Electrical system, control cabinets

The electrical system control cabinets are located in the cab module and in the motor compartment. The cabinets are described in the spare-parts list (electrical circuit diagram) together with the designation of the electrical components.

Breather filter

In the control cabinets

 For the 6600 V power supply,

 For the 400 V system,

 For the 24 V system, the air is drawn in and cleaned by a ventilator with filter.

Emptying the dust trap

 Press dust trap (14, Fig. 3-17:) and hold until the dust trap is empty.

Emptying the dust collector

 Loosen clips (11, Fig. 3-17:).

 Remove dust collector (12) and empty.

Filter element, clean / replace

 Remove dust collector (12, Fig. 3-17:).

 Withdraw filter element (13, Fig. 3-18:).

 Replace or clean filter element (13).

 Refit dust collector (12, Fig. 3-17:).

Checking and cleaning the filter element

 Check the filter paper of the element by inserting a lamp into the element (Fig. 3-19:). 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. 3-20:) 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 / 43psi.

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 control cabinets behind the cover.

 Check filter mats visually and replace if necessary.

Draining water from the switchgear cabinet

 Check control cabinets for condensation.

 Unscrew drain plugs and drain off water.

The base of the control cabinets must be kept clean.

Slip ring assembly, servicing work

(Fig. 3-21:)

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.

 Clean insulators and check for damage.

 Check condition of slip ring contact surfaces; remove any sign of oxydation, "splatter" or burn spots. Then coat with contact grease.

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

Electrical circuit diagrams

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

Replacing fuses

Fuses and their function are listed on a sheet inside the switch-cabinets in the cab module. Use only original fuses with the specified current rating.

Replacing lamps and bulbs

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

Xenon-working floodlights are operated with high voltage.

Read and observe the chapter: “Floodlight projector, replacing the lamp”.

Floodlights working with LED-technology do not have replaceable lamps / bulbs. The floodlight must be replaced if defective.

Fig. 3-21:

Xenon floodlight projector (optional), 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 bolts (1, Fig. 3-22) and withdraw the reflector (2) from the projector housing.

 Withdraw connector (Fig. 3-23) from Xenon lamp socket.

 Unscrew Xenon lamp holding clamp (Fig. 3-24).

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

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

 Plug the power supply connector onto the lamp.

 Re-assemble the housing.

Lighting systems in LED technonogy, instructions

The lights of the maintenance lighting system (Fig. 3-25) as well as the working floodlights (Fig. 3-26) are equipped with lamps in LED technology (lightemitting diodes).

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

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

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

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

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

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

Hydraulic System

Hydraulic system - Safety instructions

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

Switch off the electric motor.

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

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

Risk of burning caused by hot hydraulic components (e.g. hydraulic oil reservoir, cylinder, valves).

Wait until the hydraulic system is cooled down to moderate temperature before starting work.

Contact with hydraulic oil can cause skin injury. Avoid skin contact with hydraulic oil.

Wear protective gloves and firm working clothing.

Depressurizing the hydraulic system

Hydraulic systems may only be opened if they are completely depressurized.

Even when an excavator is parked on a horizontal surface with the working equipment resting on the ground (Fig. 3-27: and Fig. 3-28:) and with its electric 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 excavator on a horizontal surface.

 Set the working equipment on the ground.

 Switch off the electric motor.

 Do not switch off the electrical system, sit down on the operator's seat,

Sections 1 and 2: servo control and working hydraulics:

 Shift both control levers and all pedals repeatedly into all directions (Fig. 3-29:).

Checking the hydraulic oil level

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

 Park the machine on a horizontal surface.

 Stand working equipment on the ground as shown on signs (2, Fig. 3-30: and Fig. 3-32:).

The oil level must be between the “min” and “max” marks of the signs (2, Fig. 3-30:) near the level indicator tube (1).

Section

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.

The hydraulic oil level is monitored by the BCS. The BCS displays a warning on the screen (Fig. 3-30:) if the hydraulic oil level is too low or too high. In this case: Switch off the electric motor, locate cause and rectify.

Stand working equipment on the ground as shown on the signs (Fig. 3-32:).

The signs (2, Fig. 3-33:) are attached beside the level indicator tube (1).

Hydraulic oil can also be filled in by means of the service station (Fig. 3-35:).

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.

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

 Fill in hydraulic oil until the oil level is between the “min” and the “max” marks of the sign (2, Fig. 3-33:) beside the level indicator tube. (Oil grade see "LUBRICANTS / CONSUMABLES" section).

The acoustic warning signal “Travel Alarm” sounds.

 Disconnect the filling hose; the express coupling closes automatically.

 Screw protective cap back in place

Fill in hydraulic oil through the return-flow filters.

 Remove cover (19, Fig. 3-34:).

 Fill in hydraulic oil through the opening until the oil level lies between the ½ and the ¾ marks of the inspection glass.

(Oil grade see "LUBRICANTS / CONSUMABLES" section).

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

 Fit cover together with sealing ring.

Hydraulic oil return-flow filters, replace

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Wait until the hydraulic oil has cooled down before starting work on the filters.

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

Shut off the electric motor.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

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

Dispose of used filter elements accordding to the environmental regulations.

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 (arrow, Fig. 3-37:). In this case, the filter elements (9, Fig. 3-38:) are heavily contaminated;

 after repairs on the hydraulic system;

 in case of damage.

Remove return flow filter elements

 Remove covers (3, Fig. 3-38:) together with sealing rings (5).

 Unscrew ring nuts (6) and remove retaining disk (7).

 Remove press parts (8) with o-rings (10).

 Withdraw filter elements (9) with o-rings (11) from filter-baskets (12).

 Inspect filter elements for damage.

If no damages are visible, insert new filter elements (9) with new o-rings (11) into filterbasket (12), (see: “Install return flow filter elements”).

If a filter element (9) is damaged, remove filterbasket (12) and inspect / clean, (see: “Remove filter-basket, inspect / clean”).

Install return flow filter elements

 Insert new filter elements (9, Fig. 3-39:) into filter-basket with marking “TOP” upwards.

 Attach new o-rings (10 and 11) to press parts (8).

 Put press parts (8) onto filter elements (9).

 Fasten retaining disk (7) with ring nuts (6).

 Clean magnetic rod (17, Fig. 3-40:). The magnetic rod is located under cap (16). If metal filings are detected, locate cause and rectify. Contact your Caterpillar dealer service, if required.

It is essential to find the source of the metal filings and eliminate the failure. Otherwise there is a risk of serious damage in the hydraulic system.

 Reattach cap (16) together with magentic rod and sealing ring to cover (3).

 Install covers (3) together with sealing rings (5). Tighten bolts (18) crosswise using a torque wrench (torque = 79 Nm / 58.3 lbf ft).

Remove filter-basket, inspect / clean

If you found one of the return flow filter elements (9, Fig. 3-40:) damaged, remove the filter-basket (12) and inspect / clean the filter-basket as well as the filter chamber of the hydraulic tank. To do so:

 Unscrew bolts (13) and remove washers (15) and brackets (14).

 Remove filter-basket (12) and clean in paraffin oil.

 Inspect the filter chamber inside the hydraulic oil tank for contamination. If significant contamination or foreign objects are detected, contact your Caterpillar dealer service immediately.

It is essential to find the source of contamination and foreign objects and eliminate the failure. Otherwise there is a risk of serious damage in the hydraulic system.

 Reinsert the filter-baskets (12).

 Place brackets (14) in the correct position and screw in bolts (13) together with washers (15).

 Tighten bolts (13) using a torque wrench (torque = 46 Nm / 34 lbf ft).

 Install new return flow filter elements (9), see “Install return flow filter elements”.

Hydraulic oil return-flow filters, replace (from machine no. 340169)

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Wait until the hydraulic oil has cooled down before starting work on the filters.

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

Shut off the electric motorr

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

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

Dispose of used filter elements accordding to the environmental regulations.

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 (arrow, Fig. 3-42:). In this case, the filter elements (9, Fig. 3-43:) are heavily contaminated;

 after repairs on the hydraulic system;

 in case of damage.

Remove return flow filter elements

 Remove covers (3, Fig. 3-43:) together with sealing rings (5).

 Unscrew ring nuts (6) and remove retaining disk (7).

 Remove press parts (8) with o-rings (10).

 Withdraw filter elements (9) with o-rings (11) from filter-baskets (12).

 Inspect filter elements for damage.

If no damages are visible, insert new filter elements (9) with new o-rings (11) into filterbasket (12), (see: “Install return flow filter elements”).

If a filter element (9) is damaged, remove filterbasket (12) and inspect / clean, (see: “Remove filter-basket, inspect / clean”).

Install return flow filter elements

 Insert new filter elements (9, Fig. 3-44:) into filter-basket with marking “TOP” upwards.

 Attach new o-rings (10 and 11) to press parts (8).

 Put press parts (8) onto filter elements (9).

 Fasten retaining disk (7) with ring nuts (6).

 Clean magnetic rod (17, Fig. 3-45:). The magnetic rod is located under cap (16). If metal filings are detected, locate cause and rectify. Contact your Caterpillar dealer service, if required.

It is essential to find the source of the metal filings and eliminate the failure. Otherwise there is a risk of serious damage in the hydraulic system.

 Reattach cap (16) together with magentic rod and sealing ring to cover (3).

 Install covers (3) together with sealing rings (5). Tighten bolts (18) crosswise using a torque wrench (torque = 79 Nm / 58.3 lbf ft).

Remove filter-basket, inspect / clean

If you found one of the return flow filter elements (9, Fig. 3-44:) damaged, remove the filter-basket (12) and inspect / clean the filter-basket as well as the filter chamber of the hydraulic tank. To do so:

 Unscrew bolts (13) and brackets (14).

 Remove filter-basket (12) and clean in paraffin oil.

 Inspect the filter chamber inside the hydraulic oil tank for contamination.

If significant contamination or foreign objects are detected, contact your Caterpillar dealer service immediately.

It is essential to find the source of contamination and foreign objects and eliminate the failure. Otherwise there is a risk of serious damage in the hydraulic system.

 Replace o-ring (15) located in the filter brackets top plate.

 Reinsert the filter-baskets (12).

 Place brackets (14) in the correct position and screw in bolts (13).

 Tighten bolts (13) using a torque wrench (torque = 46 Nm / 34 lbf ft).

 Install new return flow filter elements (9), see “Install return flow filter elements”.

Bypass valves, clean / replace

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Wait until the hydraulic oil has cooled down before starting work on the filters.

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

Shut off the electric motor.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

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

Dispose of used filter elements accordding to the environmental regulations.

Cleaning the filter screens

 Remove covers (3 and 4, Fig. 3-46:) together with sealing rings.

 Unscrew bolts (25, Fig. 3-47:). 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 bolts (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. 3-47:) and a new sealing ring.

 Insert bypass valve with new sealing ring (243) and fasten with bolts (25).

Hydraulic oil tank breather filters, replace

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

Wait until the hydraulic oil has cooled down before starting work on the filters.

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

Shut off the electric motor.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

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

Dispose of used filter elements accordding to the environmental regulations.

Replacing the filter elements

Two breather filters (Fig. 3-48:) on top of the hydraulic tank ensure venting of the hydraulic oil tank at varying hydraulic oil levels.

Inspect and replace the filter elements according to the maintenance plans.

In case the machine is working in very dusty conditions or in an environment with high air humidity, the filter elements must be inspected and replaced in shorter intervals.

This protects the hydraulic tank from beeing contaminated.

To replace the filter elements:

 Unscrew bolts (21, Fig. 3-48:) and remove holding brackets (22).

 Withdraw filter elements (20).

 Check foam rings on top of filter elements, replace if damaged.

 Attach new filter elements (20) with foam rings to their cylindrical connections

 Install holding brackets (22) using bolts (21).

Filter (servo control circuit), replace

Risk of scalding caused by hot hydraulic oil.

The filter housings themselves may also be hot.

Wear protective gloves and firm working clothing.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact. Read and observe the "Inspection and servicing – Safety instructions" chapter.

 Shut off the electric motor.

 Depressurize the hydraulic system.

 Clean the filter housings as well as the immediate vicinity carefully.

 Dispose of waste oil, used filters and oilstained cleaning rags properly and separated from other waste.

Replacing the filter element

To filter the hydraulic oil in the control circuit, the machine is equipped with a high-pressure filter (arrow, Fig. 3-49:).

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

 Place a suitable collecting recipient under the filter housing (Fig. 3-49:).

 Collect escaping hydraulic oil and used filter elements. Discard without polluting the environment.

 Unscrew filter housing (5, Fig. 3-50:) by counterclockwise rotation. Pour out the oil.

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

 Check filter housing (5) as well as used filter surface for debris.

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

 Check seals (8) and replace, if required.

 Screw in the filter housing (5) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.

 Check high-pressure filters for leaks after putting the hydraulic system back into operation.

High-pressure filter for working hydraulics, replace

To filter the hydraulic oil on the high-pressure side of the working hydraulic system, the machine is equipped with four high-pressure filters (arrows, Fig. 3-51:).

Risk of scalding caused by hot hydraulic oil.

The filter housings themselves may also be hot.

Wear protective gloves and firm working clothing.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

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

 Shut off the electric motor.

 Depressurize the hydraulic system.

 Clean the filter block and the filter housings carefully.

 Dispose of waste oil, used filters and oilstained cleaning rags properly and separated from other waste.

Replacing the filter elements

 Place a suitable collecting recipient under the filter housings (Fig. 3-51:).

 Collect escaping hydraulic oil and used filter elements. Discard without polluting the environment.

 Unscrew drain plug (11, Fig. 3-52:) by counterclockwise rotation. Pour out the oil.

 Disengage filter element (15) with a slight turn from the centering spigot in the filter head.

 Check filter housing (9) as well as used filter surface for debris.

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

 Check sealing ring (13) and support ring (14) on the filter housing for position and damage. Replace, if necessary.

 Install the new filter element (15) with a new seal (10) on the spigot again by slightly turning it.

 Screw in the filter housing (9) to stop. Then turn out the filter housing by an 1/8 turn so that the filter housing is not stuck due to pressure pulsation and can be easily loosened in case of maintenance works.

 Check high-pressure filters for leaks after putting the hydraulic system back into operation.

Filters for swing charge pump, replace

The excavator has three high-pressure filters (Fig. 3-53:) for the feeding circuits of the swing pumps. The filters are installed beside the pump drive gearbox.

Risk of scalding caused by hot hydraulic oil.

The filter housings themselves may also be hot.

Wear protective gloves and firm working clothing.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

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

 Shut off the electric motor.

 Depressurize the hydraulic system.

 Clean the filter housings as well as the immediate vicinity carefully.

 Dispose of waste oil, used filters and oilstained cleaning rags properly and separated from other waste.

Replacing the filter elements

 Place a suitable collecting recipient under the filter housings (Fig. 3-53:).

 Collect escaping hydraulic oil and used filter elements. Discard without polluting the environment.

 Detach flange (4, Fig. 3-54:).

 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.

 Install new filter element (6, Fig. 3-54:) 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

Risk of scalding caused by hot hydraulic oil.

The hydraulic oil reservoir itself may also be hot.

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

Shut off the electric motor.

Skin contact with hydraulic oil may cause skin injury. Avoid skin contact.

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

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

Avoid mixing of different hydraulic fluids (see chapter “Avoid mixing of different hydraulic fluids” for more information).

Oil grade see “LUBRICANTS / CONSUMABLES” section.

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

Avoid mixing of different hydraulic fluids

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

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

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

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

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

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

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

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

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

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

Draining off hydaulic oil using the Service Station (tanklift)

The hydraulic oil can also be drawn off through the service station (Fig. 3-55:).

A description of the Service Station can be found in Part 2 of this manual, chapter “Service Station (tanklift)”.

 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.

 Drain oil.

 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.

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

Use only diesel fuel or a special flushing oil for cleaning the hydraulic tank.

Skin contact with hydraulic oil, diesel fuel or special flushing and cleaning fluids may cause skin injury. Avoid skin contact.

Wear protective gloves and firm working clothing. Dispose of contaminated hydraulic oil, diesel fuel or special flushing and cleaning fluids without polluting the environment and separately from other waste.

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

 Remove caps (3,4, and 5, Fig. 3-56:).

 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 caps (3, 4 and 5).

Filling in hydraulic oil using the service station

 Fill in hydraulic oil by means of the service station (Fig. 3-57:).

The use of the hose line is described under "hose line for oil changes".

 Unscrew cap of express coupling (10).

 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 on the sign (2, Fig. 3-58:) near the inspection glass (1).

(Oil grade see "LUBRICANTS").

 The oil level is also displayed on the BCSscreen (Fig. 3-59:).

 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.

Filling in hydraulic oil through the return-flow filters.

 Remove cap (19, Fig. 3-60:).

 Fill in hydraulic oil through the opening until the oil level lies between the “min” and the “max” marks on the sign (2, Fig. 3-61:) near the inspection glass (1). (Oil grade see " LUBRICANTS ").

 Vent the hydraulic system.

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

 Refit cap (19, Fig. 3-60:).

Venting the hydraulic system

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

 after assembly on site and prior to initial commissioning,

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

 after each hydraulic oil change,

 after replacement of hoses or lines.

Venting the hydraulic components

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

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

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

 Hydraulic cylinder

Before the initial admission of the cylinder with oil, the piston must be in either of the two extreme piston positions. In other words, the piston rod (1, Fig. 3-62: and Fig. 3-63:) 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. 3-62:),

 the rod-side port (4) when the piston rod is extended (1, Fig. 3-63:).

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

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

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

Always vent only the system section that has been opened.

 the travel brake valve at the venting screw,

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

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

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

Cleaning the hydraulic oil cooler

Risk of injury from rotating cooler fan blades.

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. 3-64:) are thermostat-controlled. The fan motors run at maximum speed when the hydraulic oil temperature reaches ca. 60°C / 140°F.

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).

 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 excavator 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. 3-65:) 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. 3-66:).

 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 (1, Fig. 3-67:).

The pressure accumulator (1) is located in the superstructure and is accessible from the ground.

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

Pressure-accumulator inspection regulations

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

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.

Pump Drive Gearbox

Risk of scalding caused by hot gearbox oil. The gearbox housing may be hot too.

Shut off the electric motor.

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

Read and observe: "Inspection and servicingSafety instructions.

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

Details for selecting the correct gearbox oil refer to chapter “LUBRICANTS / CONSUMABLES”.

Pump drive gearbox, checking oil level / Topping up with oil

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.

 Screw out and wipe dipstick (1, Fig. 3-68: and 1, Fig. 3-69:).

 Insert dipstick (1) again until the thread lies on top of the dipsticks tube (2, , Fig. 3-69:). Do not screw in.

 Withdraw dipstick again and check oil level. The level should reach up to between the “min” and “max” markers on the dipstick.

 Top up with oil if required through the plug of filler tube (arrows, Fig. 3-70:).

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

 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.

Topping up with oil

 Screw out plug of filler tube (arrows, Fig. 3-70:).

 Fill fresh oil through the filler tube. (Oil grade see: “LUBRICANTS / CONSUMABLES”).

 Check oil level.

 Fit plug again.

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. 3-71:) 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 station (Fig. 3-71:).

 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. 3-68).

 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. 3-70:).

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.

Pump drive gearbox, prechamber

Checking oil level, topping up with oil

The oil level in the pre-chambers is visually at the inspection glas (3, Fig. 3-73) 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, venting

The gearbox is vented through the breather valve (arrow, Fig. 3-74).

Clean breather valve in accordance with servicing plan.

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

 Screw breather filter back in place.

Pre-chambers working pumps, draining oil, changing oil

Draining oil:

 Place a suitable receptacle for used oil under the plugs (13, Fig. 3-75:).

The required receptacle capacity is specified in the „Filling quantities – oil“ table.

 Drain oil from the expansion reservoir.

 Unscrew plugs (13) and allow oil to drain. Screw in plugs and fill in oil after repair work has finished.

Changing oil:

 Oil change is necessary only after repairs or after changing a working pump. In this case drain oil and fill in oil as described above.

Oil quantity see „Filling quantities – oil“ table.

Pre-chambers swing pumps, draining oil, changing oil

Draining oil:

 Place a suitable receptacle for used oil under the plugs (23, Fig. 3-76:).

The required receptacle capacity is specified in the „Filling quantities – oil“ table.

 Drain oil from the expansion reservoir.

 Unscrew plugs (23) and allow oil to drain. Screw in plugs and fill in oil after repair work has finished.

Changing oil:

 Oil change is necessary only after repairs or after changing a swing pump. In this case drain oil and fill in oil as described above.

Oil quantity see „Filling quantities – oil“ table.

Pump gearbox, oil filter

Oil for the pump drive gearbox is cleaned in the filter (Fig. 3-77:).

Check the gear oil filter

 In accordance with the servicing plan.

 If the tell-tale pin (1, Fig. 3-77:) on the underpressure indicator (2) springs out and can not be pressed back in.

Changing filter element

 Take filter element (43, Fig. 3-78:) out of housing (42).

 Clean filter housing and sealing surface on filter head using white spirits or petroleum.

 Fit new filter element into housing (42). Fit new, lightly oiled seal rings (45 and 46) to filter head.

 After starting operation again, check filter for leakages.

If the tell-tale pin (1, Fig. 3-77:) appears, it is possible that the filter is contaminated with metal particles. Inspect the filter element carefully. Trace any cause and remedy.

Swing Gearbox

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. Details for selecting the correct gear oil refer to chapter “LUBRICANTS / CONSUMABLES”.

Changing the gearbox 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.

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

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

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

 Screw out dipstick (1, Fig. 3-79:) and wipe clean.

 Insert dipstick (1) fully again (do not screw in) and withdraw a second time. The oil level must reach up at least to the lower mark on dipstick (1). Top up with gearbox oil, if required.

 Screw dipstick (1) back in place.

Draining off oil

 Attach hose (8, Fig. 3-80:) to drain valve (7) and drain off oil completely.

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

The drain valve (7) is accessible from the undercarriage.

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

Filling in new oil / Topping up

 Unscrew plug (4, Fig. 3-81:) and fill in new oil.

 Check oil level with dipstick (1).

 Screw in plug (4) again.

Swing gearbox, venting ,

The gearbox is vented through breather filter (2, Fig. 3-81:).

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.

TRAVEL GEARBOX (GEARBOX P/N 3683483)

Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot too.

Shut off the electric motor.

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

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

Read and observe: "Inspection and servicingSafety instructions”.

Details about selecting the correct gear oil can be found in chapter “LUBRICANTS / CONSUMABLES”.

To identify the gearbox partnumber (P/N) check the name plate attached to the gearbox.

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

 Move the hydraulic shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-82:) are in the displayed position.

 Unscrew checking screw (1). The oil level should reach up to the lower edge of the opening. Top up with oil, if required.

Oil grade see: „LUBRICANTS / CONSUMABLES“.

 Screw checking plug (1) back in place.

Spur gear section - Checking the oil level / Topping up with oil

 Check oil level at the inspection glass (2, Fig. 3-83:).

The oil level should reach the center of the inspection glass. Top up with oil if required through the bore of plug (4).

Oil grade see: „LUBRICANTS / CONSUMABLES“.

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

 Unscrew checking screw (6, Fig. 3-84:). 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.

Oil grade see: „LUBRICANTS / CONSUMABLES“.

Travel gearbox - Changing oil

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

Draining off oil

 Move the hydraulic shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-85:) 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 (3) allows the oil to run out more readily.

 Clean screw plugs (2 and 3)

 Screw screw plug (2) back in place.

Filling in oil

 Unscrew screw plug (1 and 3).

 Fill in oil through opening in plug (3) until it flows out of opening in plug (1). Oil grade see: „LUBRICANTS / CONSUMABLES“.

 Screw plugs (1 and 3) back in place.

Spur gear section - Changing the oil / Draining off oil

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

 Unscrew drain plug (3, Fig. 3-86:) and drain off the oil completely. Slackening plug (4) allows the oil to run out more readily

 Clean screw plugs (3 and 4)

 Screw screw plug (3) back in place.

Filling in oil

 Unscrew screw plug (4).

 Fill in oil through opening of plug (4) until it reaches the center of the inspection glass (2). Oil grade see: „LUBRICANTS / CONSUMABLES“.

 Screw plug (4) back in place.

Brake housing - Changing oil

Draining off oil

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

 Unscrew drain plug (7, Fig. 3-87:) and drain off the oil completely. Slackening breather filter (5) allows the oil to run out more readily.

 Clean screw plug (7).

 Screw 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 the bore of plug (6). Oil grade see: „LUBRICANTS / CONSUMABLES“.

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

Travel gearbox - Breather filter

 Unscrew breather filters (1 and 5, Fig. 3-88:) and clean in white spirit or parafin.

TRAVEL GEARBOX (GEARBOX P/N 3683496)

Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot too.

Shut off the electric motor.

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

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

Read and observe: "Inspection and servicingSafety instructions”.

Details about selecting the correct gear oil can be found in chapter “LUBRICANTS / CONSUMABLES”.

To identify the gearbox partnumber (P/N) check the name plate attached to the gearbox.

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

 Move the hydraulic shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-89:) are in the displayed position.

 Unscrew plug (3). The oil level should reach up to the lower edge of the bore. Top up with oil, if required.

 Screw plug (3) back in place.

Alternatively:

 Open cover of travel motors.

 Check oil level at the inspection glass (arrow, Fig. 3-90:). The oil level should reach the center of the inspection glass. Top up with oil if required through the bore of plug (3, Fig. 3-89:). Oil grade see: „LUBRICANTS / CONSUMABLES“.

Hydraulic motor chamber / Brake housing - Checking the oil level / Topping up with oil

 Unscrew checking screw (6, Fig. 3-91:).

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.

Oil grade see: „LUBRICANTS / CONSUMABLES“.

Travel gearbox - Changing oil

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

Draining off oil

 Move the hydraulic shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-92:) 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) as well as the drain plug at the bottom side of the hollow wheel (arrow) and drain off the oil completely. Slackening plug (3) allows the oil to run out more readily.

 Clean screw plugs.

 Screw screw plugs (2 and arrow) back in place.

Filling in oil

 Move the shovel slowly until plug (3) reaches the “3-o’clock” position shown in (Fig. 3-93:).

Drive only this short way to bring plugs in the shown position. Driving longer distances may damage the gearbox.

Remember, the gearbox is without oil.

 Unscrew screw plug (3).

 Fill in oil through bore of plug (3) until it flows out of the bore.

Oil grade see: „LUBRICANTS / CONSUMABLES“.

 Screw plug (3) back in place.

 Open cover of travel motors.

 Check oil level at the inspection glas (Fig. 3-94:). Fill in oil if necessary.

Hydraulic motor chamber / Brake housing - Changing oil

Draining off oil

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

 Unscrew drain plug (7, Fig. 3-95:) and drain off the oil completely. Slackening breather filter (5) allows the oil to run out more readily.

 Clean screw plug (7).

 Screw 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 the bore of plug (6). Oil grade see: „LUBRICANTS / CONSUMABLES“.

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

Travel gearbox -Breather filter

 Unscrew breather filters (1 and 5, Fig. 3-96:) and clean in white spirit or parafin.

TRAVEL GEARBOX (GEARBOX P/N 3749598)

Risk of scalding caused by hot gearbox oil. The gearbox housings may be hot too.

Shut off the electric motor.

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

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

Read and observe: "Inspection and servicingSafety instructions”.

Details about selecting the correct gear oil can be found in chapter “LUBRICANTS / CONSUMABLES”.

To identify the gearbox partnumber (P/N) check the name plate attached to the gearbox.

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

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

 Unscrew plugs (1 and 3). The oil level should reach up to the lower edge of the bore of plug (3). Top up with oil, if required through bore of plug (1).

 Screw plugs (1 and 3) back in place.

Alternatively:

 Open cover of travel motors.

 Check oil level at the inspection glass (arrow, Fig. 3-98:). The oil level should reach the center of the inspection glass. Top up with oil if required through the bore of plug (1, Fig. 3-97:). Oil grade see: „“LUBRICANTS / CONSUMABLES”.

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

 Unscrew checking screw (6, Fig. 3-99:). 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. Oil grade see: “LUBRICANTS / CONSUMABLES”.

Travel gearbox - Changing oil

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

Draining off oil

 Move the hydraulic shovel into such a position that the screw plugs (1, 2 and 3, Fig. 3-100:) 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) as well as the drain plug at the bottom side of the hollow wheel (arrow) and drain off the oil completely. Slackening plug (1) allows the oil to run out more readily.

 Clean screw plugs.

 Screw plugs (2 and arrow) back in place.

Filling in oil

 Unscrew plugs (1 and 3, Fig. 3-101:Fig. 3-102:).

 Fill in oil through bore of plug (1) until it flows out of the bore of plug (3). Oil grade see: “LUBRICANTS / CONSUMABLES”.

 Screw plugs (1 and 3) back in place.

 Open cover of travel motors.

 Check oil level at the inspection glas (Fig. 3-102:). Top up with oil if necessary.

Hydraulicmotor chamber - Brake housing - Changing oil

Draining off oil

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

 Unscrew drain plug (7, Fig. 3-95:) 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 the bore of plug (6). Oil grade see: “LUBRICANTS / CONSUMABLES”.

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

Travel gearbox - Breather filter

 Unscrew breather filters (1 and 5, Fig. 3-96:) and clean in white spirit or parafin.

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 excavator with the working equipment and allow track to turn.

 Clean the side member supporting the track.

 Clean support and track rollers (1 and 2 ,Fig. 3-105:) thoroughly.

 Clean the sliding planes on the idler guides.

Track rollers (Option)

The track rollers (2, Fig. 3-106:) have a permanent grease filling (Not when the machine is equipped with a central lubricating system for the undercarriage).

Nevertheless press in grease filling at regular intervals.

It is necessary to be sure that always sufficient grease in the roller bearings.

Track roller fastening

 Check fastening bolts (4, Fig. 3-107:) regularly for tightness.

 Tighten bolts with a torque wrench to the prescribed tightening torque (see "Service Manual").

Fig. 3-106:

 Unscrew plug (6, Fig. 3-106:) from breather line.

 Remove dust cap (1) from coupling (2).

 Remove dust cap (4) from plug (5).

 Connect grease hose (3) to couling (2).

 Press in grease as long as used grease emerges from breather line.

 Screw on plug (6) to breather line.

 Disconnect the grease hose (3).

 Fix dust caps (1 and 4) back in place.

Support roller fastening

 Check fastening bolts (3, Fig. 3-107:) regularly for tightness.

 Tighten bolts 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. 3-108: and Fig. 3-109: show parts of the tracks and the tensioner:

Techncal data

Track tensioning pressure ca. 70 bars/1015psi

Pressure limiting valve 330 bars / 4786psi

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

Function

The tensioning system is under permanent pressure of ca. 70 bars / 1015psi which keeps both tracks permanently tensioned. Pressure losses are compensated as soon as the electric motor is switched on. 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 (3, Fig. 3-109:) to slacken the tracks.

Fig. 3-108:

1 Pressure accumulator

2 Pressure cylinder

3 Pressure limiting valve

4 Mini- measuring port

 After the work, screw down the pressure limiting valves (3) to the limit stop.

The pressure-limiting valves (3) are preset to a pressure of 330 bars / 4786psi and sealed in this position. The lead seal must not be removed and the pressure setting of 330 bars / 4786psi 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. See under "Function".

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 swing ring, the swing ring seals or the swing ring housing.

Remove old grease completely before filling in new grease.

If greater losses are detected, locate cause immediately to prevent damage to the swing 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. 3-110:).

Internal gearing

The internal gearing (1, Fig. 3-111:) and the pinion (2) are enclosed in a housing (3, Fig. 3-112:). 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. 3-110:). 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. 3-112:). 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. 3-113:).

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 swing the superstructure when refilling grease.

Swing ring - Checking the bolts for tightness

The fastening bolts 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 bolts are perfectly tight.

Loosen slack bolts before tightening them with a torque wrench to the prescribed torque (see "Service Manual").

CENTRAL LUBRICATING Design and function

The excavator 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.

If a fault occurs, BCS gives a warning on the screen (Fig. 3-115:).

Actuate the "Reset" button (64, Fig. 3-114:) to eleminate the fault. Is this is not possible, call in servicing personal.

For further information on the function and setting refer to the SERVICE MANUAL – PLC (Programmable Logic Controller).

Function

The grease is pumped by the pump (1, Fig. 3-116:) via greasing lines from the grease container to the main distributors on the superstructure and on the undercarriage.

The control elements of the lubricating system are installed on the panels (3).

For machines with automatic greasing of the track rollers, optional:

The grease is pumped by the pumps (1 and 3, Fig. 3-117:) via greasing lines from the grease container to the main distributors on the superstructure and on the undercarriage.

The control elements of the lubricating system are installed on the panels (3 and 21, Fig. 3-118:).

As soon as the grease container is empty, the BCS (Fig. 3-119:) 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.

Filling up the grease container

Fill up the grease container through the service station (Fig. 3-120:).

The use of the hose is described in the chapter "Flexible hose for the change of oil "

 Switch on the indicator system with toggle switch (23, Fig. 3-120:).

 Unscrew the cap of the express coupling (11).

 Connect the filling hose of the service vehicle.

 When the grease container is full, the indicator lamp (24) lights up.

 Remove the flexible hose. The express coupling closes automatically.

 Refit the protective cap.

Breather filter

Check/change the breather filter at regular intervals.

 Unscrew wing nut (10, Fig. 3-121:).

 Withdraw cover (7, Fig. 3-122:) and filter element (8).

 Check filter element. Replace if necessary.

 Re-install breather filter.

Checking the greasing pressure

Check every week, whether the oil pressure indicated by pressure gauge (4, Fig. 3-123:) is 60 bars / 870psi (the pressure is dependind on temperature and viscosity of the oil and may vary).

The necessary greasing pressure of 320 bar / 4641psi for the superstructure 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.

This oil pressure is reduced so that the pressure indicated by pressure gauge (2) is 47 – 50 bars (681-725psi).

Checking the greasing pressure

(for machines with automatic greasing of the track rollers, optional)

Check every week, whether the oil pressure indicated by pressure gauge (4, Fig. 3-124:) is 60 bars / 870psi (the pressure is depending on temperature and viscosity of the oil and may vary).

The necessary greasing pressure of 320 bar / 4641psi for the superstructure and 180 bar / 2610psi for the lundercarriage is generated by means of a pressure translator.

The greasing pressure for the superstructure is indicated by pressure gauge (9, Fig. 3-124:) and for the undercarriage by pressure gauge (22).

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.

This oil pressure is reduced so that the pressure indicated by pressure gauge (2, Fig. 3-125:) is 35 –40 bars (507-580psi) and by pressure gauge (4) is 49 – 51 bar (710-739psi).

Unblocking a grease line.

Put the excavator 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. 3-126:).

 Withdraw sieve and clean with white spirit or paraffin oil.

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

Unblocking a grease line.

(for machnes with automatic greasing of the track rollers, optional)

Put the excavator 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. 3-127:).

 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.

Switch 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. For filtering of the hydraulic oil, high pressure filter (11, Fig. 3-128:).is installed in the pumping line.

Replacing the filter element

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

Fig. 3-129:

 Unscrew filter housing (5, Fig. 3-129:).

 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 (Filling the grease container)

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

Switch off the electric motor.

Grease filter (13, Fig. 3-130:) is installed in the greasing line to the grease container.

Checking the filter element

 Unscrew filter housing (32, Fig. 3-131:).

 Withdraw filter element (33) from housing (32).

 Remove the grease.

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

 Insert filter element into housing (32) and attach to the filter head with a new, slightly oiled sealing ring (36).

 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.

Grease filter (Grease lines)

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

Switch off the electric motor.

Grease filter (12, Fig. 3-132:) is installed in the greasing line to the grease container.

Checking the filter element

 Unscrew filter housing (42, Fig. 3-133:).

 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

Heating and air conditioning

Check and clean the filter mats in the air suction regulary.

The filter mats are located in the air conditioner housing (Fig. 3-134:) below the cab roof.

Equipment, check for cracks

Check the welded joins of the working equipment regulary.

Inspections must be carried out acc. to the "Structural Inspection Reports" every 500 OH and every 5000 OH.

"Structural Inspection Report" forms for those inspections can be downloaded from the CGM HMS GmbH website, section "Support, Warranty".

The inside located joins are accessible through the man-holes in stick (arrow, Fig. 3-135:) and boom (arrow, Fig. 3-136:).

 Open housing of air conditioner.

 Check and clean filter mats or replace if necessary.

 Close housing.

Reservoirs for used grease at the A-frame, emptying

Remove used grease from the reservoirs (Fig. 3-137:) regularly according to the maintenance plans.

Do not re-use the grease because it is polluted. Dispose off used grease as well as cleaning rags without polluting the environment and separately from other waste.

Hydraulic ladder, pressure accumulator

To allow the ladder (Fig. 3-138: and Fig. 3-139:) to be lowered with the electric motors at standstill as well as in an emergency, the ladder mechanism is equipped with a pressure accumulator (1, Fig. 3-140:). The pressure accumulator (1) is located in the superstructure and is accessible from the ground.

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 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

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

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

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

ON-BOARD CRANE, DRIVE UNIT

The drive unit supplies the crane with hydraulic power. The drive unit comprises the diesel engine, fuel tank, starter batteries and the hydraulic system.

Crane engine

More and detailed information about the diesel engine can be found in the Operating and Maintenance Manual for the crane engine.

 Before each shift check engine oil level. If necessary top up with engine oil through opening of dipstick (3, Fig. 3-141:).

 After each shift fill up fuel tank (1).

 Regularly check batteries (4) and cable connections.

 Regularly, at least once a year: - change engine oil, - replace engine oil filter, - check / replace air filter (2), - replace fuel filter. Do not start engine with air filter (2) removed.

Hydraulic system

For more and detailed information, see crane operating instructions.

 Prior to each deployment, check the hydraulic oil level at the inspection glass (1, Fig. 3-142:); top up with hydraulic oil if necessary.

 Check contamination of hydraulic oil filter regularly at contamination indicator (4).

 Regularly, but at least once a year replace the hydraulic oil filter (3) and the breather filter (2).

On-board crane, lubricating Servicing work

 Lubricate all bearings regularly and as required, and spray swing ring with a graphite spray (Fig. 3-143:)

1 - bearing 4 lube points

2 - joint (column/boom) 2 lube points

3 - cylinder bearing 5 lube points

4 - swing ring Graphite spray

On-Board crane, checking tightness of fastening bolts

The hydraulic driven on-board crane (Optional) is fixed on the uppercarriage of the machine by means of 16 fastening bolts. The upper and lower fastening bolts (Fig. 3-144:) are important and safety relevant components, they carry all loads and forces of the crane.

Check tightness of all fastening bolts:

 in regular intervals according to the maintenance plans and

 before every start of the on-board crane. Check tightness of the fastening bolts by means of a torque wrench. The tightening torque for fastening bolts M20, quality 10.9, lightly oiled is: 557 Nm.

Putting The Excavator Out Of Operation And Recommissioning

Putting the excavator out of operation

 Park the excavator on firm and level ground.

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

 Set all control element to "0"

 Clean the machine.

 Carry out a visual inspection of the excavator.

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

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

 Remove the batteries; see "Battery storage".

 Secure the machine against unauthorized starting by: withdrawing the key from the key-switch setting the battery main switch to OFF 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 - swing 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.

Part 2

Part 3

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.

Part 4

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