstick once again. The oil level should now lie between the marks (arrows, Fig. 3-13:). If the oil level is at the "min" mark or below, top up with engine oil through the fillertube (2, Fig. 3-12:).

Changing the engine oil

Read and observe: "Inspection and servicing – Safety instructions".

Risk of scalding from hot engine oil. The engine may also be hot. Wear protective gloves and firm working clothing. Collect escaping oil and discard without polluting the environment.

 Bring engine oil to operating temperature.

 Park the machine on a horizontal surface and secure.

 Shut off the engine.

 Drain off engine oil using the oil draining hose. The use of the oil draining hose is described in the "Draining hose for oil changes" chapter.

After draining of the oil:

 Replace the engine oil filter.

 Remove the hose line. The automatic drain coupling closes automatically.

 Screw on protective cap.

 Fill in engine oil through the filler tube (2, Fig. 3-14:) until the oil level reaches the "max" mark (Fig. 3-15:).

 Start the engine and allow to run for abt. 2 minutes at idling.

 Check oil level and top up with oil up to the "max" mark, if required.

Replacing the engine oil filter

Read and observe: "Inspection and servicing – Safety instructions".

Risk of scalding from hot engine oil. The filter housing may also be hot. Wear protective gloves and firm working clothing. Collect escaping oil and discard with-out polluting the environment

Renewing of filters

 Carry out servicing of the oil filters (1, Fig. 3-17:) in accordance with the engine operating instructions.

 Shut off the engine.

 Open hatch 1 (Fig. 3-16:). The oil filters are now accessible.

 Unscrew filters.

 Install new filters with slightly oiled sealing ring and tighten by hand.

After renewing the oil filters, the oil of the engine must be changed in accordance with the engine operating instructions.

Then

 Allow engine to run at idling for a short time and check filters for leaks.

 Shut off engine.

 Check oil level after abt. 10 minutes and top up with oil, if required.

Centrifuge (optional)

The centrifuge (Fig. 3-18:) filters out engine oil impurities in the bypass line by centrifugal forces.

Servicing

 Shut off the engines

 Wait 5 minutes

The rotor of the centrifuge must be stationary.

The pressure in the centrifuge must have disappeared.

The centrifuge may also be hot.

Wear protective gloves and firm working clothing.

 Loosen clamp (2, Fig. 3-19:) and withdraw housing (1).

 Check housing seal (8) and replace, if required.

 Unscrew knurled nut (3) and draw off rotor cap (4).

 Remove dirt from the rotor cap by tapping lightly against the cap.

 Clean rotor cap (4) and vertical tube (5) thoroughly with white spirit and dry.

Adhering dirt causes the rotor to run unbalanced. Any unbalance may damage the bearings.

 Replace seal (6) inserting it slightly smeared with oil.

 Check nozzle (7) for free passage. If necessary, open up nozzle with a wire or with compresse air.

 Place paper filter into the rotor cap.

The paper filter must adhere uniformly to the rotor casing.

Thereafter

 Allow engines to run for short while and check centrifuge for tightness and leaks before shutting off the engines.

 Check oil level after abt. 10 minutes and to up, if required.

Cold-starting fluid (ether) - Replacing the pressure vessel

Read and observe: "Inspection and servicingSafety instructions"

Risk of injury

Cold-starting fluid is composed mainly of ether.

Ether is toxic when the mists and vapours are inhaled. Ether is harmful to the eyes, the skin, the respiratory system and the central nervous system. Prolonged inhalation of ether can be fatal.

In contact with the skin, ether can cause frostbites and irritations.

Ether is toxic and highly flammable; the vessels are under pressure.

These pressure vessels can explode if exposed to high temperatures (above 49°C/ / 120°F) or in the event of damage.

Before replacing an empty pressure vessel:

Read and observe the instructions on the pressure vessels.

For further details please refer to the instructions and safety data-sheets of the manufacturer / supplier of pressure vessels with cold starting fluid (ether).

Provide for sufficient ventilation of the surroundings.

Do not eat, drink or smoke when replacing an empty vessel.

Do not inhale the vapours of escaping cold-starting fluid (ether).

Avoid skin contact. Wear suitable protective gloves and goggles.

If the machine is used in low temperatures, the engine may be equipped with a cold-starting device.

The pressure vessel containing the cold-starting fluid (ether) can be installed in or near the engine compartment.

The vessel is screwed onto an electro-mechanical metering valve. At temperatures below 0°C (32°F), this valve is activated automatically by the engine electronics and injects a precisely metered amount of cold-starting fluid into the air intake duct of the engine.

Replacing the pressure vessel:

 Remove the clamp around the pressure vessel.

 Unscrew the pressure vessel carefully from the metering valve.

 Remove the used seal from the metering valve.

 Insert a new seal into the valve (supplied with the new pressure vessel).

 Screw the new pressure vessel onto the metering valve and tighten by hand.

 Fasten the clamp round the pressure vessel. Even apparently empty pressure vessels can contain rests of ether and therefore explode if they are damaged or heated up above 49°C / 120°F. They must therefore be handled in the same way as full pressure vessels.

 Do not keep them on the machine.

 Do not damage or open the vessels.

 Do not expose the vessels to great heat or direct sunlight.

 Do not dispose of in fire.

 Keep the vessels in a place unaccessible to unauthorized persons.

 Dispose of the vessels properly.

Cooling System

Read and observe: "Inspection and servicing - Safety instructions".

Secure the machine as described in the "Securing the machine" section.

Shut off the engine and allow to cool down.

Risk of scalding from hot cooling liquid. Collect escaping cooling liquid and discard without polluting the environment.

Protect the skin from contact with cooling liquid.

Skin contact with cooling liquid is a potential health hazard.

Wear protective gloves and firm working clothing.

Temperature

The cooling-liquid circuit is controlled by a thermostat. The maximum admissible temperature is ca. 100° C / 212°F. In case of higher temperatureswarning lamp on satellite I illuminated - locate cause and rectify.

Topping up cooling liquid

If the cooling-liquid level is too low, a warning lamp on satellite I lights up.

The cap (2) is accessible from above.

Risk of scalding from hot cooling liquid. Open radiator cap cautiously.

 Turn radiator cap (2) back to the first notch.

 When the pressure has been released turn cap into the "open" position and remove.

The cooling-liquid level is displayed at the level indicator (3). Liquid level should be between the “LOW” and the “MAX” mark.

Top up with cooling liquid, if required.

Fill cooling liquid into the cooling system through the filler tube.

Do not fill in cold cooling liquid when the engine is at operating temperature.

Before refilling, allow engine to cool down to below 50° C / 122°F.

For topping up of the cooling system use specially prepared water only.

Specially prepared water must consist of:

 Calcium-free water, distilled water, rain water

 anti-freeze compound

The mixing ratio of anti-freeze / cooling water must be at least 50 % : 50 % (anti-freeze protection down to -40 °C / -40°F).

 For use at lower temperatures, the amount of anti-freeze must be increased accordingly.

Radiators

The radiator (1, Fig. 3-20:) is located on the superstructure.

 After each working shift: examine radiator fins for dirt and clean, if required.

 After filling in cooling liquid allow the engine to run for short period to eliminate air voids before topping up with cooling liquid to the lower edge of the filler tube.

 In case of significant cooling-liquid losses, the whole cooling system must be checked for leaks.

Check regularly:

 All lines for leaks and all hose clamps for tightness.

Cooling liquid change

Read and observe: Inspection and servicing – Safety instructions.

Risk of scalding from hot cooling liquid.The radiators may also be hot. Wear protective gloves and firm working clothing.

Collect escaping cooling liquid and discard without polluting the environment.

The cooling liquid must be changed regularly and after two years at the latest.

The engine operating instructions describe in detail how to prepare cooling water and how to check the cooling liquid. Check in case of imminent frost whether the concentration of the anti-freeze compound added to the cooling liquid at the factory is sufficient for the temperatures to be expected.

To do so:

 Prepare a collecting recipient for used cooling liquid. Choose the required recipient capacity in accordance with the "Refilling quantitiesOther" table.

 Shut off the engine and let cool down.

 Open hatch 2 (Fig. 3-21:).

 Unscrew plug (arrow, Fig. 3-22:) and drain off cooling liquid completely.

 Fill in cooling liquid after having re-inserted the plug with a new sealing ring.

The cooling-liquid level is displayed at the level indicator (3, Fig. 3-20:). Liquid level should be between the “LOW” and the “MAX” mark.

Checking the cooling liquid

Check the cooling liquid in the cooling system regularly to ensure that the water-filter change interval resp. the DCA4-concentration is sufficient to prevent corrosion under the existing operating conditions.

Water filter replace

Read and observe: "Inspection and servicing – Safety instructions".

Risk of scalding from hot cooling liquid. The filter housings may be hot, too. Wear protective gloves and firm working clothing. Wear fall arresters.

Collect escaping cooling liquid and discard without polluting the environment.

Replace water filter regularly, to do so:

 Open hatch at the right side of the uppercarriage (2, Fig. 3-23:).

 Close valve (2, Fig. 3-24:).

 Unscrew water filter (3).

 Screw on new water filter until the sealing ring contacts the filter head. Continue to tighten the filter by another ½ to ¾ turn.

Tightening the filter element with a tool can damage or deform the filter head.

 Open valve (2).

AIR-INTAKE SYSTEM

Read and observe the "Engine - Safety instructions" chapter.

Wear fall arresters.

Risk of injury caused by rotating or hot parts of the engine. Shut off the engine before working on the air-intake system.

Secure the machine as described in the "Securing the machine" section.

Do not start the engine when parts of the air-intake system have been detached.

Engine damage may occur if the engine is allowed to draw in unfiltered air.

The air-intake system is equipped with two dry-air filters (Fig. 3-25:) consisting of main and safety filter elements.

Clean or renew main filter element only if the vacuum-meter nindication changes to "RED" with the engine running at high speed.

Main filter element

An insufficient air-intake performance, caused by a contaminated main filter element, is indicated by the vacuum-meter (8, Fig. 3-26:).

Removal and installation

 Unscrew nut (1, Fig. 3-25:) and remove cover (2).

 Unscrew nut (3, Fig. 3-27:) and withdraw main filter element (4). Do not loose the washer under nut (3).

 Clean or renew main filter element.

New or cleaned main filter elements should always be at hand to shorten excavator downtimes.

 Before installing the filter element, clean contact faces at cover (2, Fig. 3-28:) and at filter housing.

 Put on cover (2) and tighten nut (1).

During the removal of the main filter element, the safety element (5, Fig. 3-29:) must remain in the filter housing.

Replace damaged or deformed elements immediately.

Check element seal. When the seal is damaged, the filter element must be replaced, too.

Cleaning with compressed air is suitable if the filter element is to be re-used immediately.

Checking and cleaning the main filter element

Examine the filter paper of the element with a lamp which is introduced into the element (Fig. 3-30:). Any damage is then clearly visible.

Blow filter element (Fig. 3-31:) clean with dry compressed air from the inside by moving the compressed-air gun up and down.

The pressure at the nozzle must not exceed 3 bars / 43psi.

Cleaning is terminated when all visible dust has been blown out of the filter element.

Never clean filter element by beating against hard objects.

Replace the main filter element after 1000 operating hours or 3 cleaning cycles; and, after one year of operation at the latest.

Safety filter element Replacement

Replace the safety filter elements (5, Fig. 3-32:) after 1000 operating hours or 3 cleaning cycles; after one year of operation at the latest. Never clean the safety filter element, but always renew.

 Remove main filter element (4, Fig. 3-33:) as described above.

 Unscrew nut (6, Fig. 3-32:) and withdraw safety filter element (5).

 Install the new safety filter element and a cleaned or a new main filter element.

Air-intake lines

At regular intervals:

 check intake lines for leaks and hose clamps for tightness;

 replace hoses between filter housing and engine.

During all works on the air-intake system ensure proper sealing to prevent unfiltered air from reaching the engines.

Dust collection

Dust accumulating on the filter-housing bottom is constantly sucked away by the exhaust system during operation.

The non-return valves (7, Fig. 3-34:) in the suction lines prevent engine exhaust gases from being sucked in.

At regular intervals:

 check suction lines for leaks and hose clamps for tightness.

Fuel System

Fuel system - Safety instructions

Read and observe the "Inspection and servicing – Safety instructions" chapter.

When working on the fuel system:

 shut off the engines

 secure the machine as described in the "Securing the machine" section

 keep away naked flames

 do not smoke.

Collect escaping fuel and discard without polluting the environment.

Avoid skin contact with diesel fuel.

Diesel fuel may cause skin injury.

Wear firm working clothing.

Wear protective gloves or use a barrier cream.

Prior to initial commissioning or after repairs on the refuelling system carry out the following works:

 Loosen elbow union (12, Fig. 3-35:) and fill pump (11) with fuel.

 Retighten elbow union (12).

Replacing the fuel filter

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Collect escaping fuel and discard without polluting the environment.

Avoid skin contact with diesel fuel.

Diesel fuel may cause skin injury.

Wear firm working clothing.

Wear protective gloves or use a barrier cream.

The fuel filters (3) serve at the same time as water traps.

 Open valve (4) and drain off water until fuel emerges.

 Close valve (4).

Venting the fuel system

The fuel tank is vented with breather valve (4, Fig. 3-38:).

Clean breather valve regularly.

 Open hatch 1 (Fig. 3-36:) to gain access to the filters.

 Unscrew filters (3, Fig. 3-37:).

 Fill new filter with clean fuel and screw it onto the filter head by hand.

 Continue to tighten filter by a further 1/2 to 3/4 turn.

Tightening the filter element with a tool may damage or deform the filter head.

 Remove breather valve, flush with paraffin oil and blow clean with compressed air.

Cleaning the fuel tank

Explosion hazard. Read and observe the "Inspection and servicing. Safety instructions" chapter.

Do not use white spirit, paraffin oil or other solvents.

For flushing and cleaning use diesel fuel. Avoid skin contact.

Skin contact with diesel fuel may cause skin injury. Wear firm working clothing. Wear protective gloves or use a barrier cream.

Fuel must be prevented from penetrating into the soil. Keep fuel for re-use or discard without polluting the environment.

 Use up as much fuel as possible.

 Check how much fuel remains in the tank and place a collecting recipient of sufficient size under the drain plugs of the tanks.

 Loosen drain plug (5, Fig. 3-39:) at fuel the tank and drain off fuel.

 Flush tank with diesel fuel.

 Screw drain plug (5) back in place.

 Fill in fuel through the filter sieve in the filler tube (2).

Refuelling station (optional)

Sparking caused by static or electric charges may set fuel on fire.

Check earthing strap (equipotential bonding) (4, Fig. 3-40:) regularly for tightness.

Only a perfectly connected earthing strap can remove static or electric charges and thus avoid the risk of fire during refuelling.

Water trap (option)

Water contained in the fuel is removed by the water trap (Fig. 3-41:).

Servicing

Draining off water

Carry out the following works in accordance with the servicing schedule and at regular intervals:

 Loosen venting plug (9, Fig. 3-42:) and leave drain valve (3) open until there is no more water in the diesel fuel flowing out of the valve.

Collect escaping liquid in a recipient suitable for diesel fuel and discard without polluting the environment.

The liquid flowing out of the valve flushes and cleans the filter element (6) von from top to bottom.

 Close drain valve (3) and tighten venting plug (9).

Checking / cleaning the filter element

Replace filter element (6, Fig. 3-43:) only when the suction resistance is too high.

 Clean recipient (1) and filter housing (4).

 Loosen flange (2).

 Take off recipient (1) and clean with diesel fuel

 Check cover sealing and replace, if necessary.

 Attach recipient (1) with flange (2) at filter housing (4).

Check for proper sealing.

 Loosen venting plug (9) and leave drain valve (3) open until the reservoir is completely empty.

Collect escaping liquid in a recipient suitable for diesel fuel and discard without polluting the environment.

 Remove cover (5).

 Remove spring holder (7) and filter element (6) from filter housing (4).

 Check / replace filter element (6)

 Clean filter housing (4) using diesel fuel.

 Check cover sealing and replace,if necessary.

 Insert filter element (6) and spring housing (7) into filter housing (4).

 Fasten cover (5) on filter housing (4).

Check for proper sealing.

Electrical System

Electrical system - Safety instructions

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Risk of injury caused by battery acid and gases. Wear goggles, working gloves and firm working clothing.

Carry out voltage and continuity checks only by means of a test lamp or a measuring instrument. Do not check by "touching ground" with a bare wire. The short-circuit thus produced damages the alternator and the electronic modules of the PMS.

Alternator - Instructions

Never disconnect cables from the alternator, regulator and the battery when the engine is running to avoid damage to the alternator and regulator.

Do not interchange the cables when connecting the battery (observe polarity).

Carry out voltage and continuity checks only by means of a test lamp or a measuring instrument. Do not check by "touching ground" with a bare wire. The short-circuit thus produced damages the alternator and the regulator.

The electrical circuit diagrams are annexed to thespare-parts list. Further information can be found in the CGM HMS booklet "Working with circuit diagrams".

The electrical system switch-cabinet is located behind the hydraulic reservoir. The cabinet is described in the spare-parts list together with the designation of the electrical components.

Cables and cable lugs must not get in contact with other metal parts. Replace broken or damaged cables and the respective cable lugs.

If a bulb does not work after replacement, the pertaining fuses, connection cables and contacts must be checked.

Gas-discharge lamps (optional) are operated with high voltage.

Battery main switch / Main fuse

The battery main switch and the main fuse are located under a lockable hatch (5, Fig. 3-44:) beside the batteries and the tool box.

Battery

Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Wash hands after handling.

Checking the battery fluid level

(Not applicable in case of maintenance-free batteries)

 Unscrew caps (Fig. 3-46:).

 If checking inserts are provided, the battery acid must reach up to their bottom.

After withdrawing the key from the key-switch (control panel in driver's cab), the electrical lines from the key-switch to the consumers are de-energized. The lines from the battery to the key-switch are, however, still under tension. These lines can be de-energized with the battery main switch. Shut off the electrical system with the battery main switch when carrying out repair work or during prolonged downtimes of the excavator.

Battery main switch (Fig. 3-45:):

Position I - ON

Position II - OFF

In position II, the battery main switch handle can be withdrawn.

 If no checking inserts are provided, insert a clean wooden rod into the battery until it contacts the upper edge of the cell plates. The rod must be moistened over at least 10 mm / 0.4".

 If the fluid level is too low, top up with distilled water only

Removing and installing the battery

The acid temperature must be 20 ° C / 68°F.

 Unscrew caps of the battery (Fig. 3-47:

 Measure the acid density of the battery using a commercial acid tester (Fig. 3-47: The acid density measured is in direct correlation with the battery charge.

Removing and installing the battery

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Wash hands after handling.

Wear protective gloves and firm working clothing. Shut off the engines before removing the batteries to avoid damaging the alternator and the regulator. Turn key in key-switch to position "0" and withdraw.

Switch battery main switch (Fig. 3-48:) to "OFF" Disconnect and reconnect the terminal clamping lugs in the prescribed order.

Disconnecting and connecting in the wrong order may cause short-circuits.

The batteries are located under the lockable hatch (5, Fig. 3-49:). The two 12-volt batteries are connected in series, so that the system voltage is 24 volts.

Before installing the new battery, the contact faces of the battery terminal posts and the cable lugs must be cleaned down to the bright metal.

 Unscrew battery holder (3, Fig. 3-50:).

 Disconnect the cable lug from the negative terminal of the battery.

 Disconnect the cable lug from the positive terminal of the battery. Insulate the cable lugs.

Install the new battery:

 Connect the cable lug to the positive terminal of the battery.

 Tighten the clamping screw of the cable lug.

Do not use too much force to avoid deformations.

 Connect the cable lug to the negative terminal of the battery.

 Apply special terminal grease or acid-free vaseline on the battery terminal posts and clamping lugs.

 Fasten battery holder (3).

Loose or corroded clamping lugs will lead to alternator or regulator overloading.

Floodlight projector, safety instructions

The floodlight projectors use xenon technology. The lamp is not a usual incandescent lamp, but a gas discharge lamp which is operated with a ballast unit. The ballast unit is integrated in the floodlight projector.

When the projector is turned on, the ballast unit generates a high-voltage pulse of up to 25000 volts to start the xenon lamp.

Warning!

This high-voltage pulse can be a lifethreatening risk, if a person comes into contact with any of the live components. This can be the case, for instance,

 if the lamp is operated improperly,

 if the projector housing is opened in an inapropriate way or

 by sticking one's hand into an opened or damaged projector.

Protect yourself from potential risks by reading and by observing the following safety instructions.

Always switch off the projector and disconnect it from its power supply before replacing the Xenon lamp.

Allow the xenon lamp to cool off before removing it from the projector.

Wear googles and safety gloves when replacing the lamp.

Never stick your hand into the lampholder. The contacts may still be live with residual voltage.

Never switch on the projector when the xenon lamp has been removed. There is a risk of voltage discharge and damage to the lampholder.

The glass body of the xenon lamp is filled with different gases and metal gases and is under gauge pressure (risk of injury from splinters)

If the xenon lamp breaks apart in closed room (workshop), all persons must leave the room and the room must be ventilated for at least 20 minutes to exclude any health risks caused by gases.

Further instructions

Always hold the xenon lamp by the base. Never touch the glass bulb. Sweat and grease from the skin would evaporate when the lamp is in operation and obscure the reflector.

If the fingers have nevertheless come into contact with the glass bulb, the fingerprints must be removed with a clean cloth and some alcohol.

The replaced Xenon lamp must be disposed of as special waste.

Never switch on projectors when housing or electrical wiring is damaged.

Have damaged projectors be replaced by a qualified electrician as soon as possible.

Floodlight projector, replacing a defective xenon bulb

Read and observe “Floodlight projector, safety instructions”

 Switch off the projector, shut off the engine and cut out the battery main switch.

 Wait until the housing of the floodlight projector has cooled down.

 Withdraw the power supply connector from the projector.

 Remove four screws (1, Fig. 3-51:) and withdraw the reflector (2) from the projector housing.

 Withdraw connector (Fig. 3-52:) from Xenon lamp socket

 Unscrew Xenon lamp holding clamp (Fig. 3-53:).

 Remove the defective Xenon lamp and replace by a new one. Do not touch the glass bulb of the lamp.

 Reinstall the new lamp. Screw lamp holding clamp back in place.

 Plug the power supply connector onto the lamp.

 Re-assemble the housing.

Lighting systems in LED technonogy, instructions

The lights of the maintenance lighting system (Fig. 3-54) as well as the working floodlights (Fig. 3-55) are equipped with lamps in LED technology (lightemitting diodes).

High-performance LEDs ensure the emission of light with high luminance. If the light is allowed to shine directly into the eyes from a short distance and over prolonged periods, there is a risk of injury to the retina.

Do not look for a prolonged period into the light cones of the LEDs.

Adjust the lights in such way that they do not shine directly into the eyes and that you are not blinded by the glare.

The lights become hot in operation. The heat is dispersed via the ribbed metal housing.

For this reason, the housings must not be covered up and cleaning rags or similar things placed over them.

The high-performance LEDs in these lights have a very long service life and can therefore not be replaced. If one or more of these LEDs fail, the light can remain in service if the remaining luminance is still sufficient.

Hydraulic System

Hydraulic system - Safety instructions

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Before working on the hydraulic system, make sure that the system is without pressure and that the residual pressures have also been eliminated. Shut off the engines.

Risk of burning caused by hot hydraulic components (e.g. hydraulic oil reservoir, cylinder, valves). Secure the machine as described in the "Securing the mmachine section.

Avoid skin contact with hydraulic oil.

Contact with hydraulic oil can cause skin injury. Wear protective gloves and firm working clothing.

Depressurizing the hydraulic system

Hydraulic systems may only be opened if they are completely depressurized. Even when an excavator is parked on a horizontal surface with the working equipment resting on the ground (Fig. 3-56:and Fig. 3-57:) and with its drive engines stationary, there may still be a considerable amount of residual pressure in parts of the hydraulic system, as e.g. the primary pressure resulting from the last hydraulic movements before the immobilization.

Residual pressures disappear only gradually. If work is to be carried out on the hydraulic system immediately after the immobilization, the system must be freed from pressure, i.e. depressurized:

 Locate the system section to be opened.

 Depressurize the section to be opened. If required, the necessary measures described must be combined

 Open the depressurized system section with caution.

Examples of system sections:

1) working hydraulics

2) servo control circuit

3) precharged return-flow line

Depressurizing

 Park the excavator on a horizontal surface.

 Set the working equipment on the ground.

 Shut off the drive engine.

Sections 1 and 2: servo control and working hydraulics

- Shift both control levers repeatedly into all dIrections (Fig. 3-58:).

Topping up with hydraulic oil

 Remove cover (20, Fig. 3-60:) and retaining disk (23).

 One of the return-flow filters is now visible in the filter chamber.

Section 3: return-flow line

After shutting down the engine, the precharging pressure decreases rapidly through the precharging valve. No measures are required before opening the return-flow line.

Checking the hydraulic oil level

 Bring hydraulic oil to operating temperature (abt. 50 °C / 122°F).

 Park the machine on a horizontal surface.

 Move all hydraulic cylinders to their central positions.

The oil level must lie between the ½ and ¾ marks of the inspection glass (1, Fig. 3-59:).

 Fill in hydraulic oil through this return-flow filter until the oil level lies between the ½ and ¾ marks of the inspection glass (oil grade see "Refilling quantities - Oil").

 Before fitting retaining disk (23) and cover (20), check sealing ring (26) and replace if damaged.

 Fit cover together with sealing ring.

Changing the hydraulic oil returnflow (hydraulic oil reservoir)

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engine.

Risk of scalding caused by hot hydraulic oil. The hydraulic oil reservoir itself may also be hot. Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing. Collect escaping hydraulic oil and discard without polluting the environment.

The return-flow filters must be replaced:

 when servicing works in accordance with the servicing plan are carried out;

 when the "Hydraulic oil filter" warning lamp (satellite II) lights up when the hydraulic oil is at operating temperature. The filter elements (25, Fig. 3-61:) are then heavily contaminated. (The warning can be disregarded if the lamp lights up only shortly during starting of the engine);

 after repairs on the hydraulic system;

 in case of damage.

 Remove cover (20) and retaining disk (23) as described under "Topping up with hydraulic oil".

 Clean the magnetic rod (24).

If abraded metal and metal filings adhere to the magnetic rod, locate the cause or contact the CGM HMS Service.

 Withdraw filter element (25) together with sealing ring (22).

If the filter elements are damaged, remove basket (28) and clean down with spirits or petroleum.

 Lower basket (28) into tank.

 Insert new filter element (25) together with sealing ring (22).

 Fit retaining disk (23) with sealing ring (27).

 Refit cover (20) with sealing ring (26).

Proceed in the same way to replace the other filter elements (25).

Bypass valves (working circuit)

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engine.

Risk of scalding caused by hot hydraulic oil. The hydraulic oil reservoir itself may also be hot. Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing. Collect escaping hydraulic oil and discard without polluting the environment.

Cleaning the filter screens

 Remove cover (10, Fig. 3-62:). Remove screws (12) and take out the bypass valve. Withdraw sieve (13) and clean in white spirit or paraffin oil. Replace, if required.

 Check sealing ring (16) for damage and replace, if required.

 Re-assemble the bypass valve.

 Check sealing rings (14 and 15) for damage and replace, if required.

 Insert the bypass valve. Make sure the valve fits properly.

 Refit cover (10) with sealing ring (15).

Replacing the bypass valves and the sealing rings

 Remove the bypass valve as described under "Cleaning the sieve".

 Re-assemble new bypass valve with sieve (13) and new sealing ring (16).

 Insert bypass valve with new sealing ring (14).

 Refit cover (10) with new sealing ring (15).

Bypass valves (cooling circuit)

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Shut off the engine.

Risk of scalding caused by hot hydraulic oil. The hydraulic oil reservoir itself may also be hot. Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing. Collect escaping hydraulic oil and discard without polluting the environment.

Cleaning the valve

 Remove cover (7, Fig. 3-63:).

 Unscrew screws (33, Fig. 3-64:) and withdraw valve carrier (31) together with valve (32).

 Clean valve (32) in white spirit or paraffin oil and replace, if required.

 Insert valve (32) into valve carrier (31).

 Fasten valve carrier (31) with screws (33) in the hydraulic oil reservoir. Refit cover (7, Fig. 8) with a new sealing ring.

Changing the valve

 Remove bypass valve as described under "Cleaning".

 Remove valve (32, Fig. 3-64:) and replace by a new one.

 Fasten bypass valve (31) on the hydraulic oil reservoir.

 Refit cover (7, Fig. 3-63:).

Breather filter

Read and observe the "Inspection and servicing - Safety instructions" chapter.

Shut off the engine.

Risk of scalding caused by hot hydraulic oil. The hydraulic oil reservoir itself may also be hot. Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing.

Replacing the filter elements

The breather filters (20, Fig. 3-65:) ensure venting of the hydraulic oil reservoir at varying hydraulic oil levels.

 Unscrew butterfly nut (50, Fig. 3-66:). Withdraw hood (51) and withdraw filter element (52) from the holding rod.

 Insert new sealing ring (53) and new filter element and secure hood (51) with nut (50).

High-pressure filter for working hydraulics

To filter the hydraulic oil on the high-pressure side of the working hydraulic system, the machine is equipped with two high-pressure filters (30, Fig. 3-67:).

Checking/cleaning the filter elements

 Unscrew filter housing (31, Fig. 3-67:) and pour out the oil.

 Withdraw filter element (32) from housing (31).

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Checking/changing the filter elements

Shut off the engine.

Risk of scalding caused by hot hydraulic oil. The filter housings themselves may also be hot. Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing. Collect escaping hydraulic oil and discard without polluting the environment.

 Clean filter housing and contact faces at the filter head (35, Fig. 3-68:) with white spirit or paraffin oil and replace, if required.

 Insert filter element into housing (31, Fig. 11) and attach to the filter head (35) with new, slightly oiled sealing rings (33 and 34) and a new retaining ring (36).

Check high-pressure filter for leaks after the system has been put into operation.

Replacing the filter elements

 Detach the filter element as described under "Checking the filter elements".

 Clean filter housing (9, Fig. 3-68:) and the sealing faces at the filter head with white spirit or paraffin oil.

 Insert new filter element into filter housing (9) and refit to the filter head with new, lightly oiled sealing rings (10 and 14) and a new retaining ring (13).

Check high-pressure filter for leaks after putting it into operation.

High-pressure filters for the servo circuit and the feeding circuit of the slewing pump

The excavator is equipped with a high-pressure filter (40, Fig. 3-69:) for the servo circuit and §another filter (41) for the feeding circuit of the slewing pump.

Checking/cleaning the filter elements

 Unscrew filter housing (42, Fig. 3-70:) and pour out the oil.

 Withdraw filter element (43) from housing (42).

 Clean filter housing and contact faces at the filter head with white spirit or paraffin oil.

 Insert filter element into housing (42) and attach to the filter head with a new, slightly oiled sealing ring (46).

 Check the high-pressure filter for leaks after thesystem has been put into operation.

Read and observe: "Inspection and servicing - Safety instructions".

Shut off the engine.

Risk of scalding from hot hydraulic oil. The filter housings may also be hot. Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm protective clothing.

Collect escaping hydraulic oil and discard without polluting the environment.

Replacing

The Filter Elements

 Detach the filter elements as described under "Checking the filter elements".

 Insert new filter element (43) and re-assemble.

 Check the high-pressure filter for leaks after putting it into operation.

Changing the hydraulic oil

Read and observe the "Inspection and servicing - Safety instructions" chapter.

Shut off the engine.

Risk of scalding caused by hot hydraulic oil. The hydraulic oil reservoir itself may also be hot. Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing. Collect escaping oil and discard without polluting the environment.

Do not start up the drive engine when the hydraulic oil reservoir is empty. The hydraulic pumps may be destroyed if they are allowed to run dry.

Avoid mixing of different hydraulic fluids

The machine has been run in at the factory with BM Long Term Hydraulic Fluid HSS (Part-No. 2482971). CGM HMS GmbH recommends using this high-grade hydraulic fluid also in operation as it has been made especially for use in these machines to which it is also perfectly adapted.

If oil analyses are performed regularly and with positive results, the BM Long Term Hydraulic Fluid can remain in the machine for up to 10 000 operating hours.

If an alternative hydraulic fluid is to be used, it must fulfil the same specifications. Please note that the change interval for alternative fluids is fixed at 5 000 operating hours.

There is an increased risk of damage to hydraulic components, if different hydraulic fluids are mixed during topping up as well as when changing over to a fluid of a different type or from another manufacturer.

For topping up, it is therefore necessary to use only same hydraulic fluid as the one that is already in the hydraulic system.

When changing over to an alternative hydraulic fluid, please observe that there is always a small amount of old fluid remaining in the hydraulic system even after the system has been emptied. The mixing of this residual amount of old fluid with the new alternative fluid reduces the properties of the fluid dramatically and can cause damage to components of the hydraulic system in operation.

To avoid this result, the change-over to the alternative fluid must be performed in strict compliance with the manufacturer's prescriptions. The manufacturer must confirm that his hydraulic fluid is compatible with the BM Long Term Hydraulic Fluid. The remaining amount of old fluid must not exceed 2% of the total volume. This can only be achieved by repeated flushing with the total fluid volume.

If the remaining amount of fluid exceeds 2% of the total volume, the fluid becomes a detrimental "mixed fluid".

The operation of the system with mixed fluids must by all means be avoided.

CGM HMS GmbH assumes no warranty for damage caused as a result of the machine having been operated with consumables of inappropriate specification or with mixed fluids.

Drawing off hydaulic oil

 Bring the hydraulic oil to operating temperature (abt. 50 ° C / 122°F).

 Position the machine with a slight inclination towards the drain valve (5, Fig. 3-71:).

The drain valve is located at the back of the hydraulic oil reservoir and accessible from the bottom.

 Retract the hydraulic cylinders as far as possible and stand the working equipment on the ground.

 Shut off the engine.

 Place suitable recipients under the drain valve (5) of the hydraulic oil reservoir. For the required capacity refer to the "Refilling quantities - Oil" table.

 Connect hose (15) to drain valve (5) and drain off used oil completely. Draining is facilitated if the breather filter (6, Fig. 3-72:) is removed during the process.

The use of the oil draining hose is described in the "Draining hose for oil changes" section.

 Remove hose. The drain valve closes automatically.

Cleaning the hydraulic oil reservoir

Explosion hazard.

Read and observe the "Inspection and servicing - Safety instructions" chapter.

Shut off the engine.

Do not use white spirit, paraffin oil or other solvents for cleaning.

Use diesel fuel or a special flushing oil.

Avoid skin contact.

Skin contact with hydraulic oil may cause skin injury.

Wear protective gloves and firm working clothing. Dispose of contaminated hydraulic oil without polluting the environment and separately from other waste.

 Drain off hydraulic oil as described under "Draining off the hydraulic oil".

 Remove cap (7, Fig. 3-73:).

 Place a collecting recipient for the flushing oil under the hydraulic oil reservoir.

 Clean the inside of the hydraulic oil reservoir with diesel fuel or flushing oil. Remove all sediments and also the residues of the cleaning agent thoroughly

 Refit cap (7).

Filling in hydraulic oil

Fill in hydraulic oil as described under "Topping up with hydraulic oil".

 Vent the hydraulic system.

 Check the oil level in the hydraulic oil reservoir and top up with oil, if required.

Venting the hydraulic system

Hydraulic pumps, hydraulic motors, hydraulic cylinders, travel brake valves, suction lines of hydraulic pumps, oil cooler manifolds and the servo control system must be vented

 after assembly on site and prior to initial commissioning,

 before each recommissioning of the excavator, e.g. after extensive repair work to the hydraulic system or after prolonged downtimes,

 after each hydraulic oil change,

 after replacement of hoses or lines.

Venting the hydraulic components

 Hydraulic pumps and hydraulic motors (with electric motors shut off).

Open the highest leakage oil port and fill in clean hydraulic oil up to the lower edge of the opening.

Check the hydraulic system under load. Pay attention to noises produced by the hydraulic pump or the hydraulic motors. Abrupt movements of the working equipment are a sign of entrapped air in the system. Remaining air pockets can be eliminated by actuating all hydraulic functions.

 Hydraulic cylinder

Before the initial admission of the cylinder with oil, the piston must be in either of the two extreme piston positions. In other words, the piston rod (1, Fig. 3-74: and Fig. 3-75:) must be either completely retracted or completely extended.

Always admit oil first to that side of the cylinder where the piston (2) is. This is

• the piston-side port (3) when the piston rod is retracted (1, Fig. 3-74:),

• the rod-side port (4) when the piston rod is extended (1, Fig. 3-75:).

If, for assembly reasons, the piston rod is inmiddle position, admit oil first to the piston-side port (4).

When oil is admitted for the first time to the cylinder, the oil flow must be reduced. Therefore extend or retract the piston rod as slowly as possible.

The screws/nozzles of the following components must be opened until oil emerges bubble-free from the opening:

Always vent only the system section that has been opened.

 the travel brake valve at the venting screw,

 the oil cooler manifold at the mini-measuring ports,

 the servo system at the venting screws of the control blocks (under the servo caps),

 the intake line at the venting screw (with drive motors stationary).

Cleaning the hydraulic oil cooler

Risk of injury from rotating cooler fan blades.

Shut off the engine.

Never start cleaning work until the cooler fan blades have stopped turning.

The hydraulic oil coolers reach the same temperature as the hydraulic oil. Risk of burning. Allow the hydraulic oil cooler to cool down. Wear protective gloves and firm protective clothing.

If the machine is used in places with heavily contaminated ambient air, the hydraulic oil coolers must be cleaned more often than specified in the servicing plan.

The speeds of the fan motors are thermostatcontrolled. The fan motors run at maximum speed when the hydraulic oil temperature reaches ca. 60°C 140°F.

Cleaning

 Remove the grid (7, Fig. 3-77:) above the cooler.

 Blow the cooling fins clean with compressed air proceeding from top to bottom.

Loose dirt drops through the cooler down to the ground.

Pressure accumulator

To permit lowering of the working equipment in case of emergency, the machine is equipped with a pressure accumulator (1, Fig. 3-77:).

The pressure accumulator (1) is located under the superstructure baseplate.

The following regulations are applicable only in the Federal Republic of Germany. Please observe the corresponding regulations in your own country.

Inspection and servicing

Extract from the German acceptance regulations

Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations]. Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory:

Checking the gas charging pressure in the pressure accumulator

After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year.

Extract from the German regulations

The accumulator vessel must not be subjected to welding, soldering or any other mechanical work. Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been released

Pump Transfer Gearbox Pump Transfer Gearbox

Read and observe: "Inspection and servicing - Safety instructions.

Read and observe: "Inspection and servicingSafety instructions. Shut off the engine.

The gearbox housings may be hot, too.

Secure the machine as described in the "Securing the machine" section.

Protect the skin from contact with gearbox oil. Skin contact with cooling liquid is a potential health hazard.

Wear protective gloves and firm working clothing.

Checking the gearbox oil level / Topping up with oil

Park the machine as described in the "Securing the machine" section.

 Screw out dipstick (1, Fig. 3-78:) and wipe clean.

 Insert dipstick (1) fully again and withdraw a second time.

The oil level must reach up at least to the lower mark on dipstick (1). Top up with gearbox oil, if required.

 Screw dipstick (1) back in place.

Pre-chamber, checking oil level

The oil level in the pre-chambers is visually at the inspection glas (3, Fig. 3-79) in expansion reservoir (1).

The oil level should reach up at least to the middle of the inspection glas (3). Top up with gearbox oil, if required.

Changing the gearbox oil

Draining off oil

 Prepare a collecting recipient for used oil.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

 Unscrew plug (3, Fig. 3-80:) and drain off oil.

Screwing out breather filter (2) facilitates draining off the used oil. Plug (3) is accessible from the bottom.

 Screw plug (3) back in place.

Pre-chamber, changing gearbox oil

Draining off oil

 Prepare a collecting recipient for used oil.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

 Unscrew plug (7, Fig. 3-80:) and drain off oil.

Plug (7) is accessible from the bottom.

 Screw plug (7) back in place.

Filling in oil

 Unscrew breather filter (2, Fig. 3-81).

 Fill in new oil through opening of breather filter (2).

The oil level should reach up at least to the middle of the inspection glas (3).

Fig. 3-80:

Filling in oil

 Unscrew breather filter (2, Fig. 3-80:).

 Fill in new oil through opening of breather filter (2). After oil changes, plug (3) must be tightened beforehand.

 Check oil level with dipstick (1).

Oil can also be filled in through the opening of the breather filter (2, Fig. 3-81).

Gearbox venting

The gearbox is vented through breather filter (2, Fig. 3-82:).

Clean breather filter in accordance with the servicing plan.

 Unscrew breather filter, clean in white spirit or paraffin oil and blow dry with compressed air.

 Screw breather filter back in place.

Pre-chamber

The pre-chambers are vented through breather filter (2, Fig. 3-83:).

Clean breather filter in accordance with the servicing plan.

 Unscrew breather filter, clean in white spirit or paraffin oil and blow dry with compressed air.

 Screw breather filter back in place.

Slewing Gearbox

Read and observe: "Inspection and servicing - Safety instructions.

Shut off the engine.

The gearbox housings may be hot, too. Secure the machine as described in the "Securing the machine" section.

Protect the skin from contact with gearbox oil. Skin contact with cooling liquid is a potential health hazard.

Wear protective gloves and firm working clothing.

The oil level must reach up at least to the lower mark on dipstick (1). Top up with gearbox oil, if required.

 Screw dipstick (1) back in place.

Changing the gearbox oil

 Prepare a collecting recipient for used oil.

Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Gearbox - Checking the oil level / Topping up with oil

 Park the machine as described under "Securing the machine".

 Screw out dipstick (1, Fig. 3-78:) and wipe clean.

 Insert dipstick (1) fully again (do not screw in) and withdraw a second time.

Draining off oil

 Attach hose (8, Fig. 3-85:) to drain valve (7) and drain off oil completely.

The use of the oil draining hose is described in the "Draining hose for oil changes" chapter.

The drain valve (7, Fig. 3-85:) is accessible from the undercarriage.

 Remove hose. The oil drain valve closes automatically.for oil and cooling liquid change" section.

Filling in new oil / Topping up

 Unscrew plug (4, Fig. 3-86:) and fill in new oil.

 Check oil level with dipstick (1, Fig. 3-86:).

 Screw in plug (4) again.

Gearbox venting

The gearbox is vented through breather filter (2, Fig. 3-86:).

Clean breather filter in accordance with the servicing plan.

 Unscrew breather filter (2), clean in white spirit or paraffin oil and blow dry with compressed air.

 Screw breather filter (2) back in place.

Output pinion

Grease bearing regulary.

 Fill in approximate 50cm3 / 1.7oz grease through grease nipple (5, Fig. 3-87:) by means of a hand grease pump.

Travel Gaerbox

Read and observe: "Inspection and servicing - Safety instructions.

Shut off the engine.

The gearbox housings may be hot, too. Secure the machine as described in the "Securing the machine" section.

Protect the skin from contact with gearbox oil. Skin contact with cooling liquid is a potential health hazard.

Wear protective gloves and firm working clothing.

Gearbox - Checking the oil level / Topping up with oil

 Park the machine as described under "Securing the machine".

 Move the excavator until one of the two drain plugs (6, Fig. 3-88:) is at the bottom and screw out the upper plug.

The oil level should reach up to the lower edge of the opening. Top up with oil, if required.

Travel gearbox - Changing the oil

 Park the machine as described under "Securing the machine".

 Place a collecting recipient for used oil under the travel gearbox. Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

 Unscrew lower plug (6) and drain off oil completely. Screwing out the upper plug facilitates draining off the used oil.

Before filling in new oil, screw lower plug (6) back in place.

Filling in new oil / Topping up

 Unscrew upper plug (6) and fill in new oil through the borehole until the oil level reaches up to the lower edge of the opening.

Gearbox venting

The gearbox is vented through breather filter (2, Fig. 3-89:).

Clean / change breather filter in accordance with the servicing plan.

 Unscrew breather filter, clean in white spirit or paraffin oil and blow dry with compressed air.

 Screw breather filter back in place.

CRAWLER TRACKS Cleaning

Clean tracks, track and support rollers, sprockets and idlers regularly and whenever required. Cleaning is especially important in winter to prevent

 the tracks from being thrown off

 oil from leaking out of track and support rollers, sprockets and idlers

 excessive wear

 the track from breaking.

Track rollers, support rollers, track pads

The track rollers (1, Fig. 3-91:) and the support rollers (2, Fig. 3-92:) have a permanent oil filling. Inspect all track and support rollers visually for leaks and free movement at regular intervals.

Track roller fastening

Check fastening screws (3, Fig. 3-91:) regularly for tightness:

 Tighten screws with a torque wrench to the prescribed tightening torque (see "Technical Handbook").

To clean the tracks:

 raise one side of the excavator with the working equipment and allow track to turn;

 clean the side member supporting the track;

 clean track and support rollers (1 and 2 , Fig. 3-90:) thoroughly, especially at those places indicated by arrows;

 clean the sliding planes on the idler guides.

Support roller fastening

Check fastening screws (4, Fig. 3-92:) regularly for tightness:

 Tighten screws with a torque wrench to the prescribed tightening (see "Technical Handbook").

Track pads

Check fastening screws (5, Fig. 3-93:) regularly for tightness:

 Tighten screws with a torque wrench to the prescribed tightening (see "Technical Handbook").

Track tensioner Design

The tracks are tensioned with the help of the hydraulic pressure created during travelling. Fig. 3-94:and Fig. 3-95: show parts of the tracks and the tensioner:

Function

The tensioning system is under permanent pressure of ca. 100 bars / 1450psi which keeps both tracks permanently tensioned. Pressure losses are compensated as soon as the engines have been started. Retensioning is not required.

For cleaning and servicing work, the tracks can be slackened.

To do so:

 Stop the engine

 Open both pressure limiting valves (6, Fig. 3-95:) to slacken the tracks.

 After the work, screw down the pressure limiting valves (6) to the limit stop.

4 Pressure accumulator

5 Pressure cylinder

6 Pressure limiting valve

9 Mini- measuring port

10 Idler

11 Drive sprocket

12 Track roller

13 Crawler track

14 Support roller Techncal data

Track tensioning pressure ca. 100 bars / 1450 psi

Pressure limiting valve 250 bars / 3626psi

Gas pressure in pressure accumulator (nitrogen filling pressure) 80 bars / 1160psi

The pressure-limiting valves (6) are preset to a pressure of 250 bars / 3626psi and sealed in this position. The lead seal must not be removed and the pressure setting of 250 bars / 3626psi must not be changed.

The track tensioners are maintenance-free.

Idlers

The idlers have a permanent oil resp. grease filling.

Checking for leaks

Inspect the idlers visually for leaks and free movement after each working shift. If leaks are detected, the idler must be reconditioned.

Pressure-accumulator inspection regulations

The following regulations are applicable only in Germany. Please observe the relevant regulations in force in your own country.

Extract from the German regulations

The accumulator vessel must not be subjected to welding, soldering or any other mechanical work. Work on systems containing accumulators (repairs, connection of pressure gauges or similar work) may be carried out only when the fluid pressure has been relieved.

Extract from the German acceptance regulations

Hydraulic accumulators are pressure vessels and are therefore subject to the "Druckbehälterverordnung (DruckbehV)" [Pressure Vessel Regulations]. Their installation, equipment and operation are governed by the "Technische Regeln Druckbehälter (TRB)" [Technical Rules for Pressure Vessels]. The pressure vessels of hydraulic accumulators are classified by the admissible operating pressure p in bars, the capacity l in liters and the product of pressure and capacity p x l. Depending on the class to which the accumulator belongs, the following inspections are mandatory:

Checking the gas charging pressure in the pressure accumulator

After commissioning (new installation or repair), the gas charging pressure in the pressure vessel must be checked at least once during the first week. If no pressure loss is detected, the second pressure test must be performed after ca. 3 months. If no pressure loss is detected in this test either, the testing interval can be fixed at once pressure test each year

The above-mentioned pressure tests are required to ensure the functioning of the track tensioner. They are no substitute for the inspections as required by the "Pressure Vessel Regulations".

Before checking the gas charging pressure (nitrogen filling pressure) in the pressure accumulator, the track must first be slackened, i.e. the hydraulic part of the tensioning system must be depressurized. See under "Function".

Slewing Ring

Read and observe: "Inspection and servicing - Safety instructions.

Shut off the engine. Wear protective gloves and firm protective clothing.

Slewing ring – Instructions

The grease filling must be replaced:  when repairs have been carried out on the slewing ring, the slewing ring seals or the slewing ring housing.

Remove old grease completely before filling in new grease.

If greater losses are detected, locate cause immediately to prevent damage to the slewing ring. Greases and greasy cleaning rags must not be allowed to pollute the environment. Discard grease and greasy cleaning rags separately from other waste without polluting the environment.

Bearing races

The central lubricating system supplies grease continuously to the two roller bearing races and the internal gearing

The grease is pumped to the greasing points of the bearing races by a distributor (Fig. 3-96:).

Internal gearing

The internal gearing and the pinion are enclosed in a housing (5, Fig. 3-97:). The housing forms a grease-filled trough in which the pinion of the slewing mechanism moves.

The grease is pumped to the greasing port of the grease trough by the distributor (Fig. 3-96:). The amount of grease used up during operation is replenished by the central lubricating system.

The housings have a check opening which is closed with a cover (6, Fig. 3-98:For checking, the cover must be removed.

Slewing ring - Checking the grease filling

Read and observe: "Inspection and servicing - Safety instructions.

Shut off the engines

Wear protective gloves and firm protective clothing.

At regular intervals

 check internal gearing and teeth of slewing mechanism pinion for condition

 check that the grease filling is sufficient.

The housing must always contain enough grease for the gearing - measured from its lower edge - to run in at least 20 mm / 0.8" of grease over its whole circumference (Fig. 3-99:).

In the event of greater grease losses, eliminate cause immediately and add grease to prevent the internal gearing and the pinion from being damaged by continued slewing movements.

Slewing ring - Filling in grease

Prior to initial commissioning, the grease trough of the internal gearing must be filled with grease. Add grease when

 the housing has been replaced

 old grease has been removed in the course of other work.

Always fill in fresh grease by hand.

Risk of accidents. Never slew the superstructure when refilling grease.

Slewing ring - Checking the screws for tightness

The fastening screws of the slewing ring in the superstructure and the undercarriage are tightened with their respective check torque (see "Technical Handbook").

When these values are reached, the fastening screws are perfectly tight.

Loosen slack screws before tightening them with a torque wrench to the prescribed torque (see "Technical Handbook").

CENTRAL LUBRICATING Design and function

The excavator is equipped with an automatic central lubricating system ensuring regular the regular supply of grease to all greasing points except those mentioned in the "Lubricating chart - Grease" for the backhoe bucket.

All lubricating points connected to the system are greased at regular intervals. During the greasing cycle, indicator lamp (24, Fig. 3-100:) is lit up. A grease pump (5, Fig. 3-102:) with attached grease container (6) pumps the grease through lines (7) to the main distributors (17 and 18, Fig. 3-102: and Fig. 3-103:).

When the electrical system is switched on with the key-switch, the indicator lamp (23, Fig. 3-100:) lights up and the lubricating system is activated. The indicator lamp (23) is visible after removing cover (20, Fig. 3-101:).

There is no main distributor (18) if the excavator is equipped with a backhoe bucket.

In the case of trouble-free operation, two control pins in the main distributors must always move up and down when the pertaining pistons in the main distributors are being switched over.

Control pin movement is monitored by means of sensors. Indicator lamp (24, Fig. 3-104:) flashes on and off in the event of a fault.

See fault indication table.

In the event of trouble, shut off engine and rectify. Check during every working shift

 that no grease escapes from the pressurerelief valves (9, Fig. 3-105:) and

 that the grease container contains a sufficient amount of grease.

Always refill the grease container in time to avoid malfunctions caused by air penetrating into the lubricatingsystem.

The grease container (6) can also be filled by hand.

Switch off the electrical system and withdraw key from the key-switch.

The level of grease in the container is visible from outside.

If grease escapes from the pressure valves (9), the line system is clogged. In this case, rectifiy the fault as described under "Unblocking a grease line".

If the amount of grease left in the container is insufficient, refill container through greasing nipple (10, Fig. 3-105:) with a manual grease gun or with a mobile service station. The filling pressure must be ca. 5 - 8 bars / 72-116psi.

Unscrew cover (8)of the grease container and fill in grease manually. Screw cover (8) back in place.

Greasing cycle

The greasing cycle is initiated by a electronic unit. The duration of a single cycle is controlled by the check-back signal from the sensors in the greasing circuit.

Presetting the pause duration

The pause duration is preset with jumper (21, Fig. 3-106:) and rotary switch (22).

Jumper (21) placed over contact pins on the left and in the middle: presetting of minutes.

Do not change the setting

Rotary switch (22) is used to preset 15 time ranges 1 thru and A thru F.

The optimal adjustment of the pause duration is attained when an increasing ring of grease forms at the greasing (friction) points. If one of the greasing points shows a different behaviour, it is not being supplied with sufficient grease. In this case, the pause duration must be adapted accordingly.

Indicators

Diode (23, Fig. 7) lights up when the power supply in on.

Diode (24) lights up in the event of malfunctions (code flashing sequence see table in Fig. 8).

The control panel indicator "Lubrication" in the driver›s cab flashes in the same sequence.

A = Drive motor defective

B = Malfunction of lubricating circuit 1

C = Malfunction of lubricating circuit 2

D = Malfunction of lubricating circuits 1 and 2

E = Container empty (Optional)

F = Pump running indicator extinguished during greasing pauses

Rotary switch (22) is set to range "1". The corresponding pause duration is the 4 minutes.

If rotorary switch (22) is set to range "2", the pause duration will 8 minutes. In range "3", the duration is 12 minutes.

Increasing the range by one step of the switch prolongs the pause duration by another 4 minutes.

Set the pause duration at first to 4 minutes.

If required, the pause can be prolonged later on.

Malfunctions

 greasing point(s) blocked up

 distributor (s) blocked up

 main line to distributor with piston movement sensor interrupted

 air in greasing system

 container empty

Reset button (25, Fig. 3-108:)

Depressing reset button (25) for more than 2 seconds initiates an additional greasing cycle.

After having rectified a malfunction, reset button (25) must be depressed shortly (1 second) to cancel the fault message.

The malfunctions mentioned above prevent the pistons in the monitored distributor from moving up and down. Lamp (24) will then indicate the corresponding fault by flashing on and off in the following intervals:

Malfunction of lubricating circuit 1

B = 0,5 seconds - "ON" - 1 second "OFF"

Malfunction of lubricating circuit 2

C = 1 second - "ON" - 0,5 seconds "OFF"

Malfunction of lubricating circuit 1 and 2

D = 2 seconds - "ON" - 2 seconds "OFF"

Container empty (option)

Indicator lamp (24) flashes in the following intervals

E = 0,5 seconds - "ON" - 0,5 seconds " OFF"

The "container empty" signal starts flashing only after 6 revolutions of the motor.

In the event of malfunction, the piston sensor (initiator) can no longer detect piston movements and therefore not switch off the motor.

The monitoring timer of the control unit operating in parallel switches off the pump after the monitoring time has elapsed.

The system indicates a fault.

Indicator lamp (24) flashes on and off. The pump does not restart automatically.

Venting the grease pump

 Refill grease container (6, Fig. 3-109:).

 Unscrew lines (7) from connections (12).

 Start up grease pump (5) until grease emerges from connections (12).

 Switch off grease pump and reconnect lines (7).

Venting the grease lines

If air has penetrated into the line system - e.g. when lines are being replaced - the lubricating system must be vented.

 Disconnect lines (7, Fig. 3-109:) from the distributors.

 Start up grease pump (5) until grease emerges from lines (7).

 Switch off grease pump (5) and reconnect lines (7) to the distributors.

 Disconnect all other lines one after the other from the distributors, start up grease pump (5) and wait until grease emerges from the respective connection.

 Repeat these procedures at all other distributors.

Unblocking a grease line

Proceed as described under "Venting the line system".

Put the excavator back into operation only after the lubricating system works properly and after activating the unloaded working equipment for abt. 5 minutes. This is required to supply sufficient grease to the cylinder bearings.

Cleaning the grease sieves

Check the grease sieves (13, Fig. 3-110:) for contamination and clean, if required. The grease sieves must also be cleaned after a blockage in one of the grease lines has been removed

Cleaning

 Loosen nut (12) by holding union (16) in place with a wrench.

 Unscrew disk (14).

 Remove sieve (13) and clean with white spirit or paraffin oil.

 Refit (13) and fasten with disk (14).

 Screw nut (12) onto the union.

Lubricating the grease distributor of the working equipment

 Withdraw protective cap from greasing nipple.

 Clean greasing nipple.

 Press nozzle of the grease gun onto the greasing nipple.

 Inject grease until the fresh grease squeezes the used grease out of the bearing joints.

Make sure that used grease emerges from all greasing points connected to the distributor.

Only then have all greasing points connected to the grease distributor been properly greased.

 Wipe off used grease with cleaning rags.

 After greasing, place protective cap back on the greasing nipple.

Dispose of cleaning rags without polluting the environment.

Putting The Excavator Out Of Operation And Recommissioning

Putting the excavator out of operation

 Park the excavator on firm and level ground.

 Set the working equipment down on the ground, retracting the piston rods of the hydraulic cylinders as far as possible.

 Set all control element to "0"

 Clean the machine.

 Lock the superstructure

 Carry out a visual inspection of the excavator.

 Remove coarse dirt, snow and ice from the fins and fan wheel of the hydraulic oil cooler.

 Carry out engine preservation

 Protect all bright metal parts (e.g. piston rods) from rust and dirt.

 Check anti-freeze concentration of the cooling liquid to avoid freezing during the cold season.

 Fill up the fuel tank.

 Remove the batteries; see "Battery storage".

 Secure the machine against unauthorized starting by:

- withdrawing the key from the key-switch

- setting the battery main switch to OFF and withdrawing the key handle

- locking the cab door

- securing all lockable hatches.

 Cover up all openings

Battery storage

During prolonged machine downtimes, remove the batteries and store in a dry room at an ambient temperature of ca. 20°C / 68°F. Observe the following points with regard to maintenance:

 Clean the batteries.

 Check the acid density and the electrolyte level of the battery every two weeks.

 Recharge the batteries at the latest, when the acid density has dropped to 1.23 kg/dm³.

 Keep the batteries clean and dry on the outside.

Recommissioning

 Remove the covers.

 Degrease / clean all protected components.

 Remove engine preservation in acc. with the engine operationg anstructions

 Unlock the superstructure

 Check the fuel level in tank

 Check track tension (visual inspection)

 Check level and condition of the cooling liquid in the cooling system.

 Check grease filling in grease container.

 Oil level - drive engine

- slewing gearbox

- pump transfer gearbox

- travel gearboxes

 Check oil level in hydraulic oil reservoir.

 Check battery acid density and level.

 Install batteries and reconnect.

 Set the battery main switch to ON

 Function checks: - superstructure holding brake

- track brake

- lighting system

- signalling equipmen

 Vent the hydraulic system.

Part

Part 2 OPERATION

Operating personnel

Inspection and servicing personnel

Repair personnel

Operating personnel

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

Part 3 INSPECTION AND SERVICING

Inspection and servicing personnel

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Part 4 REPAIR WORK

Repair personnel

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX

Part 6 INDEX

Operating personnel

Inspection and servicing personnel

Repair personnel

Operating personnel

Inspection and servicing personnel

Repair personnel

REPAIR WORK - SAFETY INSTRUCTIONS

Operating instructions

Never carry out repair work without having read and understood the operating instructions.

Pay special attention to: "Fundamental Safety Instructions", "Inspection and servicing - safety instructions" and all warnings and safety instructions attached to the machine.

The descriptions of job sequences provide only experienced personnel with the necessary instructions.

The operating manual must be kept with the machine at all times.

Repair personnel

Repair personnel must have know-how and experience relevant to repairing this or comparable machines.

In the absence of such know-how, meticulous training must be given by experienced repair personnel, e.g. from CGM HMS.

Working in greater heights

Always wear safety harnesses when working at greater heights.

Wear an approved safety harness; it must be equipped with fall arresters and safety cables.

Prestressed units

Never open defective prestressed units but replace them as an entirety.

In exceptional cases, open only when the system and the operating sequence are precisely known and any special tools required are available.

The operating manual contains no information on this point.

Dismantling components

Never do dismantling while the machine is at operating temperature.

Oils, greases, or coolants may have a high temperature and result in burning or scalding.

Leave time for the machine to cool down.

Before starting work, depressurize piping and hoses, cylinders, radiator, hydraulic tank and other systems or units.

Replace defective components in good time to prevent major damage.

Clean the defective component carefully before dismantling it.

Mark the dismantled parts in the correct sequence to faciliate re-assembly.

When dismantling the component, close off exposed hose and piping connections, exposed drill holes and housings carefully to prevent any dirt from penetrating.

Never remove lead seals

Never change rated pressure of pressure relief valves without the explicit authorization of CGM HMS.

Never remove lead seals from pressure relief valves and accumulators.

After the repair work

To prevent corrosion, coat all bright metal machine parts with a grease film.

On completing the work, re-assemble all protective devices, covers and noise- and vibrationinsulation material.

Never start up the drive engines while work is being done on the machine.

Check the repaired components and all machine functions in a trial run.

Never release the machine for recommissioning until it is fully functioning.

Repair work

REPAIR WORK, FIRE AND EXPLOSION HAZARD Safety instructions

Prior to commencing work, obtain informationon the national and corporate rules for the prevention of accidents and avoiding fires.

Pay particular attention to hazards caused by combustible and easily flammable substances.

Obtain information on the safe handling of the fire extinguishers to be used.

Avoid smoking and open fire on, next to and below the excavator.

Even battery gases can ignite in open flames or fire.

Combustible and easily or highly inflammable substances or liquids increase the risk of fire and explosion. This is also valid for pressure vessels containing flammable substances as, for instance, spray oil or cold-starting fluid (ether). They are heat-sensitive and can explode even if exposed only to intensive sunlight.

These substance can also ignite themselves if they come close to hot units or objects as, for instance, a turbocharger.

Do not store these substances on the excavator. If combustible, easily or highly flammable substances or liquids were used during maintenance operations, they must be completely removed from the excavator at the end of the work.

Avoid parking the excavator in places where

 combustible substances such as coal dust or tar are present.

 open or smouldering fire may occur.

Remove the excavator from such an area where combustible or easily flammable liquids have spilled from the excavator onto the ground.

Flying sparks (caused by welding, flame cutting, grinding, electrical short-circuit) may cause fire on the ground that can spread to the excavator.

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work.

If necessary, also cover the ground with fireprotective blankets.

Apply special protection to cables, cable ducts as well as to hose and pipe lines.

Have all your welding, flame cutting and grinding work approved before starting work.

The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Ensure sufficient ventilation.

Do not keep any fire extinguishers that are not suitable or have not been tested.

Do not extinguish flammable liquids with water. Use:

 dry-powder, carbon-dioxide or foam extinguishing compounds.

When getting into contact with burning substances, the fire-fighting water would abruptly evaporate and distribute the substance such as oil over a wide area. Water causes short-circuits in the electrical system thus possibly entailing new hazards.

Call the fire brigade.

Clean the excavator carefully after the maintenance, if oil, grease, fuel, detergents or coldstarting fluid have been spilt over the machine. If possible, use a steam-jet cleaner for cleaning.

REPAIR WORK, ENGINE

Read and observe the "RepairSafety instructions" chapter and the engine operating instructions before working on the engine. The engine compartment can be equipped with pressure vessels containing cold-starting fluid (ether). Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage. Protect the pressure vessels against damage before beginning to work in or close to the engine compartment.

Risk of injury from hot or rotating parts of the engine.

Risk of injury caused by rotating or hot parts of the engine.

Shut off the engine and allow to cool down.

Carry out repair work only if the machine has been secured as described in the "Securing the machine" section of these operating instructions. Check and replace V-belts only when the engine is stationary.

Before cleaning the engine

Exhaust pipes and turbo chargers in the engine compartments are covered with special heat-insulating material. This material must not be spraywashed with steam-jet cleaners or high-pressure cleaners. It will be damaged. Therefore cover all the insulating material with plastic foils before using steam-jet cleaners or highpressure cleaners inside the engine compartments.

Electrical System

Assisted starting (with jumper cables) – Safety instructions

Keep any potential ignition sources, such as unshielded lights or burning cigarettes, away from the batteries. Battery gases are highly flammable. Explosion hazard.

Do not lean over the batteries when starting the machine from another vehicle.

Risk of injury from acid splashes and battery gases.

Never use assisted starting when the batteries are defective or frozen.

Never connect batteries (battery assemblies) unless they have the same voltage.

Use only tested jumper cables with insulated terminal clips and an adequate lead diameter.

Ensure that the bodies of the supplying and receiving machines are not in contact. Otherwise a current flow could result from connecting the positive poles. Risk of short-circuiting.

Never use welding generators or welding transformers as a source of current.

Position the jumper cables in such a way that they cannot be caught by rotating engine components.

Read and observe: "Inspection and servicing – Safety instructions", paying particular attention to the section "Handling batteries".

Assisted starting (with jumper cables)

Prior to assisted starting

Read and observe the section: "Assisted starting – Safety instructions".

Starting the engine with jumper cables (external batteries

Before connecting the jumper cables (external bateries) check the own batteries for proper operation. Checking is done by switching on the excavator's electrical system.

Do not switch on electrical consumers (e.g. floodlamps) when checking the batteries. In case of doubt, remove the batteries and have them tested.

 Assisted starting with batteries installed Connect first the positive terminal of the jumper cable to the batteries and then to the supplying unit. Connect the negative terminals in the same order. After starting, disconnect the jumper cable in reverse order, i.e. first the negative terminal and then the positive terminal.

 Assisted starting without batteries installed (only for engine trial run)

Do not disconnect the starting aid when the engine is running.

After disconnecting, the alternator runs without batteries.

 Connect the jumper cable in the above- described order and disconnect after starting.

 Switch off all consumers at the receiving machine and turn the key-operated switch to "0"

 Switch off all consumers at the supplying machine (charged batteries) and shut off the engine.

Connecting the jumper cables

 Connect the red jumper cable to the positive pole of the empty battery (1,Fig. 4-1:), then to the positive pole of the charged battery (2).

 Connect the black jumper cable first to the negative pole of the charged battery (3), then to the negative pole of the empty battery (4).

Explosion hazard

When the negative terminal is connected to ground, a strong current flows through the jumper cable.

The sparks produced in the contact area can ignite the gases emanating from the discharged battery.

The negative terminal must therefore be connected to ground at a place as far away from the discarged batteríes as possible.

Starting up the engines

 Start up the engines of the supplying machine and run at high speed.

 Start up the engine of the receiving machine. If the engine fails to start up after 15 seconds, wait for one minute and thenstart again.

 When the engine has started up, continue running both machines in no-load operation for about two or three minutes with the jumper cables still connected.

Disconnecting the jumper cables

 Negative pole at the receiving machine (4)

 Negative pole at the supplying machine (3)

 Positive pole at the supplying machine (2)

 Positive pole at the receiving machine (1)

 For machines with electronic modules:

- Run engine for about half an jour at low speed. The batteries are partially charged.

- Shut off engine

- Make all electrical connections to the modules.

- Start up engine without jumper cables.

HYDRAULIC SYSTEM Repair – Instructions

Always depressurize the hydraulic system before removing hydraulic hoses or pipes. Read and observe also the chapters "Inspection and servicing - Safety instructions" and "RepairSafety instructions".

Replace damaged and leaking hydraulic hoses as soon as possible by new ones. Use original spare parts from CGM HMS. They are adapted to the respective function.

Do not re-use old hoses.

Never repair damaged hoses.

Discard escaped oil and oily wastes without polluting the environment. These substances must not be allowed to penetrate into the soil.

Hydraulic hoses – Instructions

Even hoses that have been properly stored or used are subject to natural ageing. Their useful life is therefore limited.

Hydraulic hoses must replaced after a service life of six years (including a storage time of 2 years). Check the date of manufacture on the hose or on the hose fitting regularly.

The recommended interval after which hydraulic hoses - and especially those used in harsh conditions - must be replaced depends on the number of operating hours and on pressure loading.

The use of hoses close to their recommended load limit shortens the replacement interval (e.g. high temperatures, frequent working cycles, extremely high pulse frequencies as well as multi-shift operation and round-the-clock work).

Hydraulic hoses must be replaced, if one of the following defects is detected during a visual inspection:

 Damage to the outer fibre reinforcement layer reaching down to the inner layer (cuts, chafe marks, cracks).

 Embrittlement of the outer fibre reinforcement layer (cracks in the hose material).

 Changes in the ususal shape of the hose under pressure or in pressureless condition in bends or curves such as detachment of fibre layers, formation of bubbles or bulges.

 Leaks.

 Non-observance of fitting requirements.

 Damage to or deformation of hose fittings that may result in a reduction of the strength of the screwed union.

 Detachment of the hose from the fitting.

 Corrosion in fittings reducing the strength of the function of the fitting.

Pressure Accumulatorssafety Instructions

The hydraulic system is equipped with pressure accumulators containing nitrogen under high initial pressure.

Even when the hydraulic pressure in the system is reduced, the nitrogen in the accumulator will remain under pressure.

The accumulators are completely safe in operation. If incorrectly handled, however, there is a risk of explosion.

So:

 Never handle accumulators mechanically, never weld or solder.

 Testing and servicing work must be carried out by experts only.

 Prior to any testing and servicing work, depressurize the hydraulic part of the system.

 To dismantle the accumulator, always wear goggles and working gloves.

 Fill accumulator with nitrogen only, never with compressed air or oxygen.

 Report any defects or damage to the machine owner without delay.

 Prior to recommissioning, an inspection by a specialist or expert is essential if the accumulator was damaged or if the admissible operating temperature or operating pressure was exceeded.

Never remove or paint over warning and information plates, rating plates or type identification markings. Replace illegible or damaged plates immediately

WELDING AND FLAME CUTTING WORKS - SAFETY INSTRUCTIONS

The present safety instructions are valid for both types of work. For easier reading, the text only uses the terms "welding work", "welding" or simply "work". These terms do however always refer to both types of work, i.e. "welding and flame-cutting work".

Read these safety instructions before starting any welding or flame-cutting operations.

Welding work by qualified personnel only

Carry out welding work only if you have received special training and if you have been ordered to perform such work.

Always bear in mind that you are performing welding work on heavily loaded components. The quality of your welding work can be decisive for the operational capability of the machine and also for the health and life of persons.

Observe the health protection and accident prevention laws and regulations as well as the fire protection regulations in force in your country.

Observe all warning and instruction signs attached to the machine.

Wear the prescribed personal protective equipment such as:

 protective clothing,

 protective gloves,

 protective mask and,

 a fall-arrest system for persons working at height.

Increased risk of fire during welding work

Always bear in mind that the heat, the sparks or dripping red-hot metal or slag produced in the process constitute a considerable risk of fire. The present safety instructions provide information on how to minimize the risk of fire.

Remove all combustible materials close to the welding location or cover them up with noncombustible materials.

If works in the vicinity of combustible materials cannot be avoided, further persons with firefighting equipment must be present on site as fireguards.

Observe the instructions of the machine owner and of the mine.

Health hazards

Welding operations produce harmful gases. Do not inhale the fumes and gases and make sure the surroundings of the welding location are well ventilated or equipped with an exhaust system. Remove all kinds of paint and all coatings as well as all residues of oils and greases from the weld area.

Do not wind the welding cables round your body or parts of your body. The electromagnetic fields produced may damage your health.

Tanks, pressure vessels and pressure accumulators

Any work on vessels containing or having contained

 combustible or combustion-accelerating substances,

 potentially explosive substances or

 substances susceptible to develop harmful gases, fumes, mists or dusts during welding may only be carried out under expert supervision and only by experienced personnel especially assigned to such work.

This prescription applies, for instance, to all tanks and reservoirs for hydraulic fluid, engine oil, diesel fuel or lubricating grease.

Welding work on pressure vessels and pressure accumulators is forbidden.

Pressure vessels containing cold-starting fluid (ether) may be installed in or near the engine compartment.

Ether is toxic and highly flammable; the vessels are under pressure. These pressure vessels can explode if exposed to high temperatures (above 49°C / 120°F) or in the event of damage.

Protect the vessels against damage and high temperatures.

Do not perform welding work in the vicinity of these pressure vessels before they have been covered up safely against accidental contact or flying sparks. Have the pressure vessels removed from the machine, if safe protection cannot be ensured. Inform yourself about the locations in the machine where the pressure accumulators of the hydraulic system are installed. Do not perform welding work in the vicinity of these pressure accumulators before they have been covered up safely against accidental contact or flying sparks. Have the pressure accumulators removed from the machine, if safe protection cannot be ensured.

Slewing rings and articulated joints

The welding current must not flow through ballbearing or roller-bearing slewings rings, through bolted connections or articulated joints or through hydraulic cylinders.

An electric current flowing through an air gap (e.g. in the bearing or in the articulation) produces a spark which damages the metallic surface.

The welding clamps must therefore always be connected very close to the weld area (max. 2 - 3 m away (6.6-9.8 ft)).

Information relating to the electrical system and to electronic modules

Electric arc welding produces electromagnetic fields, electrostatic charges and voltage spikes which can cause damage to electronic modules. Although the electronic modules of the machine are carefully protected against these influences, it is nevertheless necessary to take additional precautions in order to prevent such damage to the greatest possible extent.

• Switch off the electrical system ("ignition OFF").

• Open the battery main switch (or disconnect the starter batteries from the machine).

• Lay the welding cables as far away from electric lines as possible.

If it is not possible to implement all of the abovementioned precautions, all connectors must be removed from the electronic modules before beginning any welding work.

• Protect withdrawn terminals and connectors from short circuits and soiling. Cover up terminals and connectors with foils or adhesive tape.

• Never touch the enclosures of electrical and electronic modules with the welding electrode.

• Protect electric lines against the heat emanating from the weld area.

• Restore all electrical connections when the welding operations are terminated.

Never connect the ground clamp of the welding cable to the enclosures of electric or electronic modules.

Welding on the counterweight

Counterweights may contain a build-up of flammable gases. Before starting to work, counterweights must be flushed for at least 20 minutes with compressed air in order to remove these build-ups of gas. To permit flushing, the counterweight has two bores in its upper part: a threaded bore M18x1.5 for the compressed-air line and another unthreaded bore to let the air out.

Detailed information / instructions on this subject can be found in Service Information 2006-33 which is available on the CGM HMS GmbH website under Maintenance & Service.

Welding on components of the working equipment and on other fully or partly closed steel structures

Components may be equipped with pipelines routed inside. These lines can contain combustible substances such as hydraulic oil or lubricating grease which may be set on fire by welding operations.

• Check whether pipes or hosepipes are connected to the steel component.

• Depressurize these lines.

• Open the screwed connections and empty the lines routed inside the component.

• Start welding only after these operations have been carried out.

Electric lines may also be be laid inside partly open steel structures in order to protect them against damage. They are not always visible from each viewing direction. Electric lines may catch fire as a result of the heat produced during welding.

• Therefore check carefully whether electric lines are laid in the vicinity of the weld area.

• Protect electric lines against the heat produced at the weld area or have them removed before starting the welding operations.

Welding on the cab

The driver's cab is designed in such a way that it meets the FOPS (Falling Objects Protective Structure) requirements in accordance with DIN EN ISO 3449.

Welding and other mechanical work is forbidden as there is a risk of reducing the structural stability of the cab.

Further information

More detailed information concerning the state-ofthe-art execution of welding operations can be found in the technical handbook "Welding for maintenance and repair".

For problems or queries please contact the competent service personnel.

If parts of the machine have to be removed or dismantled, please read and observe the chapters: "Assembly of working equipment, safety instructions", "Inspection and servicing, safety instructions", "Repair, safety instructions".

Disposal At The End Of The Service Life

Dismantling and removal instructions

Before beginning work, think about the risks involved, e.g.:

 Most of the machine components have considerable mass. Therefore use only lifting gear and slings of sufficient bearing capacity.

 Risk of residual pressures still in the hydraulic system. Be very careful when opening hydraulic lines.

Read the following text attentively and observe the instructions given. Respecting the instructions will help you to protect yourself against health hazards and injuries and to prevent avoidable environment pollution.

Risk of deflagrations

In the course of time, flammable gases may have formed or accumulated in the hollow spaces of welded constructions, e.g. the counterweight. To remove these flammable gases, the hollow spaces must be purged carefully with compressed air before work with hand grinders, flame cutters or other sparking tools is being undertaken.

Risk of fire

Remainders of fuel or oils may lead to the formation of flammable gases in tanks or other hollow spaces. When these tanks or hollow bodies are cut into pieces, the gases may ignite or even explode. For this reason, remove all fuel or oil remainders from these components and purge them carefully with compressed air in order to eliminate flammable gases (other efficient methods of removing flammable gases can also be applied) before work with hand grinders, flame cutters or other sparking tools is being undertaken.

Disposing of the machine without polluting the environment

Before stripping down the machine at the end of its service life observe the following instructions:

The assemblies of the machine contain various operating fluids or lubricants. These substances may pollute the environment (so-called hazardous substances) and must therefore be disposed of properly.

Observe the national laws and regulations governing the non-polluting disposal of these substances. Remove all operating fluids from the systems, remove all lubricants and dispose of these substances properly.

 Fuel system: fuel tanks, fuel filters, fuel lines, filling station. Auxiliary attachment and units, such as an onboard crane or an auxiliary heater have their own fuel tanks with the correpsonding line systems.

 Hydraulic oil: hydraulic oil reservoir, hydraulic cylinders, hydraulic motors, hosepipes, piping, hydraulic pumps, hydraulic valves, hydraulic oil filter, filling station.

 Engine coolant: engine, radiator, expansion reservoir, piping and hosepipes, filling station.

 Gearbox oil in swing, travelling and transfer gearbox systems, expansion tanks, piping and hosepipes, filling station; idlers, support and track rollers.

 Have the refrigerant (R134A) sucked out of the air conditioner system.

 Grease from the central lubricating system, grease drum, piping and hosepipes, distributors, filling station; grease accumulations in bearings of the working equipment, grease filling in the swing ring, grease filling in track and support rollers as well as in idlers.

Further hazardous substances

 Batteries contain lead and acid.

 Electronic modules are located in switch cabinets of the cab module, the engine module, the control column.

 Pressure accumulators contain nitrogen under high pressure and possibly remainders of hydraulic oil.

 Lamps of Xenon working lights contain mercury.

The required electronic control circuits are integrated in the housings of the working lights.

 The fluorescent lamps of the maintenance lighting (discharge types) contain mercury.

 Insulating material of cables can contain PVC.

 The fire extinguishing system (if installed) contains trigger charges (ATTENTION, explosion risk) on the extinguishing agent containers. Pressure accumulators, extinguishing gas and extinguishing powder.

For more detailed information please refer to the manufacturer's safety datasheets.

Appropriate disposal of batteries

The machine is equipped with batteries containing lead and other harmful and polluting substances. Damaged or used batteries must therefore not be disposed of in the environment. They must be disposed of properly and separately from other waste. The batteries are marked with the corresponding symbols (Fig. 4-2:).

Since batteries contain also reusable materials, they are taken back free of charge by the manufacturer, dealer or by other specialized companies.

In the European Community, the final consumer is obliged by law to to dispose of used batteries in designated waste collections centers.

Observe the current regulations and laws of your country with regard to the handling of damaged or used batteries.

The symbols in Fig. 4-2: have the following meaning:

 Crossed-out waste bin= Do not dispose of batteries with normal household waste.

 Pb……= Chemical symbol for lead.

 Circle of bent arrows= Recycling symbol, ingredients of the battery can be reused.

Part 2

Part 3

Operating personnel

Inspection and servicing personnel

Repair personnel

Operating personnel

The operating personnel must have knowhow relevant to the operation and the application of this or comparable machines.

AND SERVICING Inspection and servicing personnel

Part 4 REPAIR WORK

The inspection and servicing personnel must have know-how relevant to the inspection and servicing of this or comparable machines.

Repair personnel

The repair personnel must have know-how and experience relevant to the repair of this or comparable machines.

Part 5 ANNEX Operating personnel

Inspection and servicing personnel

Repair personnel

Part 6 INDEX Operating personnel

Inspection and servicing personnel

Repair personnel

Troubleshooting

Instructions on troubleshooting

Faults are often due to the machine not being correctly operated or serviced.

For this reason, it is vital to read through the relevant section of the operating instructions once again before rectifying any faults.

If you are unable to detect the cause of the fault or to rectify it, apply to the CGM HMS after-sales service.

Describe the fault and all accompanying circumstances as precisely as possible when calling on the CGM HMS after-sales service. Exact data allow for fast troubleshooting.

Never do any jobs for which you are not qualified.

The fault table lists all faults which have been reported to date and outlines their possible causes and rectifying measures. In exceptional cases, a described fault may also have a different cause.

Layout of the fault table Fault

The fault is described here as the outcome of an observation or a previous activity. Therefore make careful observations. Study the problem carefully. First think, then act. Ask yourself the following questions:

 Which warning signals preceded the fault?

 What repair and servicing work was carried out previously?

 Has this defect already occurred?

 Is it one or several simultaneously occurring faults?

Possible causes

The possible causes of the observed fault are outlined in this group. They are arranged in order of probability, i.e. the possible cause occurring in most cases heads the list.

Measures

This describes the troubleshooting procedure. Section

This specifies where information on troubleshooting is given in the operating instructions. If there is no entry, the CGM HMS after-sales service should be consulted

Fault Tables

Combustion engine - Fault table

gets too hot, temperature warning activated

Engine not working at full power Engine not working on full cylinder papacity Engine without oil pressure or oil pressure too low

1) Contact the CGM HMS Engine oil comsumption too high Service Engine emits blue smoke Engine emits white smoke Engine emits black smoke Engine cannot be stopped Engine throttled down strongly Cause

Working hydraulics – Fault table

• Hydraulic oil temperatur too high (warning lamp lit, PMS fault indicator lamp lit) oil cooler contaminated

• Engine coolant temperature too high (warning lamp lit and PMS fault indicator lamp flashing)

• Malfunction of solenoid valves

• • Malfunction of control spool

• Engine coupling defective

Track drive – Fault table

No forward travel and no reversing travel

Maximum travel speed cannot be reached

Insufficient traction power

•

• Malfunction of pressure-relief valves

•

• Servo system pump defective

•

• Malfunction of travel valve (pedal)

• Engine nominal speed too low

• • Malfunction of control spool

• ECO-power switch in 80%-position

• Insufficient engine power Engine malfuction

• Hydraulic oil temperatur too high (warning lamp lit, PMS fault indicator lamp lit) oil cooler contaminated clea-

• Engine coolant temperature too high (warning lamp lit and PMS fault indicator lamp flashing) 1)

Slewing mechnism – Fault table

Central lubricating system – Fault table

Grease pump not working, the BCS does not indicate a warning Automatic circuit breaker on working, pilot lamp lit working, no grease delivered too high or too low

• Grease container empty

• Grease pump does not suck grease

Hydraulic Circuit Diagram

Detailled information can be found in the „Technical Handbook“ chapter 8 or contact CGM HMS Service.

Abbreviations

A Ampere (SI base unit of electric current) abt. about acc. according to

Ah Ampere hours (SI base unit of quantity of electricity)

API American Petroleum Institute approx. approximately

BA = OI = Operating instructions

Bh = OH = Operating hour

CE Communauté Européenne = European community

CECE Committee for european Construction Equipment (Defines a measure for bucket, grab or scoop filling)

CEN European Standardization Committee cm centimeter (= 1/100 m) cm3/rev Cubic centimeters per revolution dB(A) Decibel (sound intensity according to measuring method A) dia. Diameter

DIN German Industrial Standard eff. effective e.g. for example etc. etcetera

Fig. Figure, serial number of illustration

FOPS Falling objects protective structures

FS Face shovel (working equipment) ft foot gal gallon (3.71 litres)

GLR Full-load controller (electronic module for PMS)

HD Heavy duty

Hydr. Hydraulic, Hydraulics i Transmission ratio i.e. id est = that is

IFN ISO service rating, blocked

Incl. including, inclusive of ISO International Standardization Organization kg Kilogram (unit of weight) kg/dm3 Kilograms per cubic decimeter (= unit of specific density) km/h Kilometers per hour kNm KiloNewtons per meter (1 kNm = 1000 Nm) = unit of torque kW Kilowatt (1 kW = 1.36 hp) l Liter lb pound

Lb/in² Pounds per square inch (= psi)

LC Long crawler

LED Light-emitting diode l/min Liters per minute

LpA Sound pressure at workplace

LS Limited slip

LS Load sensing

LwA Sound power level of the machine in stationary operation m Meters

MA Tightening torque

MA Milliampere (=1/1000A) max. maximal, maximum min. minimal, minimum min-1 Revolutions per minute mm Millimeter (=1/1000 m)

N Normal, standard version

N, kN Newton, kiloNewton (unit of force)

NLGI National Lubricating Grease Institute (USA)

NLGI-Klasse Consistency - lubricant classification acc. to DIN 51 818

Nm Newtonmeter (unit of torque)

No. Number

OH Operating hour op.inst. Operating instructions

OW Superstructure

Abbreviations

PMS Pump Managing System

P/No. Part number (CGM HMS)

PS Metric horsepower (1 PS = 0.74 kW)

Qty. Quantity

R, r Radius resp. Respectively

RH Crawler hydraulics (excavator)

ROPS Roll-over protective structures rpm Revolutions per minute (= min-1)

SAE Society of Aotomotive Engineers (USA) sec./s. Second

SN Item number

SW Width across flats t Metric ton (= 1000 kg)

THB Technical Manual

TL Backhoe dipper (attachment) tm Tons by meters (obsolescent unit of swing torque) typ. Typical

U/min Revolutions per minute

UW Undercarriage

V Volt (unit of electric voltage)

VDMA Association of German Machinery and Systems Manufacturers

W Watt (unit of electric power)

°C Degrees Celsius (temperature)

°F Degrees Fahrenheit (temperature)

°kW Degrees crank angle

> greater than

< less than

Standard Undercarriage