INSPECTION AND SERVICING

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

Filling quantities – Grease

on the type of container built in) filling only when not connected to the central lubrication system)

10 cf. "LUBRICANTS" section

11 apply a thin layer of low temperature grease

Inspection plan – Oil (legend)

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

Inspection And Servicing

12 cf. "LUBRICANTS" section

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

OMM 6030AC, 6030ACFS(3 847 030.00)-EN INSPECTION AND SERVICING

Filling quantities - oil

Filling quantities - other

LUBRICANTS Notes on the selection of oils and greases

Original CGM HMS GmbH 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 GmbH Operating Instructions contain specifications for the oils and greases that are approved for use in CGM HMS GmbH machines. These oils and greases are especially adapted to CGM HMS GmbH 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 GmbH 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 GmbH 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 GmbH specifications, CGM HMS GmbH 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 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.

The oils and greases filled into the machine must meet at least the specifications mentioned in the

II. Oil for hydraulic system

III.b Oils for swing gearboxes

OMM 6030AC, 6030ACFS(3 847 030.00)-EN

V. Grease for bearings, slew rings and track system (Central lubrication system)

OMM 6030AC, 6030ACFS(3 847 030.00)-EN INSPECTION AND SERVICING

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

SERVICING WORK Hose line for oil change

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.

Filling and draining is can be done by means of a hose through the service station (tanklift) (Fig. 3-14:).

For filling and draining, a flexible hose is connected to the express coupling on the service station and to the service vehicle at the other end.

The filling operations require an overpressure, whereas the draining operations require low pressure.

The swing gearboxes are moreover equipped with automatic drain valves (1, Fig. 3-15:)

These automatic drain valves permit oil changes without polluting the environment.

Change oil as follows:

Place a collecting recipient for used oil under the corresponding automatic drain valve. For the recipient capacity refer to the "Re-filling quantities - Oil" table or to the "Refilling quantities - Other" table.

Unscrew protective cap from automatic drain valve.

Screw on hose line (2) to open the valve, so that the oil or the cooling liquid can flow out. When the oil has drained away, unscrew hose line to allow the valve to close automatically. Screw protective cap back in place.

ELECTRIC MOTOR Electric motor - Safety instructions

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

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

Wear protective gloves and firm working clothing. Switch off electric motor, to do so actuate switch (52, Fig. 3-16:).

Set servicing switch (4, Fig. 3-17:) to locked position and secure in this position with a padlock.

Cleaning the electric motor

Clean the electric motor, the cooling fins, bearing shields and ventilators from dust with compressed air, brushes and clothes only.

Remove the fan guard before cleaning the ventilator fan. Install it after cleaning.

Don't damage the protective coating while cleaning the electric-motor.

For more information see the manufacturers manual for the electric motor.

It is not permissible to clean the electric motor or any live shovel components with a steam cleaner and steam jet.

After finishing work on the electric motor remove the padlock from servicing switch (4, Fig. 3-17:) and unlock.

Electric motor, greasing

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

Secure the machine as described in the "Securing the machine" section. Wear protective gloves and firm working clothing.

During greasing the electric motor must be switched on. Be extremely careful to rotating parts.

Grease the bearings of the electric motor in regular intervals (see plate on the electric motor (Fig. 3-18:)).

Additional information on servicing the electrical motor is given in the electric motor operating instructions from the motor manufacturer.

Up to 30 minutes after greasing the temperature of the bearings might heavily increase. Thereafter the temperature decrease to normal. This is normal, the procedure is monitored on the BCS display.

Additional servicing work

All servicing and maintenance work not described here are carried out by the CGM HMS GmbH after sales service resp. by the Service Dept. of the manufacturer of the electric motor. (see electric motor operating instructions).

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. The electrical circuit diagrams are annexed to the spare-parts list. Further information can be found in the CGM HMS GmbH Service Manual "Working with circuit diagrams".

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.

Interrupt electrical circuits with the circuit breaker before start working on the electrical system. All electric lines upwards from the circuit breaker are then without voltage (refer to the "Safety instructions for shovels with electric motor" at the beginning of this chapter).

Before starting live-line servicing work e.g. measuring and testing with voltage applied, press switch (4, Fig. 3-19:) and secure it with a padlock. Now voltage is supplied to the whole system but the electric motor can not be switched on. This prevents accidents, inadvertent starting of the electric motor, and short circuits.

The 24V circuits are energized by the two batteries when the circuit breaker is switched off. These lines can also 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 shovel.

Gas-discharge lamps in Xenon working lights are operated with high voltage.

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. 3-20:).

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

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

Checking the charge condition of the battery

The acid temperature must be 20 °C (68°F).

Unscrew caps of the battery (Fig. 3-20:).

Measure the acid density of the battery using a commercial acid tester (Fig. 3-20:).

The acid density measured is in direct correlation with the battery charge.

Acid

Removing and installing the battery

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

Wear protective gloves and firm working clothing. Switch off the electric motor before removing the batteries to avoid damaging the alternator and the regulator.

Turn key in key-switch to position "0" and withdraw.

Set battery main switch (Fig. 3-21:) to “OFF“ position.

Disconnect and reconnect the terminal clamping lugs in the prescribed order.

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

The batteries (1, Fig. 3-22:) are located in the cab module underneath the operators cab.

The 12-volt batteries are connected in series and in parallel, so that the system voltage is 24 volts.

Detach battery holder (3).

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.

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

Install the new batteries.

Connect the cable lug to the positive terminal of the battery. Tighten the clamping screws of the cable lugs. Do not use too much force to avoid deformation.

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

Charging the batteries

The batteries are charged by the battery charger ( Fig. 3-23:) only if the electrical system with the circuit breaker is switched on.

The battery main switch (Fig. 3-24:) must be in position I "ON".

Switchgear cabinet

Breather filter

In the switchgear cabinet

For the 6.3 kV power supply (2, Fig. 3-25:), For the 400 V system (1, Fig. 3-25:), For the 24 V system (3, Fig. 3-26:).

The air is drawn in and cleaned by a ventilator with filter.

Emptying dust trap

Press dust trap (14, Fig. 3-27:) and hold until the dust trap is empty.

Emptying the dust collector

Loosen clips (11, Fig. 3-27:).

Remove dust collector (12) and empty.

Filter element, replace

Remove dust collector (12, Fig. 3-27:).

Withdraw filter element (13, Fig. 3-28:).

Replace or clean filter element (13).

Refit dust collector (12, Fig. 3-27:).

Checking and cleaning the filter element

Check the filter paper of the element by inserting a lamp into the element (Fig. 3-29:). Any damage can then be seen.

Replace damaged or distorted element immediately.

Check element seal. If damaged, replace filter element too.

Cleaning with compressed air allows the filter element to be re-used immediately.

Blow filter element (Fig. 3-30:) dry with compressed air by moving the compressed-air piston up and down inside it.

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

Cleaning is completed when no more dust is seen to leave the filter element.

Never clean filter element by beating it against hard objects.

Replace main filter element after 1000 operating hours or 3 cleaning cycles, but not later than after one year of operation.

Replacing filter mats

A filter mat is installed in the switchgear cabinet (Fig. 3-31:) behind the cover (4). Check filter mats visually and replace if necessary.

Slip ring maintenance

See (Fig. 3-32:)

High voltage, Danger to Life.

Switch off power supply at the transformer station.

Check that the slip ring assembly is without tension before opening it. Read and observe the "Inspection and servicing – Safety instructions" chapter as well as the chapter “Electrical system, safety instructions”.

Observe the Servicing Instructions of the slip ring manufacturer.

Remove all tracks of dirt.

There is a transparent sideplate at the housing. Check the housing inside for wear debris coming from the brushes and for grease. Remove if necessary.

Drain condensate from the switch gear cabinets

Check all cabinets for condensate.

Screw out draining plugs and drain condensate.

Keep the inner of the cabinets dry and clean.

Clean insulators and check for damage.

Check condition of slip ring contact surfaces; remove any sign of oxydation, "splatter" or burn spots.

Check carbon brushes for signs of wear. (See Servicing Instructions of the slip ring manufacturer).

Floodlight projector, replacing the lamp

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 more than 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.

Replacing a defective Xenon-lamp

Read and observe the: „Floodlight projector, replacing the lamp, Safety instructions“.

Switch off the projector, shut off the electric motor 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. 3-33) and withdraw the reflector (2) from the projector housing.

Withdraw connector (Fig. 3-34) from Xenon lamp socket.

Unscrew Xenon lamp holding clamp (Fig. 3-35).

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.

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. Switch off the electric motor.

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 shovel is parked on a horizontal surface with the working equipment resting on the ground (Fig. 3-36:) and with its drive motor switched off, 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 shovel on a horizontal surface. Set the working equipment on the ground.

Switch off the electric motor.

Do not switch off the electrical system

For sections 1 and 2, servo control and working hydraulics:

Shift both control levers repeatedly into all dIrections (Fig. 3-37:).

For section 3, return-flow line:

After switching off the electric motor, 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 “min” and the “max” marks of sign (2) near the inspection glass (1, Fig. 3-38:).

The hydraulic oil level is monitored by the BCS. The BCS displays a warning on the screen (Fig. 3-39:) if the hydraulic oil level is too low or too high.

Switch off the electric motor, locate cause and rectify.

Stand working equipment on the ground as shown on the sign (Fig. 3-40:).

Sign (2, Fig. 3-41:) is attached beside the level inspection glass (1).

Hydraulic oil can also be filled inby means of the service station (Fig. 3-43:).

Unscrew cap of express coupling (10). Connect filling hose express coupling of the service vehicle.

The use of the hose line is described in the "Hose line for oil change" section.

Fill in hydraulic oil until the oil level lies between the “min” and the “max” marks of the sign near the inspection glass (1, Fig. 3-41:) (oil grade cf. "LUBRICANTS").

Unscrew the hose line; the express coupling closes automatically.

Screw protective cap back in place

Fill in hydraulic oil through the return-flow filters.

Remove cover (19, Fig. 3-42:). abnehmen.

Fill in hydraulic oil through the opening until the oil level lies between the “min” and the “max” marks of sign (2) near the inspection glass (oil grade cf. "LUBRICANTS").

Before fitting the cover (19), check the sealing ring and replace, if damaged.

Fit cover together with sealing ring.

Changing the hydraulic oil returnflow filter (hydraulic oil reservoir)

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

Switch off the electric motor.

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 BCS displays a warning on the screen (Fig. 3-44:). In this case, the filter elements (9, Fig. 3-46:) are heavily contaminated; after repairs on the hydraulic system; in case of damage.

Remove cover (3, Fig. 3-45:) together with sealing ring (5) and retaining disk (7).

Remove cap (8, Fig. 3-46:) and sealing ring (10).

Withdraw filter element (9) and sealing ring (11) from basket (12). Insert a new filter element. If a filter element (9) is damaged, remove basket (12) and check/clean.

Loosen screws (13, Fig. 3-47:) and take off spring clip (14) and disk (15).

Remove basket (12) and clean in paraffin oil.

Install basket (12).

Insert filter element (9) together with sealing ring (11) and cap (8) with sealing ring (10).

Refit cover (3).

Clean the magnetic rod

The magnetic rod is located under cap (19).

OMM 6030AC, 6030ACFS(3 847 030.00)-EN INSPECTION AND SERVICING

If metal filings are detected, locate cause and rectify.

Contact the CGM HMS GmbH Service, if required.

Bypass valves (hydraulic oil reservoir)

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

Switch off the electric motor. 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 (3, Fig. 3-49:) together with sealing ring. Unscrew screws (25). Withdraw bypass valve. Take off screen (21) together with sealing ring and clean in white spirit or paraffin oil. Replace, if required.

Check sealing ring for damage and replace, if required.

Re-assemble the bypass valve. Check sealing ring (28) for damage and replace, if required.

Insert bypass valve and fasten with screws (25).

Replacing the bypass valves and sealing rings

Remove bypass valve as described under "Cleaning the screens".

Re-assemble the bypass valve with a new screen (21, Fig. 3-49:) and a new sealing ring. Insert bypass valve with new sealing ring (243) and fasten with screws (25).

Replacing the hydraulic oil return-flow filters (filter housing)

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

Switch off the electric motor. 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.

Replace the return-flow filters (15, Fig. 3-50:) together with the return-flow filters in the hydraulic oil reservoir.

Detach cover (10, Fig. 3-51: resp. Fig. 3-50:) together with sealing ring (12). Withdraw filter element (15).

Insert a new filter element.

If metal filings are detected, locate cause and rectify.

Contact the CGM HMS GmbH Service, if required. Refit cover (10) with new sealing ring (12).

Bypass valves (filter housingcooling system)

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

Switch off the electric motor.

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 screens

Clean/replace the bypass valves (Fig. 3-52:) together with the bypass valves in the hydraulic oil reservoir.

Detach cover (10, Fig. 3-53: resp. Fig. 3-52:) together with sealing ring (5).

Unscrew screws (22) and withdraw bypass valve.

Take off screen (23) together with sealing ring (24) and clean in white spirit or paraffin oil; replace, if required.

Re-assemble the bypass valve.

Insert bypass valve and fasten with screws (22).

Refit cover (10) with a new sealing ring (5). Replacing the bypass valves and sealing rings

Replace the bypass valves and sealing rings together with the bypass valves in the hydraulic oil reservoir.

Remove the bypass valve as described under "Cleaning the screens".

Re-assemble the bypass valve with a new screen (23) and a new sealing ring (24).

Insert bypass valve with new sealing ring (24) and fasten with screws (22).

Refit cover (10) with a new sealing ring (5).

Breather filter

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

Switch off the electric motor.

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. 3-54:) ensure venting of the hydraulic oil reservoir at varying hydraulic oil levels.

Check filter element and replace, if required.

Filter (control circuit and auxiliary control circuit)

One filter each in the control circuit and auxiliary control circuit are installed (Fig. 3-55:).

Replacing the filter elements

To filter the hydraulic oil in the control circuit, the machine is equipped with a high-pressure filter (8, Fig. 3-56:).

Change filter element regulary and when the BCS indicates a contamination.

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

Switch off the electric motor. 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.

Unscrew filter housing (5, Fig. 3-56:).

Withdraw filter element (6) from filter housing (5).

Clean filter housing (5) and the sealing face at the filter head (9) with white spirit or paraffin oil.

Check seals (10 and 14) and replace, if required.

Insert new filter element into filter housing (5) and refit to the filter head with new, lightly oiled sealing ring (8).

Check for leaks after putting the filter into operation.

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 four high-pressure filters (8, Fig. 3-57:).

Checking/cleaning the filter elements

Unscrew drain plug (11, Fig. 3-58:) and drain the hydraulic oil from the filter housing (9). (Place a suitable resipient under the filter housing).

Unscrew filter housing (9).

Disengage filter element (15) with a slight turn from ist retaining catch and withdraw from filter housing (9).

Clean filter element (15) in white spirit or paraffin oil.

Replace filter element (15) if it is damaged. Check seals (10 and 14) and replace, if required.

Re-assemble the filter element in reverse order.

Check for leaks after putting the filter into operation.

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

Switch off the electric motor.

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.

Replacing the filter elements

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

Clean filter housing (9, Fig. 3-58:) 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 slewing circuit

Each of the two slewing circuits is equipped with a high-pressure filter (Fig. 22).

The filter elements (2, Fig. 23) are only to be cleaned/changed if necessary.

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

Checking/cleaning the filter elements

Loosen flange (6, Fig. 3-59:).

Unscrew cover (5, Fig. 3-60).

Withdraw filter element (2) together with sealing ring (3) and retaining ring (4) from housing (1).

Clean filter element (2) with white spirit or paraffin oil.

Insert filter element into filter housing (1) and refit with new, lightly oiled sealing ring (10) and a new retaining ring (4).

Screw cover (5) into housing (1).

Refit flanche (6, Fig. 3-59:) to housing (1).

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

Shut off the electric motor.

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.

High-pressure filters for feeding circuits and slewing pumps

The shovel has two high-pressure filters (Fig. 3-61:) for the feeding circuits of the slewing pumps. Two high-pressure filters each are installed beside the pump drive gearbox.

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

Checking/cleaning the filter element

Detach flange (4, Fig. 3-62:).

Remove filter housings and pour out used oil. Withdraw filter element (6) from filter housing (5).

Clean filter housings and sealing faces at filter head with white spirit or paraffin oil.

Insert new filter element into filter housing (5) and refit to filter head with a new, lightly oiled sealing ring (8).

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

Shut off the electric motor.

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".

Install new filter element (6, Fig. 3-62:) and reassemble with a new, lightly oiled sealing ring (7).

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.

Switch off the electric motor.

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 switch on the electric motor when the hydraulic oil reservoir is empty. The hydraulic pumps may be destroyed if they are allowed to run dry.

Drawing off hydaulic oil

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

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

Switch off the electric motor.

Drain the hydraulic oil at express couplings (1, Fig. 3-63:).

Place suitable recipients under the drain valve (1) of the hydraulic oil reservoir. For the required capacity refer to the "Refilling quantities - Oil" table.

The use of the hose line is described in the "Hose line for oil change" section.

Unscrew the hose line; the oil drain valve closes automatically.

Screw protective cap back in place.

Drawing off hydaulic oil

The hydraulic oil can also be drawn off through the service station (Fig. 3-64:).

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

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

Switch off the electric motor.

Unscrew cap of express coupling (10).

Connect hose line of the service vehicle.

The hose line and its use are described in the "Hose line for oil change" section.

Remove hose line. The coupling closes automatically.

Screw on protective cap.

Cleaning the hydraulic oil reservoir

Explosion hazard.

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

Use diesel fuel or a special flushing oil.

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

Switch off the electric motor.

Skin contact with hydraulic oil may cause skin injury.

Avoid skin contact.

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 (3, Fig. 3-65:).

Detach the return-flow filter.

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 (3).

Filling in hydraulic oil

Fill in hydraulic oil through the return-flow filters. Remove cap (19, Fig. 3-66:).

Fill in hydraulic oil through the opening until the oil level lies between the “min” and the “max” marks of the sign near the inspection glass (1, Fig. 3-67:).

(Oil grade cf. "LUBRICANTS").

Hydraulic oil can also be filled by means of the service station (Fig. 3-68:).

Unscrew cap of express coupling (10).

The use of the hose line is described under "Hose line for oil change". Connect filling hose express coupling of the service vehicle. Fill in hydraulic oil until the oil level lies between the “min” and the “max” marks of the sign near the inspection glass (1, Fig. 3-67:).

(Oil grade cf. "LUBRICANTS").

Vent the hydraulic system.

Check the oil level in the hydraulic oil reservoir. Top up with oil, if required. Refit cap (19, Fig. 3-66:).

The oil level is also displayed on the BCSscreen (Fig. 3-69:).

Vent the hydraulic system.

Check the oil level in the hydraulic oil reservoir. Top up with oil, if required.

Unscrew the hose line. The express coupling closes automatically. Screw protective cap back in place.

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 shovel, 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. 3-70: and Fig. 3-71:) 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. 3-70:),

• the rod-side port (4) when the piston rod is extended (1, Fig. 3-71:).

If, for assembly reasons, the piston rod is inmiddle position, admit oil first to the pistonside 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: 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).

Always vent only the system section that has been opened.

Cleaning the hydraulic oil cooler

Risk of injury from rotating cooler fan blades.

Switch off the electric motor. 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 (1, Fig. 3-72:) are thermostat-controlled. The fan motors run at maximum speed when the hydraulic oil temperature reaches ca. 60°C.

Cleaning

The hydraulic oil coolers are located in the oil cooler module.

Clean the hydraulic oil coolers at regular intervals.

Switch off the electric motor

Remove any accumulated dirt.

Clean the fan blades (2, Fig. 3-72:).

Clean the radiators with a jet of water or compressed air from outside to inside.

Leave hydraulic oil coolers to dry.

Check the hydraulic motors (1) for free movement.

In winter-time, check that the fans (2) turn freely and that the cooling fins are free from ice and snow.

Electronic shovel control Joystick

At regular intervals acc. to the maintenance plans: Loosen gaiter and move upwards. Apply a thin layer of low temperature grease on the control spools, the actuator plate above and the cardan joint of the joysticks (arrows, Fig. 3-73:) to prevent jamming of the joysticks. Refit gaiter using a cable strap.

Pedal

At regular intervals acc. to the maintenance plans: Remove old grease and dirt from the control spools and the actuator plate of the pedals (arrows, Fig. 3-74:).

Apply a thin layer of low temperature grease on the control spools of the pedals to prevent jamming of the control spools.

Pressure accumulator - Emergency lowering

To permit the working equipment to be lowered in an emergency, the machine is equipped with a pressure accumulator (2,Fig. 3-75:).

The pressure accumulator (2) is located in the superstructure and is accessible from the ground.

Pressure accumulator – Servo control- and feeding circuit

The machine is equipped with a pressure accumulator (1,Fig. 3-76:). For the servo control- and feeding circut.

The pressure accumulator (1) is located above the pump drive gearbox.

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 released

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.

For measuring the precharge pressure in the pressure accumulator, observe the instructions set out in the booklet "Filling and testing device for pressure accumulators" annexed to this documentation

Pump Drive Gearbox

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

Shut off the electric motor.

The gearbox housing 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.

Pump drive gearbox, checking the gearbox oil level

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

Check oil level only when gearbox is cold. Heated oil may result in inaccurate measurements. Observe the information decals attached to the gearbox housings near the dipsticks.

Unscrew dipstick (1, Fig. 3-77:) and wipe.

Insert dipstick (1) again until the thread lies on top of the dipsticks tube, do not screw in Withdraw dipstick again and check oil level. Oil level should lie between the two “min” and “max” markers on the dipstick. Top up with gearbox oil if required.

Screw in dipstick (1) again.

In case of significant oil losses check for leaks at the gearbox and on all components of the gearbox oil cooling system.

Too much oil in the gearbox may be a signal of defective seals at hydraulic components. Contact your Caterpillar dealer service.

Pre-chamber Checking

oil level

The oil level in the pre-chambers is visually at the inspection glas (3, Fig. 3-78) 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.

Pump drive gearbox, changing oil

Carry out oil change when gearoil is nearly at operating temperature. All suspended particles and contaminations will be rinsed out with the old oil.

Recommendation: If the gearbox oil is heavily soiled, the gearbox should be flushed with fresh gearbox oil. In this case contact your Caterpillar dealer.

Drawing off gearbox oil

The gearbox oil is drained with the service station (Fig. 3-79:) through express coupling (5).

Unscrew protective cap of express coupling and connect hose line of the service vehicle.

Drain gearbox oil.

Remove hose after the oil has been drained. The coupling closes automatically.

Screw on protective cap.

Filling in gearbox oil

(Oil grade see: „“LUBRICANTS / CONSUMABLES”).

Fill in gearbox oil with the service (Fig. 3-79:).

Unscrew cap of express coupling (5).

Connect hose line of service vehicle.

Fill in gear oil until the oil level reaches the „max“ mark on dipstick (1, Fig. 3-80:).

Remove filling hose after the oil has been filled in. The express coupling closes automatically.

Screw on protective cap.

Start electric motor and run for maximum two minutes, then shut off motor.

The pump drive cooling circuit has now been filled with oil.

Check gearbox oil level and top up to the correct filling level.

Check for leaks and for correct filling level after putting the machine back into operation (approx. after one hour).

Top up with oil if necessary through the plug of filler tube (arrows, Fig. 3-80:).

Note:

The oil level is to be checked after about 30, 60 and 240 minutes running time as oil collects in the mounting flanges or is accumulated there to lubricate the slined hollow shafts. The gearbox oil cooling system is also to be filled with oil. Therefore it is absolutely necessary to check the oil level and top up with oil up to the correct level.

Pre-chamber

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. 3-81) and drain off oil.

Screw plug (7) back in place.

Filling in oil

Filling in oil cf. “Check oil level”.

Gearbox venting

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

Clean breather valve (2) in accordance with the servicing plan.

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

Screw breather filter (2) back in place.

Pre-chamber

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

Clean breather valve in accordance with the servicing plan.

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

Screw breather filter back in place.

Pump drive gearbox lube oil filters

Check filter tell-tales (1, Fig. 3-83:) regulary - at operating temperature - for indication of contamination.

If the red sector is visible through transparent cap (2), the filter element must be cleaned or changed.

Filter element (5) must be changed after having been cleaned 8 - 10 times; at the latest however, after 1000 operating hours.

Remove flange (3, Fig. 3-84:).

Pour oil out of filter pot (4) and remove filter element (5).

Clean filter element in spirits or petroleum; Replace if damaged

Clean filter head (6, Fig. 3-83:) and filter pot (4). Check o-ring (7, Fig. 3-84:) for damage; change if necessary.

Oil the o-ring lightly. Place filter element into filter pot and re-assemly.

Check filters for leakages after recommencing operation.

Slewing Gearbox

(For swing gearboxes P/N 3692960)

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

Shut off the electric motor. 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.

Draining off oil

Attach hose (8, Fig. 3-86:) to drain valve (7) and drain off oil completely.

The use of the oil draining hose is described in the "Hose line for oil change" chapter.

Gearbox

- Checking the

oil level / Topping up with oil

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

Screw out dipstick (1, Fig. 3-85:) and wipe clean.

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

The drain valve (7, Fig. 3-86:) is accessible from the undercarriage.

Remove hose. The oil drain valve closes automatically.

Filling in new oil / Topping up

Unscrew plug (4, Fig. 3-87:) and fill in new oil.

Check oil level with dipstick (1, Fig. 3-87:).

Screw in plug (4) again.

Gearbox venting

The gearbox is vented through breather filter (2, Fig. 3-87:).

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.

Swing Gearbox

(For swing gearbox P/N 3676892)

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

Shut off the electric motor. 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.

The gearbox housings may be hot. Wear protective gloves and firm working clothing. Collect escaping oil carefully and dispose of in an environmentally acceptable manner. These swing gearboxes have two seperated oil chambers. Each gearbox is connected to two expansion reservoirs for gearoil:

Expansion reservoir for oil in the gearbox housing (5).

Expansion reservoir for oil in the brake chamber (6).

Gearbox - Checking the oil level / Topping up with oil

Check the oil level visually at expansion tanks (5 and 6, Fig. 3-88:). The expansion tanks must be filled with gearbox oil up to abt. 1/3.

The oil level is visible from outside (light/dark area).

If necessary, unscrew cap (7) and fill in oil.

The hoses (4, Fig. 3-88:and Fig. 3-89:) connect the gearboxes (1) with the expansion reservoirs (5 and 6).

Check all threaded joints for leaks.

Changing the gearbox oil

Gearbox housing, draining off oil

Prepare a collecting recipient for used oil. Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Unscrew caps (7, Fig. 3-92:) from expansion reservoirs (5). Oil will escaping faster then.

Attach hose (3, Fig. 3-90:) to drain valve (2) and drain off oil completely.

The use of the oil draining hose is described in the "Hose line for oil change" chapter.

The drain valve (2, Fig. 3-91:) is accessible from the undercarriage.

Remove oil draining hose. The oil drain valve closes automatically.

Screw on protection cap to the drain valve.

Gearbox housing, filling in new oil / topping up

Unscrew caps (7, Fig. 3-92:) from expansion reservoirs (5) and fill in new gearbox oil. The expansion tanks must be filled with oil up to abt. 1/3

The oil level is visible from outside (light/dark area).

Screw caps (7) back in place.

Brake chamber, draining off oil

Prepare a collecting recipient for used oil. Choose the required capacity in accordance with the "Refilling quantities - Oil" table.

Unscrew caps (7, Fig. 3-94:) from expansion reservoirs (6). Oil will escaping faster then.

Unscrew plug at the upper edge of the gearbox housing (arrow, Fig. 3-93:).

Oil escapes.

Screw plug (arrow, Fig. 3-93:) back in place.

Brake chamber, filling in new oil / topping up

Fill in new gearbox oil into expansion reservoirs (6, Fig. 3-94:).

The expansion tanks must be filled with oil up to abt. 1/3

The oil level is visible from outside (light/dark area).

Screw caps (7) back in place.

Gearbox venting

The gearbox is vented through the caps of the expansion reservoirs (7, Fig. 3-94:).

TRAVEL GEARBOX P/N 3683493 / 3737455

Risk of scalding caused by hot gearbox oil.

The gearbox housings may be hot, too.

Shut off the engines and let cool down.

Skin contact with cooling liquid is a potential health hazard. Protect the skin from contact with gearbox oil. Wear protective gloves and firm working clothing.

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

Read and observe: "Inspection and servicingSafety instructions.

Travel gearbox - Checking the oil level / Topping up with oil

Move the shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-95:) are in the displayed position.

Unscrew checking screw (3).

The oil level should reach up to the lower edge of the opening. Top up with oil, if required. Screw checking plug (3) back in place.

Brake chamber - Checking the oil level / Topping up with oil

Unscrew checking screw (6, Fig. 3-96:). The oil level should reach up to the lower edge of the opening. Top up with oil, if required. Screw checking plug (6) back in place.

Travel gearbox - Changing oil

Change the oil when the machine is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Draining off oil

Move the shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-97:) are in the displayed position.

Place a collecting recipient for used oil under the travel gearbox.

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

Unscrew drain plug (2) and drain off the oil completely.

Slackening plug (1) allows the oil to run out more readily.

Clean screw plugs (1 and 2).

Screw plug (2) back in place.

Filling in oil

Unscrew plug (1, Fig. 3-97:).

Fill in oil through opening in plug (1) until it flows out of opening in plug (1).

(Oil grade see “LUBRICANTS / CONSUMABLES” section).

Screw plug (1) back in place.

Brake chamber - Changing oil

Change the oil when the machine is at operating temperature. Warm oil flows better and carries suspended particles (carbon or abraded matter) better.

Draining off oil

Place a collecting recipient for used oil under the brake-chamber.

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

Unscrew drain plug (7, Fig. 3-99:) and drain off the oil completely.

Slackening breather filter (5) allows the oil to run out more readily.

Clean screw plug (7).

Screw plug (7) back in place.

Filling in oil

Unscrew screw plug (6).

Fill in oil through opening of breather filter (5) until it flows out of opening in plug (6).

(Oil grade see “LUBRICANTS / CONSUMABLES” section).

Screw plug (6) and breather filter (5) back in place.

Breather filter

Unscrew breather filter (1 and 5, Fig. 3-99:) and clean in white spirit or parafin. Replace according to maintenance plan.

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.

To clean the tracks: raise one side of the shovel 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. 3-100:) thoroughly; clean the sliding planes on the idler guides.

Track roller, Support roller

Inspect all track and support rollers visually for leaks and free movement at regular intervals.

Track roller fastening

Check fastening screws (4 Fig. 3-101:) regularly for tightness.

Tighten screws with a torque wrench to the prescribed tightening torque (see Service Manual).

Support roller fastening

Check fastening screws (3, Fig. 3-101:) regularly for tightness.

Tighten screws with a torque wrench to the prescribed tightening torque (see Service Manual).

Track tensioner Design

The tracks are tensioned with the help of the hydraulic pressure created during travelling. Fig. 3-102: and Fig. 3-103: show parts of the tracks and the tensioner:

Techncal data

Track tensioning pressure ca. 70 bars / 1015 psi

Pressure limiting valve 330 bars / 4786 psi

Gas pressure in pressure accumulator (nitrogen filling pressure) 50 bars / 725 psi

Function

The tensioning system is under permanent pressure of ca. 70 bars / 1015 psi which keeps both tracks permanently tensioned. Pressure losses are compensated as soon as the electric motor has been started. Retensioning is not required. For cleaning and servicing work, the tracks can be slackened.

To do so:

Switch off the electric motor.

Open both pressure limiting valves (7, Fig. 3-103:) to slacken the tracks.

After the work, screw down the pressure limiting valves (7) to the limit stop.

The pressure-limiting valves (7) are preset to a pressure of 330 bars / 4786 psi and sealed in this position. The lead seal must not be removed and the pressure setting of 330 bars / 4786 psi must not be changed. The track tensioners are maintenance-free.

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. Cf. under "Function".

For measuring the precharge pressure in the pressure accumulator, observe the instructions set out in the booklet "Filling and testing device for pressure accumulators" annexed to this documentation.

Swing Ring

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

Switch off the electric motor. Wear protective gloves and firm protective clothing.

Swing 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. 3-104:).

Internal gearing

The internal gearing (1, Fig. 3-105:) and the pinion (2) are enclosed in a housing (3, Fig. 3-106:). The housing forms a grease-filled trough in which the pinion of the swing mechanism moves.

The grease is pumped to the greasing port of the grease trough by the distributor (Fig. 3-104:). 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 (2, Fig. 3-106:). For checking, the cover must be removed.

Swing ring - Checking the grease filling

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

Switch off the electric motor. Wear protective gloves and firm protective clothing.

At regular intervals check internal gearing and teeth of swing 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 (0.78”) of grease over its whole circumference (Fig. 3-107:).

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 swing movements.

Swing 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.

Swing ring - Checking the screws for tightness

The fastening screws of the swing ring in the superstructure and the undercarriage are tightened with their respective check torque (see Service Manual).

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 Service Manual).

CENTRAL LUBRICATING Design

The shovel is equipped with an automatic central lubricating system which provides grease regularly to all greasing points except those mentioned in the "Lubricating chart - Grease".

The central lubricating system is activated when the electrical system is switched on with the keyswitch and the electric motor is running. All greasing points connected to the system are greased at regular intervals.

The central lubricating system is controlled electrohydraulically by the programmable SPC contoller. The SPC is located in a switch box underneath the cab.

Fig. 3-109:

If a fault occurs, BCS gives a warning on the screen (Fig. 3-109:).

Actuate the "Reset" key (73, Fig. 3-108:) to eleminate the fault. If this is not possible, call in servicing personal.

For further information on the function and setting refer to the SERVICE MANUAL – SPC (storageprogrammable control).

Function

The grease is pumped by the pump (2, Fig. 3-110:) via greasing lines from the grease container to the main distributors on the superstructure.

As soon as the grease container is empty, the BCS (Fig. 3-112) gives a warning signal. In the event of a fault, the "dumping" function is switched off automatically after 15 min. Work can be continued when the grease container is filled with grease.

Replacing the grease drum

Detach lines (11, 12, 13 and 14 Fig. 3-113:).

Unscrew wing nuts (6).

Detach plate (5).

Remove cover (4) together with grease pump (2) from grease drum (1).

Replace the empty grease drum by a full one. Place cover (4) with grease pump (2) back onto the grease drum.

Fasten plate (5) with wing nuts (6) on grease drum (1).

Refit lines (11, 12, 13 and 14).

Checking the greasing pressure

Check every week, whether the oil pressure indicated by pressure gauge (4, Fig. 3-114:) is 60 bars / 870psi (the pressure is dependind on temperature and viscosity of the oil and may vary).

The necessary greasing pressure is generated by means of a pressure translator.

The greasing pressure is indicated by pressure gauge (9).

In the event of deviating pressure values, switch off the electric motor and check the central greasing system.

Lower oil pressure means that not all of the greasing points are supplied with grease.

Higher oil pressure may cause bursting of a greasing line.

Always refill the grease container in time to avoid air from penetrating into the greasing system. Air in the greasing may cause malfunctions.

Unblocking a grease line.

This oil pressure is reduced so that the pressure indicated by pressure gauge (3, Fig. 3-115:) is 35 –40 bars (507psi – 580psi).

Put the shovel back into operation only after the lubricating system works properly and after having actuated the unloaded working equipment for abt. 5 minutes. This is necessary in order to supply sufficient amounts of grease to the cylinder bearings.

Check the grease sieve regularly for contamination and clean, if required. The grease sieve must also be cleaned after an obstruction in one of the grease lines.

Cleaning

Loosen nut (6, Fig. 3-114:).

Withdraw sieve and clean with white spirit or paraffin oil.

Re-insert sieve and fasten with nut (6).

Oilfilter (hydraulic circuit grease pump)

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

Shut off the electric motor.

Risk of scalding caused by 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 working clothing.

Replacing the filter element

Change filter element regulary and when the BCS indicates a contamination.

Fig. 3-116:

For filtering of the hydraulic oil, high pressure filter (11, Fig. 3-116:).is installed in the pumping line.

Fig. 3-117:

Unscrew filter housing (5, Fig. 3-117:). Withdraw filter element (6) from filter housing (5).

Clean filter housing (5) and the sealing face at the filter head (9) with white spirit or paraffin oil.

Check seals (10 and 14) and replace, if required.

Insert new filter element into filter housing (5) and refit to the filter head with new, lightly oiled sealing ring (8).

Check for leaks after putting the filter into operation.

Grease filter (grease lines)

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

Shut off the electric motor.

Grease filter (12, Fig. 3-118:) is installed in the greasing line to the grease container.

Checking the filter element

Unscrew filter housing (42, Fig. 3-119:). Withdraw filter element (43) from housing (42). Remove the grease.

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 the system has been put into operation.

Replacing the filter element

Remove filter element as described under "Checking the filter element".

Insert new filter element and reassemble. Check high-pressure filter for leaks after the system has been put into operation.

Other Maintenance

Cleaning the cooling system

Check the radiators regularly.

Shut off the electric motor.

Remove any accumulated dirt.

Clean the fan blades.

Clean the radiators with a jet of water or compressed-air from the outside.

Dry up coolers.

Do not clean radiators with a wire brush or similar hard objects.

In case of firmly adhering dirt, remove radiator and clean.

Heating and air conditioning

Change the filter mats in the air intake regulary. The filter mats are located inside the air conditioner housing at the operator’s cab roof (Fig. 3-120:).

Air intake filters

Empty dust trap of the intake filter (1, Fig. 3-121:) and clean filter element respectively replace. For servicing works cf. Section „Switchgear cabinet“ in the chapter „Electrical system“.

Open cover of the air conditioner housing (Fig. 3-120:).

Clean or replace filter mats. Close cover again.

Hydraulic Ladder

To allow the hydraulic ladder (Fig. 3-122: and Fig. 3-123:) to be lowered in an emergency, the ladder mechanism is equipped with a pressure accumulator (1, Fig. 3-124:).

The pressure accumulator (1) is located in the superstructure and is accessible from the ground. Check nitrogen pressure inside the pressure accumulator regularly (see Service Manual).

Pressure-accumulator inspection regulations

Checking the gas charging pressure in the pressure accumulator

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:

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. Group Inspections prior to commissioning Regular at the factory at the place of use inspections III p ≥ l bar and p·x l ≥ 200 bars p·x l ≤ 1000 bars

Preliminary inspection by an expert Prototype and pressure test certified by the manufacturer (type approval) or the expert

Acceptance inspection by an expert Inspection schedule to be drawn up by end user, based on experience with type of operation and operating fluids.

Putting The Shovel Out Of Operation And Recommissioning

Putting the shovel out of operation

Park the shovel 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.

Carry out a visual inspection of the shovel. Remove coarse dirt, snow and ice from the fins and fan wheel of the hydraulic oil cooler. Protect all bright metal parts (e.g. piston rods) from rust and dirt.

Remove the batteries; cf. "Battery storage".

Secure the machine against unauthorized starting by: withdrawing the key from the key-switch, setting the battery main switch to OFF, setting the main circuit breaker to OFF, 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.

Check track tension (visual inspection)

Check grease filling in grease container.

Oil level - slewing gearboxes, - pump drive gearboxes, - travel gearboxes.

Check oil level in hydraulic oil reservoir.

Check battery acid density and level.

Install batteries and reconnect.

Set battery main switch to ON.

Set the main circuit breaker to ON.

Function checks: - superstructure holding brake, - track brake, - lighting system, - signalling equipment.

Vent the hydraulic system.

Operation and Maintenance Manual Target group

Part 1 INTRODUCTION

FUNDAMENTAL SAFETY INSTRUCTIONS

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

Part 4 REPAIR WORK

Inspection and servicing personnel

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

Safety Instructions For Shovels With Electric Motor

Maintenance and inspection work on electrical systems may only be performed by qualified electricians or by workshops employing such personnel.

A qualified electrician for the purpose of this regulation is a person who has the corresponding technical training, know-how and experience as well as knowledge of the pertinent prescriptions and who is therefore in a position to judge the work entrusted to him and the potential dangers in connection therewith.

Before carrying out any maintenance and inspection work on the electrical system, the following precautions must be taken:

In the transformer station

Cut out the supply voltage.

Secure against switching on; apply a warning sign.

Check that the electrical system is off circuit. Connect to earth and short-circuit.

Protect adjacent and live parts against accidental contact.

On the shovel

Cut out the circuit breaker (see the " Switching off the circuit breaker " chapter in part 2 of the present Operation and Maintenance Manual)

Secure circuit breaker against switching on, apply a warning sign.

Switch off the earthing switch (see manufacturers Operating Instructions).

After finishing repair work:

In the transformer station

Disconnect the earthing and short-circuiting line.

Unlock the safety device preventing switch-on; remove the warning sign. Remove the partitions. Switch on the supply voltage.

On the hydraulic shovel

Unlock the safety device preventing switch-on; remove the warning sign.

Switch on the circuit breaker, (see the " Switching on the circuit breaker " chapter in part 2 of the present Operation and Maintenance Manual).

REPAIR WORK - SAFETY INSTRUCTIONS

Operation and Maintenance Manual

Never carry out repair work without having read and understood the Operation and Maintenance Manual.

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 GmbH .

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 GmbH .

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 electric motor 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.

FIRE AND EXPLOSION HAZARD Safety Instructions

Prior to commencing work, inform on the national and corporate rules for prevention of accidents. Pay particular attention to hazards caused by combustible and easily flammable substances.

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

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

Combustible and easily flammable substances or liquids increase the fire and explosion hazard. Do not store or handle any flammable substances during operation.

Clean the shovel thoroughly, if possible, with a steam jet (rubber parts and electric components with compressed air - refer to information label), when, for example, oil, grease, fuel or cleaner was spilled.

Such substances may spontaneously ignite if they get into the vicinity of hot units. Even battery gases can ignite in open flames or fire.

Avoid parking the shovel in places where combustible substances such as coal dust or tar are present.

open or smouldering fire may occur. Remove the shovel from such an area where combustible or easily flammable liquids have spilled from the shovel 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 shovel.

Place suitable fire guardings (fire barriers) if open fire or flying sparks cannot be avoided during repair work. Apply special protection to cables, cable ducts as well as to hose and pipe lines.

If necessary, also cover the ground with fireprotective blankets.

Ensure sufficient ventilation.

Clean the shovel before starting a job.

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

HYDRAULIC SYSTEM Repair

Always depressurize the hydraulic system before disconnecting any hydraulic hoses or pipes.

Read and observe also the chapters "Inspection and servicing - Safety instructions" and "Repair - Safety instructions".

Replace damaged and leaking hydraulic hoses and pipes as soon as possible bynew ones.

Use original spare parts from CGM HMS GmbH. 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 operator'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 Service Manual "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 corresponding 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 slewing, travelling and drive gearbox systems, expansion tanks, piping and hospipes, 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 slewing 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. 4-1:).

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. 4-1: 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

Part

Part 3

Part 4

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.

Inspection and servicing personnel

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 Operation and Maintenance Manual 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 GmbH aftersales service.

Describe the fault and all accompanying circumstances as precisely as possible when calling on the CGM HMS GmbH 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 Operation and Maintenance Manual. If there is no entry, the CGM HMS GmbH after-sales service should be consulted

Fault Tables

Working hydraulics – Fault table

Working and swing functions not operational

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

Track drive – Fault table

No forward travel and no reversing travel

•

•

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

Swing mechnism – Fault table

Central lubricating system – Fault table

Grease pump not working, the BCS does not indicate a warning Automatic circuit breaker on not working, pilot lamp lit pressure too high or too low

Hydraulic Circuit Diagram

Detailled information can be found in the „Service Manual“ chapter 8 or contact CGM HMS GmbH service.

Abbreviations

A Ampere(SIbaseunitofelectriccurrent) abt. about acc. accordingto

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

API AmericanPetroleumInstitute approx. approximately

BA = OMM = Operation and Maintenance Manual bar unitofpressure,1bar=14.5psi

Bh =OH=Operatinghour

CE Communauté Européenne = European community

CECE Committee for european Construction Equipment (Defines a measure for bucket, graborscoopfilling)

CEN EuropeanStandardizationCommittee cm centimeter(= 1/100 m) cm 3/rev Cubiccentimetersperrevolution

CCW counterclockwise CW clockwise dB(A) Decibel (sound intensity according to measuringmethodA) dia. Diameter

DIN GermanIndustrialStandard

EDS Electronicdiagnosticsystem eff. effective e.g. forexample etc. etcetera

Fig. Figure,serialnumberofillustration

FOPS Fallingobjectsprotectivestructures

FS Rockshovel(workingequipment) ft foot(unitofdistance),1ft=0.30meter gal gallon(unitofvolume),1gal=3.78liters

GLR Full-load controller (electronic module for PMS)

HD Heavyduty

Hydr. Hydraulic,Hydraulics i Transmissionratio i.e. idest=thatis

IFN ISOservicerating,blocked

Incl. including,inclusiveof ISO InternationalStandardizationOrganization kg Kilogram(unitofweight),1kg=2.2lb kg/dm3 Kilograms per cubic decimeter (= unit of specificdensity) km/h Kilometersperhour kNm KiloNewtonspermeter(1kNm=1000Nm) =unitoftorque kW Kilowatt(1kW =1.36hp) l Liter(unitofvolume),1liter=0.26gal lb pound(unitofmass),1lb=0.45kg

Lb/in² Poundspersquareinch(=psi)

LC Longcrawler

LDA Chargepressure-dependentfull-loadlimiter

LED Light-emittingdiode l/min Litersperminute

LpA Soundpressureatworkplace

LS Limitedslip

LwA Sound power level of the machine in stationaryoperation m Meter(unitofdistance),1m=3.28ft

MA Tighteningtorque mA Milliampere(=1/1000 A) max. maximal,maximum min. minimal,minimum min-1 Revolutionsperminute mm Millimeter(=1/1000m)

N Normal,standardversion

N,kN Newton,kiloNewton(unitofforce)

NLGI NationalLubricatingGreaseInstitute(USA)

NLGI-Klasse Consistency-lubricantclassificationacc.to DIN51818

Nm Newtonmeter(unitoftorque)

No. Number

OH Operatinghour op.inst. Operatinginstructions

OW Superstructure oz ounce(unitofvolume)1oz=0.03liter

Abbreviations

PMS PumpManagingSystem

P/No. Partnumber(CGMHMSGmbH)

PS Metrichorsepower(1PS=0.74kW) psi pundpersqareinch(unitofpressure), 1psi=0.069bar

PLC Programmablelogiccontroller

Qty. Quantity

R,r Radius resp. Respectively

RH Crawlerhydraulics(shovel)

ROPS Roll-overprotectivestructures rpm Revolutionsperminute(=min-1)

SAE SocietyofAotomotiveEngineers(USA) sec./s. Second

SN CGMHMSGmbH partnumber

SW Widthacrossflats t Metricton(=1000kg)

TBG Civil Engineering Employer's Liability InsuranceAssociation

THB ServiceManual

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

U/min Revolutionsperminute

UW Undercarriage

V Volt(unitofelectricvoltage)

VDMA Association of German Machinery and SystemsManufacturers

W Watt(unitofelectricpower)

°C DegreesCelsius(temperature)

°F DegreesFahrenheit(temperature)

> greaterthan

< lessthan

Noise And Vibration Information

Noise emission information

Noise emission data are specified in acc. with ISO 6394.

Time-averaged A-weighted emission sound pressure level at operator’s position with the machine running at high idle: LAeq = XX dB.

Vibration information

On the condition that the hydraulic shovel is used within the limits of its designated use, the installation of seats for operators in conformity with ISO 7096 ensures that the weighted vibration accelerations awz (measured in compliance with ISO 2631 Part I) fulfil the requirements with respect to the protection against whole-body vibrations in acc. with EC Vibration Directive 2002/44/EG.

The vibrations operatored are indicated in acc. with EC Machine Directive 2006/42/EG, Annex I; Section 3.6.3.1, resp. with the "Regulations for noise and vibration at the place of work", Section 4, as of 18.12.2008.

The effective value of the weighted acceleration to which the wole body is exposed, does not exceed 0.5 m/s2

The measurement uncertainty is ±3% (tolerance of the measuring instruments).