Inspection and servicing

Plan B – after every 500 OH (at 500, 1500, 2500 … OH)

Plan D – after every 5000 OH (at 5000, 15000, 25000 … OH)

Plan E – after every 10000 OH (at 10000, 20000, 30000, … OH) Page 3 of

7 see “Refilling quantities – Oil“ table

8 Unless it is regulary analyzed, the hydraulic oil must be changed every 5000 OH or after 3 years at the latest

Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Inspection and servicing

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH) Page 4 of

Plan A – after every 250 OH (at 250, 750, 1250 … OH)

Plan C – after every 1000 OH (at 1000, 2000, 3000, 4000 … OH)

Plan E – after every 10000 OH (at 10000, 20000, 30000, … OH)

Inspection and servicing

Plan B – after every 500 OH (at 500, 1500, 2500 … OH)

Plan D – after every 5000 OH (at 5000, 15000, 25000 … OH)

Plan A - after every 250 OH (at 250, 750, 1250 ... OH)

Plan C - after every 1000 OH (at 1000, 2000, 3000, 4000 ... OH)

Plan E - after every 10000 OH (at 10000, 20000, 30000, ... OH)

Inspection and servicing

Plan B - after every 500 OH (at 500, 1500, 2500 ... OH)

Plan D - after every 5000 OH (at 5000, 15000, 25000 ... OH)

If any suspect areas have been found additional testing is required: For detailed crack analysis prepare the surface of the relevant area to be inspected and carry out the dye penetrant, magnetic powder or ultrasonic test.

10 Do all servicing jobs at least once a year and when necessary

11 see “Refilling quantities – Oil“ table

12 „Structural Inspection Reports“ for inspections every 500 OH can be downloaded from the CGM HMS GmbH website www.bucyrus-HEX.de, section „Support, Warranty“.

LUBRICATING CHART – GREASE

BA 6060(3 847 011.02)-EN

Inspection and servicing

BA 6060(3 847 011.02)-EN

Lubricating chart – Grease (legend)

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

Filling quantities – Grease

13 see "LUBRICANTS" section

14 apply a thin layer of low temperature grease

INSPECTION PLAN - OIL

BA 6060(3 847 011.02)-EN

Inspection and servicing

Inspection plan – Oil (legend)

15 see "LUBRICANTS" section

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

17 Change oil at least once a year.

18 Change hydraulic oil at least once a year.

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 Operation and Maintenance Manual 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 Operation and Maintenance Manual.

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.

BA 6060(3 847 011.02)-EN

Inspection and servicing

LUBRICANTS / CONSUMABLES

I. Oil for combustion engines (On-Board Crane, option)

II. Oil for hydraulic system (selection)

III.a Oil for pump gearboxes and travel gearboxes

III.b Oil for swing gearboxes

BA 6060(3 847 011.02)-EN

Inspection and servicing

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

BA 6060(3 847 011.02)-EN Inspection and servicing

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

SERVICING WORK Hose line for oil changes

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

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

Filling and draining is can be done by means of a hose through the service station (tanklift) (Fig. 3-9:).

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 the swing gearboxes are equipped with automatic drain valves (1, Fig. 3-10:)

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 Operation and Maintenance Manual.

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 (42, Fig. 3-11:).

 Set servicing switch (4, Fig. 3-12:) 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 excavator components with a steam cleaner and steam jet.

 After finishing work on the electric motor remove the padlock from servicing switch (4, Fig. 3-12:) and unlock.

Electric motor, greasing

Read and observe: "Inspection and Servicing – Safety Instructions" and the electric motor Operation and Maintenance Manual.

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 plates on the electric motor, sample is shown in Fig. 3-13:).

 Press in the correct quantity of grease specified on plate (Fig. 3-13:).

 When the electric motor is at standstill, remove the old, used grease from the bearing housing.

Additional information on servicing the electrical motor is given in the electric motor Operation and Maintenance Manual 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 Operation and Maintenance Manual).

Electrical System

Electrical system - Safety instructions

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

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 excavators 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. 3-14:) and secure it w ith 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 excavator.

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

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.

Battery, checking state of charge

Warning! Battery Posts, terminals and related accessories contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Risk of injury caused by battery acid and gases.

Wear goggles, working gloves and firm working clothing.

Do not eat, drink or smoke when handling batteries.

Wash hands after handling.

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

Checking the battery fluid level

(Not applicable in case of maintenance-free batteries)

 Unscrew caps (Fig. 3-15:).

 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 charge of the battery

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

 Unscrew caps of the battery (Fig. 3-15:).

 Measure the acid density of the battery using a commercial acid tester (Fig. 3-15:).

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

Acid density

half charged, recharge discharged, recharge immediately

On closed / sealed (so called „maintenance-free“) batteries, the charging status can be checked using a charge meter. Ask your Caterpillar dealer for assistance.

Charging the batteries

The batteries are charged by the battery charger only if the electrical system with the circuit breaker is switched on.

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.

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

Set battery main switch 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. 3-16:) are located in the pedestal (cab module). The 12-volt batteries are connected in series and in parallel, so that the system voltage is 24 volts.

Fig. 3-16:

 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 bolts 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.