38 minute read
5Maintenance
5.1Safety instructions
5.1.1General safety instructions
–Maintenance and repairs may only be carried out by trained expert technicians.
–Always note the frequency intervals for inspections as contained in this operating manual.
–Insure that an adequately equipped workshop is available to perform these tasks, and note the designated qualifications of the personnel responsible for each inspection.
–The maintenance and inspection schedule sets out precisely who should, or is allowed to carry out which jobs.
The machine operator (and his staff) are allowed to carry out certain jobs, but other jobs must be carried out only by qualified and trained staff.
–Spare parts must meet the technical requirements set forth by the manufacturer. This is always ensured with original spare parts. Spare parts that do not meet the technical requirements of the manufacturer might impair the safety and proper operation of the machine.
–Wear task-appropriate personal protective equipment at all times. Example: In addition to a protective helmet and safety boots, for certain jobs protective goggles and gloves are also necessary.
–Keep unauthorized personnel away from the machine during maintenance.
–Secure a wide-ranging area for maintenance, as necessary.
–Inform the operator before starting to carry out special tasks and maintenance work. Make sure he knows the person who is in charge of the work.
–Perform all maintenance operations on the machine on alevel and stable ground with the working equipment lowered and the diesel engine turned off, unless described otherwise in the operating manual.
–Hang awell visible warning label “do not switch on“ onto the ignition during maintenance operations, especially when working under the machine. Remove the ignition key and set the main battery switch to position 0.
–Re-torque all bolts at the completion of the maintenance procedure to the required torque specification.
–If the dismantling of safety equipment is necessary, the safety equipment must be re-attached and inspected directly upon conclusion of the operations.
5.1.2Checking for cracks
–Machines are subject to different loads, depending on application, job site, duration of use and conditions of use. The different load conditions result in different service lives for various machines components. This could lead to cracks and loose connections, particularly on load-bearing parts. This applies particularly to machines used in material handling or industrial applications or for machines with special equipment, such as demolition excavators. To ensure that operating safety is maintained, the machine must be checked regularly for cracks, loose connections or other visible damage.
–To check for cracks, it is necessary to keep the machine clean and to clean it regularly.
–The inspection must be carried out according to the inspection and maintenance schedule.
–It is advisable to carry out these inspections with the machine supported, on firm and level ground.
–Specific attention should be given to the following:
•The steel structure undercarriage with axle and gear mounting, support, lower slewing ring seating with tower and slewing ring.
•The steel structure uppercarriage with bearing block for boom and boom cylinder, upper slewing ring seating, cab bearing, mounting of slewing gear and counterweight.
•Steel structure of working attachments, e.g. boom, stick, quick change adapter, digging tool and grapple.
•Hydraulic cylinder, axles, steering, pins and pin connections, steps, ladders and mounting elements.
–Check for cracks visually. If a crack is suspected or is in areas which are not easily visible, such as the slewing ring seating, then the dye penetration procedure should be used to check for cracks.
–Any damage found must be fixed immediately. Welding on load-bearing parts of earth moving machines, material handling and transport units may only be made by certified welders in accordance with acceptable welding practices. Contact LIEBHERR Service to discuss suitable measures.
5.1.3Welding
–Welding, cutting and grinding should only be done with the specific approval of LIEBHERR. Prior to any welding, cutting or grinding, clean the machine and surrounding area to remove dust and flammable materials.
–Insure adequate ventilation.
5.1.4Fuels, lubricants and process chemicals
–When handling oils, greases and other chemical substances, always observe the applicable safety regulations for the corresponding product.
–Ensure safe and environmentally friendly disposal of operating and service fluids as well as exchange parts.
–Handle hot operating and service fluids carefully (danger of burning and scalding).
5.1.5Repair
–Do not attempt to lift heavy parts. Use lifting devices with sufficient load carrying capacity. When replacing parts or large sub-assemblies, use appropriate and functioning lifting devices and adequate load carrying capacity to insure safe movement during installation. Never stand or work under suspended loads.
–Always wear work gloves when handling wire ropes.
–Only permit experienced personnel to secure loads and signal the crane operator. The guide must position himself within view of the operator or be in voice contact with him.
–When working overhead, use appropriate safe access ladders and working platforms.
Do not use parts of the machine as climbing devices, if they are not designed for this purpose.
Wear a harness when working at great heights. Keep handles, steps, railings, platforms, and ladders free of dirt, ice and snow.
–When working on the attachment (for example when replacing teeth), make sure the machine is properly supported. Never use metal-on-metal support.
–Never stand underneath a machine that has been raised with the aid of work equipment unless it has been properly and securely supported.
–Always support the machine in such a ways that any shifting weight will not endanger the stability of the machine and avoid metal to metal contact.
–Work on travel gears, brake and steering systems may only be carried out by specially trained expert personnel.
–If the machine must be repaired on an incline, block the track chains with chocks and secure the uppercarriage to the undercarriage with the locking pin.
–Only qualified, specially trained personnel may work on the hydraulic system.
–Do not check for hydraulic leaks with your hand. Use cardboard or similar material to detect leaks. Wear work gloves.
–Do not loosen any lines or bolts before lowering the equipment, turning off the diesel engine and relieving the hydraulic system. After the diesel engine has been turned off, you must move all pilot controls (right handed joystick and pedals) into all directions to reduce the control pressure and the dynamic pressure in the work cycles. Then release the pressure in the tank, as described in this operating manual.
5.1.6Electrical system
–Check the electrical system regularly. All defects, such as loose connections, burnt out fuses and bulbs, burnt or damaged wires or cables must be repair ed immediately by an electrician or specially trained personnel.
–Only use original fuses with the correct amperage.
–Only qualified technicians should attempt troubleshooting or repairs on high voltage systems.
–DO NOT work on energized attachments.
–When working on mid and high voltage components, shut off the voltage and connect the supply cable to the ground to discharge any stored energy.
–Check all disconnected parts if they are truly free of current, ground them and short circuit them. Insulate adjacent, current carrying parts.
–Disconnect the battery before working on the electrical system or before carrying out any arc welding work on the machine.
5.1.7Pressure accumulator
–Pressure accumulators contain stored energy and operate at high pressures. Only specially trained personnel may work on pressure accumulators.
–Do not operate damaged pressure accumulators.
–You must reduce the pressure in the hydraulic system as described in this operating manual prior to working on ahydraulic accumulator.
–Do not weld or solder on the pressure accumulator and do not carry out any mechanical work on them.
–Fill the pressure accumulator only with nitrogen.
–The accumulator housing can become hot during operation, there is a danger of burning.
–New pressure accumulators must be charged to the required pressure for the application before use.
–The operating data (minimum and maximum pressure) is marked permanently on the pressure accumulators. Make sure that the marking remains visible.
5.1.8Hydraulic hoses and lines
–Hydraulic lines and hoses may never be repaired!
–All hoses, lines and fittings must be checked every two weeks for leaks and visible damage. Damaged parts must be replaced immediately. Remember that escaping high pressure oil can penetrate skin. Escaping oil can also cause fires.
–Even if hoses are properly stored and used, they undergo a natural aging process. For that reason, their service life is limited.
•Improper storage, mechanical damage and impermissible use are the most frequent causes of failure.
•Using hoses and lines close to the limit ranges of permitted use can shorten the service life (for example in high temperatures, frequent work cycles, extremely high impulse frequencies, multi shift operation).
–Hoses and lines must be replaced when the following conditions are found during inspection:
•Damage to the outer layer as far as the intermediate layer (e.g. chafing, cuts and cracks);
•Brittleness of the outer layer (hose material cracking);
•Deformations, which differ from the natural shape of the hose or hose line, when under pressure or not under pressure, or in bends (e.g. separation of layers, blisters or bubbles);
•Leaks;
•Failure to follow installation instructions;
•Damage or deformation of hose fittings, which reduce the strength of the fitting or the hose / fitting connection;
•Hose slipping out of the fitting;
•Corrosion on the fittings, which reduces function and strength;
–When replacing hoses and lines, observe the following:
•Use only original spare parts.
•Route and install hoses and lines properly, observe correct connection points.
•Always ensure that the hoses and lines are free of torsion when routing. On high pressure hoses, always attach the screws of half clamps or full flange on both ends of hose first and then tighten.
•When using high pressure hoses and lines with a bent fitting, always tighten the end with the bent fitting first when tightening the flanges, then the end with the straight fitting.
•Any existing mounting clamps in the centre of the hose may only be installed and tightened thereafter.
•Check daily to ensure that all clamps, covers and protective devices are properly mounted. This prevents vibration and damage during operation.
•Route the hoses and lines in such a way that chafing with other hoses or other structures is prevented.
•A minimum distance of approximately ½ of the outer hose diameter to the other parts is recommended. The distance should not be less than 10 to 15mm (1/2 inch).
•When replacing hoses and lines on movable parts (e.g. from boom to stick), check for hose interference and kinking over the complete range of motion.
5.1.9Cab protection (FOPS)
For certain machine applications LIEBHERR offers optional cab protection systems of various designs. These systems consist of a full length FOPS (falling objects protective structure) or a top guard and front guard to protect the operator's cab and windscreen area from falling objects (for example rocks or debris).
The full length FOPS wraps around the operator's cab, is mounted to the uppercarriage and is a stand-alone system.
The top and front guards are either bolted individually or in combination to the cab structure. In that case the operator's cab is also part of the cab protection system and is subject to the following instructions.
–Never operate a machine if one of these protections is damaged in any way. –Damages may occur due to:
•structural modifications or repairs (for example welding, cutting or drilling)
•deformation after an accident
•falling objects
–Structural modifications or repairs of any kind are prohibited without the expressed, written approval of LIEBHERR.
5.2Maintenance access doors
5.2.1Overview of access doors
10 Engine hood
70 Side door, left 27 Cover battery box
80 Side door, right
The machine has 4 access doors for maintenance. The locks integrated in the handles must be unlocked before starting to travel.
Access doorLockAccess to:
Engine hoodGas pressure spring
Cover battery boxGas pressure spring
–Diesel engine
–Radiator
–Hydraulic pump
–Batteries
–Battery master switch
Side door, leftMechanical retainer–Electric box E50
–Servo oil unit
–Engine hood release
Side door, rightMechanical retainer–Refuelling pump
5.2.2Door
To stop the access doors from moving unintentionally (e.g. due to wind), open them fully and allow the door lock (see arrow) to engage.
5.2.3Engine hood release
Unlock the engine hood by opening the remote control 1 behind the left side door and push up.
Before closing the engine hood, close the remote control again.
5.3Cleaning machine
The machine should be cleaned before carrying out any maintenance or repair work. In particular, the connections and screws should be cleaned of oil, fuel and residue of cleaning agents.
Note!
High-pressure water jet cleaners (steam cleaners) can damage the coating. Do not use high-pressure water jet cleaners during the first two months after commissioning (or after recoating).
Observe the prescribed safety distances.
Before cleaning the machine:
Before cleaning the machine with water or with a steam cleaner (high-pressure water jet cleaner), carry out the following tasks to protect the equipment against penetrating water.
Lubricate all bearing points, bolt connections and the slewing ring; if necessary, use the central lubrication system to do this.
Cover or seal all openings that must be protected against penetrating water for safety reasons (particularly at risk of damage are electric motors, electric components, switch cabinets, plug connections, measuring sensors and air filters).
Cleaning:
Use flint-free cleaning cloths.
Do not use aggressive detergents or flammable liquids.
When cleaning the engine compartment, ensure that the temperature sensor of the fire alarm and extinguishing systems (if installed) are not accidentally brought into contact with the hot cleaning solution,
After cleaning:
Remove all seals and covers.
Check all fuel, engine oil and hydraulic lines for leakage, loose connections, chaffing and damage.
Repair any defects without delay.
Lubricate all bearing points, pin connections and the slewing ring to remove any water that might have been penetrated.
If required, renew the preservation layer (anti-corrosion protection) on components and surfaces.
5.4Care for rubber components
The service life of rubber seals can be prolonged by treating them with a rubber care product.
Clean and regularly treat the rubber seals on doors and panelling elements with a care product. This helps prevent premature wear and protects the rubber seals during the cold season.
Recommended care products: Silicone, talcum powder, deer tallow
5.5Tyres
Repairs to the wheel, including the removal of the tyres from the rims, must be carried out by qualified specialists with suitable tools.
5.5.1Checking tyre pressure
Danger!
Risk of injury from exploding tyres!
If the tyre inflation device is used incorrectly or without the necessary care, there is a risk of serious injury or even death due to:
–Bursting tyres caused by excessive inflation.
–Blasting out of the lip seal.
Flat tyres may not be inflated, but must be repaired in a specialist workshop. When inflating the tyres, use a suitably long inflation hose with self-adhesive pinch valve.
Ensure that no persons are standing in the danger zone when the tyre is inflated. Do not mount tyres of different size.
The tyre pressure affects the operating behaviour of the machine. The pressure must therefore be regularly checked and adjusted, if necessary.
Ensure that the machine is standing in a safe position and is secured against rolling away (chocks).
For nominal values, refer to the table below.
Attach measuring device and adjust the tyre pressure, if necessary.
Tab. 5-2 Tyre pressures
5.5.2Foam tyres
Note!
The foaming of tyres changes their rolling behaviour! This can in turn affect the operating behaviour of the machine. Use only foamed tyres supplied by LIEBHERR.
5.5.3Checking wheel lugs for proper fit
Tightening torque for wheel lugs: 460 Nm
Danger!
Loose or incorrectly tightened wheel lugs might cause wheels to become loose and even fall off, causing serious injury.
After each wheel change or loosening of the wheel lugs:
Tighten the wheel lugs with the correct torque and re-check the torque subsequently three times – after 50, 100 and 250 operating hours.
Fuels, lubricants and process chemicals
Ensure that the machine is standing in a safe position and is secured against rolling away (chocks).
Ensure that a torque spanner of the required range is available.
Check the wheel lugs on each wheel and retighten them, if necessary.
5.6Fuels, lubricants and process chemicals
5.6.1General information
Observe the instructions for lubricants and process chemicals. Lubricate the machine and change the oils at the prescribed intervals. For more information, see lubrication chart and inspection and maintenance schedule.
Keep workplaces for these activities clean. This enhances the service life and reliability of the machine.
All work on the machine must be carried out while it is standing on firm and level ground.
Switch off the diesel engine, remove the ignition key and set the battery main switch to position 0 (OFF).
Clean lubricating nipples before adding grease. Clean all filling points and the area around them before opening the caps and screws.
The oil should be changed while it is at operating temperature.
After each oil change or refilling, check the fill level in the respective unit (the specified fill levels are guide values).
Collect old oil and chemicals in suitable containers and dispose of them according to the applicable statutory regulations.
5.6.2Filling volumes, lubricating chart
5.6.2.1Recommended lubricants
Fuels, lubricants and process chemicals
Hydraulic system (system capacity / oil change volume / tank capacity)
Hydraulic Basic 100
Hydraulic HVI
Hydraulic Plus Arctic
Wheel hubs of the rigid axleLiebherr Gear Plus 20W-402.5 each Steering axleLiebherr Gear Plus 20W-409.5
Wheel hubs of the steering axle
Tracks and gearing of the slewing ring, bearing of the equipment
Universalfett 9900Hinges, joints, locksEngine
* = guide values
5.6.2.2Recommended fuels and chemicals
* = guide values
Specifications for fuels, lubricants and process chemicals
SymbolDescription
Diesel engine, check oil level
Gearbox or axle, check oil level
Hydraulic tank, check oil level
Carry out first oil change
Change oil
Lubricate machine
Lube point
Medium filling point
Observe operating manual
5.7Specifications for fuels, lubricants and process chemicals
5.7.1Fuels and lubricant for the diesel engine
For details and specifications regarding the diesel fuel, lubricant and coolant for the diesel engine, see Deutz manual
5.7.2Hydraulic oil
Hydraulic oils must meet the requirements outlined below.
Maximum water content of hydraulic oil: <0.1%
5.7.2.1Liebherr hydraulic oil
LIEBHERR recommends using the following hydraulic oils in its machines (depending on temperature range):
Specifications for fuels, lubricants and process chemicals
A Ambient temperature
B Cold-start range with warm-up instruction
C Operating range
Liebherr Hydraulic Plus and Liebherr Hydraulic Plus Arctic are suitable for both long-term use and use in environmentally sensitive areas.
If LIEBHERR oils are not available locally, use one of the engine oils listed in section "Engine oils for use as hydraulic oils" (before choosing an oil, contact the respective customer service department).
5.7.2.2Engine oils for use as hydraulic oils
When using engine oils (third-party products) as hydraulic fluids, we advise customers to request a certificate from the oil manufacturer, confirming that the product meets the following specifications.
Engine oils that are to be used as hydraulic oils must meet the following specifications:
Single-grade oils (1) API - CD / ACEA - E1 (MB 226.0 and 227.0)
Multigrade oils (2) API - CD, CE, CF / ACEA - E2, E3, E4 (MB 227.5, 228.1, 228.3 and 228.5)
B
C
5.7.2.3Warm-up instruction
The black bar B indicates ambient temperatures that are up to 20°C below the operating range C
For cold starting at an ambient temperature below range B, the following warm-up instruction for the hydraulic oil applies:
1. Start the diesel engine and set it to medium speed (not exceeding 50% of maximum speed).
2. Carefully activate the working hydraulics. Operate the hydraulic cylinders and move them briefly to the stop.
3. After approx. 5 minutes, start the travel hydraulics. Total warm-up time: approx. 10 minutes.
For cold starting at lower ambient temperatures, follow the warm-up instruction below: Before starting the engine, warm up the hydraulic oil tank. Then proceed according to the warm-up instruction in 1.
5.7.2.4Biodegradable hydraulic oil
Caution!
Do not mix hydraulic oil products!
When mixing different ester-based biodegradable hydraulic oils or mixing such products with mineral oils, aggressive chemical reactions might occur, causing damage to the hydraulic system.
Therefore never mix biodegradable hydraulic oils from different producers, and never mix bio hydraulic oils with mineral oils!
Specifications for fuels, lubricants and process chemicals
Liebherr recommends using the following hydraulic oils in its machines (depending on the temperature range):
Liebherr Hydraulic Plus or Liebherr Hydraulic Plus Arctic
When using these hydraulic oils, bypass filtration might be omitted.
If these oils are not available locally, use a fully saturated hydraulic environmental ester synthetic (HEES) fluids (before choosing an oil, contact the respective customer service department).
Caution!
The use of synthetic ester-based oils without a bypass filter causes damage to the hydraulic system!
If synthetic ester-based oils are to be used, bypass filtration is mandatory, as the water content in the oil must be kept below 1000ppm (0.1%).
Always use a bypass filter (optional equipment).
When using such fluids, we recommend replacing the hydraulic hoses every 4000operating hours or latest every 4 years.
Do not use vegetable oils, as they do not possess the necessary thermal stability. Under certain circumstances, the use of polyglycols is permitted, although they can cause damage to seals or the paintwork. Do not use oils containing polyglycols without first consulting the customer service department.
When using third-party products, we advise customers to request a certificate from the oil manufacturer, confirming that the product meets the above specifications.
5.7.2.5Oil change, oil analysis and filter change
Oil change
Note!
Liebherr recommends carrying out regular oil analyses (see chapter , "Oil analysis" on page 17).
Oil change
Oil type
LIEBHERR mineral oil
Liebherr Hydraulic HVI
Liebherr Hydraulic Basic 68
Liebherr Hydraulic Basic 100
Liebherr-PAO**
Liebherr Hydraulic Plus
Liebherr Hydraulic Plus Arctic
Not for use in environmentally sensitive areas
For use in environmentally sensitive areas (only permissible with oil analysis*) without oil analysis with oil analysis* (optional) every 3000 hevery 6000 h- *** every 4000 hevery 8000 hevery 8000 h
Third-party product - mineral oilevery 2000 hevery 2000 h- ***
Third-party product - fully saturated synthetic ester - ***- ***every 2000 h
Tab. 5-5 Oil change intervals copyright by
*If the result of the oil analysis is satisfactory, you may continue using the oil for a longer period. If the result of the oil analysis is negative, immediately change the oil.
**PAO = polyalphaolefin
***not permissible
Use in environmentally sensitive areas: machines operated in such areas must be filled with biodegradable hydraulic oil.
If the machine is operated for less than 1000 hours per year, an oil sample must be taken at least once a year. If a hydraulic oil remains in the machine for a prolonged period of time, it must be changed at least every 4 years (mineral oils and fully saturated synthetic esters) or every 6 years (Liebherr-Plus oils).
If the machine is not in use for a period of more than 6 months, carry out an oil analysis before restarting it.
Oil analysis
For regular oil analyses, LIEBHERR recommends contracting the specialist company OELCHECK and changing the oil when indicated by the test results in the lab report.
–Yellow kit for biodegradable hydraulic oils
–Green kit for mineral oils
See also customer service and product information.
Reasons for regular oil analyses:
–Reduction of costs thanks to prolonged oil change intervals
–Detailed information regarding the hydraulic system, its components and the medium
–Better protection of resources and the environment
Oil sampling / operating conditions
Oil sampling in machines operated under normal operating conditions
Oil sampling in machines operated under extremely dusty conditions
Specifications for fuels, lubricants and process chemicals
Oil sampling
Not for use in environmentally sensitive areas (oil analysis optional)
For use in environmentally sensitive areas (oil analysis mandatory)
Oil type
LIEBHERR mineral oil
Liebherr Hydraulic HVI
Liebherr Hydraulic Basic 68
Liebherr Hydraulic Basic 100
Liebherr-PAO*
Liebherr Hydraulic Plus
Liebherr Hydraulic Plus Arctic every 1000 hevery 250 h- **- ** every 1000 hevery 250 hfirst at 0 h, then every 1000 h first at 0 h, then every 250 h
Third-party product - mineral oil first at 1000 h, then every 500 h every 250 h- **- **
Third-party product - fully saturated synthetic ester - **- **first at 0 h, then every 500 h first at 0 h, then every 250 h
Tab. 5-7 Oil sampling depending on operating conditions
*PAO = polyalphaolefin
**not permissible
Filter change
Filter change / operating conditions
Filter change in machines operated under normal operating conditions
Filter change in machines operated under extremely dusty conditions
The filter change interval is determined by the actual operating conditions (for more information, see chapter "Dust-intensive applications, reduction of oil contamination").
Tab. 5-8 Symbols: Filter change depending on operating conditions
Change of return filter (use only LIEBHERR filters) every 1000 hevery 500 h
Tab. 5-9 Filter change depending on operating conditions copyright by
Change of bypass oil filter
LIEBHERR filterFilters from other manufacturers every 2000 h or as indicatedevery 500 hevery 250 h
Tab. 5-10 Filter change depending on operating conditions
5.7.2.6Dust-intensive applications, reduction of oil contamination
If the machine is normally operated with a hydraulic hammer or under similar conditions (considerable dust generation), the hydraulic oil might become more contaminated than under normal working conditions.
To prevent premature wear of the hydraulic components, the oil change and sampling intervals must be shortened.
Observe the following:
–The filter cartridge(s) in the return filter must be replaced every 500operating hours and after every hydraulic oil change.
–Use 10-µm filter cartridges instead of the standard 20/5-µm cartridges.
–The 2-µm breather filter must be replaced every 500operating hours and after every hydraulic oil change.
Machines delivered with a hydraulic hammer attachment and retrofitted hydraulic hammer kits are already equipped with 10-µm filter cartridges in the return filter. Please take this into account when ordering spare parts.
5.7.3Lubricants for axles and gearboxes
5.7.3.1Quality
Recommended lubricant
Specification
Liebherr Gear Basic 90 LSAPI: GL-5
MIL-L: 2105 D
ZF: TE-ML 05C, 12C, 16E, 21C
Liebherr Gear Plus 20W-40API: Niveau von GL4
ZF: TE-ML 05F, 06K, 17E
Liebherr Gear Hypoid 90 EPAPI: GL 5
MIL-L: 2105 B, C, D
ZF: TE-ML 05A, 12A, 16C, 17B, 19B
Liebherr Hypoid 85W-140 EPAPI: GL-5
MIL-L: 2105 D, PRF-2105 E
ZF: TE-ML 05A, 07A, 16D, 21A
Liebherr Hydraulic-Gear ATFGM: Dexron II D
ZF: TE-ML 03D, 04D, 11A, 14A, 17C
Liebherr Syntogear Plus 75W-90API: GL-4, GL-5, MT-1
MIL-L: 2105 D, PRF-2105 E
ZF: TE-ML 02B, 05B, 07A, 12B, 16F, 17B, 19C, 21B
Tab. 5-11 Lubricating oil specifications
If LIEBHERR oils are not available locally, use an oil that conforms to the specifications (before choosing an oil, contact our customer service department).
5.7.3.2Viscosity
A Ambient temperature
1 Use in gearboxes
2 Use in automatic transmissions
3 Use in axles
4 Use in pump distributor gear systems
* If the pump distributor gear is equipped with an oil cooler, the oil is not suitable for the marked temperature range (shaded area).
The choice of the lubricating oil viscosity is based on the SAE classification (Society of Automotive Engineers). The SAE classification does not provide any indication as regards the quality of a lubricating oil. The relevant factor for the correct choice of SAE class is the ambient temperature. Incorrect viscosity can impair the operation of axles and gearboxes.
The temperature ranges shown in the diagram are approximate ranges that might temporarily be exceeded.
5.7.4Lubricating oil for transmission
If LIEBHERR oils are not available locally, use an oil that conforms to the specifications (before choosing an oil, contact our customer service department).
5.7.5Grease
5.7.5.1Quality
Recommended lubricant Specification
Liebherr Universalfett 9900Soap-base grease (lithium complex)
KPF 2 N - 25 (DIN 51502)
NLGI grade: 2 (DIN 51818)
VKA welding force: > 6000 N (DIN 51350 / 4)
- Liebherr Universalfett Arctic (for lowtemperature operation)
Soap-base grease (lithium complex)
KPFHC 1 N - 60 (DIN 51502)
NLGI grade: 1 (DIN 51818)
VKA welding force: > 5500 N (DIN 51350 / 4)
The grease is used for both automatic and manual machine lubrication. it is supplied by the central lubrication system or through lubrication nipples to the respective lube points.
Examples:
–Slewing ring bearings
–Crown gears, geared wheels
–Bolts, axles and screws
–Attachments
5.7.5.2Operating temperature
A Grease temperature
* The grease is not suitable for the temperature range (shaded), if used in a central lubrication system.
** The grease may only be within the temperature range (shaded) for short periods of time. Peak temperatures of max. 200 °C (392 °F) are possible.
5.7.6Lubricants and care products for electrical and mechanical components
Medium, purposeProduct (manufacturer)
Contact spray for slip ringsCramolin
Lubricant for pistons, piston nuts and for the mounting of piston rod bearings at hydraulic cylinders
Special corrosion inhibitor for mounting recesses of sealing elements at hydraulic cylinders
Gleitmo 800
5.8Diesel engine
5.8.1Check oil level
Danger!
Risk of injury from burning. When the machine is at operating temperature, the engine oil is very hot. Avoid skin contact with hot oil or parts containing oil.
Ensure that the machine is standing on level and firm ground. Switch off the engine. Wait until the oil has collected in the oil pan.
5-11 Checking the oil level
Check oil level in the engine. The oil level must be between the min and max mark on the dip stick.
If necessary, add engine oil through the filler neck until the level reaches the max mark.
5.8.2Changing the oil
For instructions, see Deutz manual.
Note!
The oil change must be carried out when the engine is warm.
5.9Cooling system
5.9.1Checking and cleaning the cooling system
Cleaning cooling fins
The machine is equipped with a combined oil-wate r cooling system. A clean cooling system is a prerequisite for optimum cooling.
It is also necessary to regularly check the engine, fan and radiator for damage and to clean these parts.
Regularly inspect the cooling network according to the maintenance schedule. Cleaning cooling fins If necessary, release the fan 1 from its lock and tilt it to the side. Clean the cooling fins with compressed air or steam jet (from the inside out, see arrow).
Tilt back the fan 1 and secure it.
Check the state and tightness of the coolant hoses, and the connecting hoses between the coolant radiator and the engine.
5.9.2Checking coolant level
Danger!
Risk of burns from hot coolant. When the temperature is near the operating temperature, the engine cooling system is hot and pressurised.
Do not touch any parts containing coolant. Avoid contact with the coolant. Check the coolant level only after the engine has cooled down.
Turn the lid by 180 degrees (see arrow).
In this position, release any excess pressure, if necessary. When the tank is depressurised, carefully turn the lid further to remove it. The coolant level must be between the MIN and MAX marks. If necessary, add coolant. Close the lid.
After coolant has been added, switch on the engine and let it run for a short time, while the heating is on. Then check the coolant level again. Check the pressure relief valve (lid). If there is leakage, replace it.
5.9.3Corrosion inhibitor and antifreeze agent
The system must be filled with an antifreeze agent at all times.
When delivered, the cooling water contains antifreeze agent protecting the circuit to a minimum temperature of -37°C (corresponds to a antifreeze concentration of approx. 50%)
The mixing ratio of the antifreeze agent must be regularly checked in the course of routine maintenance.
Filling volume: see lubricant table
Note!
Do not exceed a corrosion inhibitor and antifreeze agent concentration of 60%! Higher concentrations tend to result in poor cooling and antifreeze protection.
5.9.4Changing coolant
Danger!
Risk of burns from hot coolant.
The coolant must be changed when the engine is cold.
When changing the coolant, observe the following instructions:
–The coolant of the entire cooling circuit must be replaced every two years.
–The coolant should be changed while the stop valves remain closed. –After refilling of the circuit, bleed it.
Draining
Coolant
5-14 Drain valve
Slowly open the radiator lid of the expansion vessel. Remove the cover plate at the base of the engine. Place a suitable container under the engine. Remove the cap of the drain valve 1 at the bottom of the radiator (arrow) and connect the hose from the tool box.
5-15 Water taps on the diesel engine
Close the water taps.
Filling in coolant
Disconnect the hose from the bottom of the radiator and close the valve. Add coolant to the expansion vessel, until it reaches the filler neck. Open the water taps.
Switch on the heating and let it run at maximum level. Run up the diesel engine. Check the coolant level and add coolant, if necessary.
5.10Fuel system
Danger!
Danger of explosion!
Avoid open flames when working on the fuel system and when refuelling. Do not smoke.
5.10.1Refuelling
To refuel and then store away the hoses, proceed as follows: Remove the tank lid.
Connect the suction hoses 1 and 2
Insert the free end of the suction hose 3 into the fuel container.
Open the stop cock 4.
Switch on the refuelling pump with the switch S25 (green) on the control unit 5 to pump fuel into the tank of the machine.
The pump is automatically switched off when the maximum fill level is reached. The refuelling pump can be switched off at any time with the switch S59 (red).
Caution!
Prevent the pump from running dry!
Ensure that the fuel level does not drop below the suction height of the suction hose.
Close the stop cock 4.
Before storing away the hose, ensure that no fuel is left in the suction hose 1 (2). Roll up the suction hose and store it away it in the storage place. Close the flap. Replace the tank lid.
5.10.2Draining the water from the fuel tank
The condensation in the fuel tank and fuel system should be drained daily. If conditions of use and fuel quality permit, the maintenance interval can be increased to once a week.
Note
To reduce condensation in the tank, keep the fuel level as high as possible.
The bottom of the tank is equipped with a drain plug 3.
Open the drain plug 3 on the underside of the fuel tank by two turns.
Drain off water until fuel emerges, close the plug again.
5.10.3Emptying and cleaning the fuel tank
To empty, remove the tank cap 1 and the drain plug 3 and allow the fuel to flow into a suitable container.
Clean the tank.
Check the tank and strainer2 regularly for contamination.
5.10.4Fuel preliminary filter
Drain the water:
Fuel preliminary filter
Screw in shutoff valve 1 slightly until the water flows off via the hose.
Drain the water visible in the glass container into a suitable container.
Close shutoff valve 1
Replace filter cartridge:
Unscrew electrical cable 2
Screw in shutoff valve 1 slightly until fuel flows off.
Drain the fuel into a suitable container.
Unscrew inspection glass 4, unscrew filter cartridge 5
Oil the seals on the filter head and inspection glass lightly (see arrows).
Screw on new filter cartridge 5 and inspection glass 4
Close shutoff valve 1.
Screw on electrical cable 2
Operate hand pump 3 until inspection glass 4 is filled with fuel.
Note
The filter cartridge can be damaged by tightening too tightly. Do not use tools to tighten the filter.
5.10.5Replacement of fuel filter cartridge (fine filter)
Unscrew the fuel filter cartridges 1 Apply a little oil to the rubber sealing ring of the new filter cartridges.
Note
The filter cartridge can easily be damaged by excessive tightening! Do not use any tools when tightening the filter element.
Insert new filter cartridge and tighten by hand. Bleed the fuel system.
5.11Dry air filter
The engine can only be protected against abrasion by dust and thus excessive wear, if the air filter is regularly cleaned or replaced.
The dry air filter is designed in such a way that it provides excellent protection with relatively long maintenance intervals.
For safety reasons, we strongly recommend not washing out the filter inserts.
Dry air filter
The maximum permissible suction underpressure might be reached, if the dry air filter is contaminated or if the dust removal valve 1 is blocked.
When this value is reached, the underpressure indicator 2 at the clean air connection and the air filter contamination indicator light are on.
5.11.1Cleaning the dust removal valve
Every week, open the discharge slot of the dust removal valve 1 by hand. Remove the dust. If the valve is cleaned regularly, it is less likely to become blocked quickly again.
5.11.2Replacing filter elements
Note!
Frequent removal and remounting of the filter elements might result in damage to the seals between the filter element and the filter housing. Do not replace the dry air filter elements more frequently than specified in the maintenance schedule.
5-22 Change of filter cartridges
1 Filter housing lid
2 Main element
3 Safety element
4 Dust removal valve
5 Seal
6 Filter housing
Replace the main element 2 at least once a year, and also if the maximum permissible intake underpressure is exceeded.
Replace the safety element 3, at least once a year, and after three replacements of the main element.
Replacing the main element:
Shut down the engine and remove the lid 1.
Remove the dirty main element 2
Clean the inside of the air filter housing and the sealing surface in the vessel with a moist cloth.
Caution!
Ensure that no dirt particles enter the engine intake system!
Do not clean the filter housing by blowing it out with compressed air.
Carefully clean the seal 5, the sealing surfaces and the inside of the filter housing. Inspect sealing surfaces for damage.
Insert the new main element, and ensure that it is positioned tightly and firmly in its seat.
Close the lid 1 of the filter housing 6
Changing the safety element:
Note!
If a visual inspection reveals that the safety element is heavily contaminated, replace it without delay.
Remove the main element 2
Remove the safety element 3
Carefully clean the inside of the air filter housing with a moist cloth.
Clean the sealing surfaces in the housing and examine for damage. Carefully insert the new safety element 3
Insert the new main element 2 and ensure that it is positioned tightly and firmly in its seat.
Close the lid 1 of the filter housing 6
5.11.3Checking the clean air line
Check the clean air line 1 between the filter outlet and the motor intake pipe for damage and leakage every time a filter element is replaced.
Note!
Clamps with spring packs (3, see arrow) can compensate changes in diameter. Retightening might interfere with their function. Do not retighten clamps with spring packs.
If necessary, retighten clamps 2
5.12Hydraulic system
Maintenance work on the hydraulic system is basically limited to the hydraulic tanks (change of return filter and oil change) and the control oil unit (change of control oil filter).
All other components of the unit do not require any special maintenance or servicing. The network of pipes and hoses must however be inspected regularly for leaks.
Danger!
High-pressure liquid might penetrate the skin and cause damage. At operating temperature, the hydraulic oil is hot and might even be under pressure. Escaping oil can cause serious injury.
Before carrying out any work on the hydraulic system, you must fully depressurise it.
Do not use your bare hands to check the equipment for leaks. Avoid skin contact with hot oil or parts containing oil.
Note!
Cleanliness is of particular importance for the proper working of the hydraulic system.
For this reasons, the following intervals must be strictly adhered to:
–Change of return filter, bypass oil filter*
–Cleaning of oil cooler
–Oil change
* optional equipment
5.12.1Checking the oil level in the hydraulic tank
The oil level in the tank is indicated by means of oil level gauges at the rear of the tank.
The lower mark - MIN - indicates the minimum oil level when all cylinders are fully extended.
To check the minimum oil level, ensure that the following conditions are fulfilled:
The hydraulic excavator is standing on level ground.
The working attachment is fully lifted, the boom regulating cylinder, boom cylinder, stick cylinder and bucket tilt cylinder are fully extended (stick and digging bucket tilted in).
The blade and/or outrigger supports are fully extended (lowered).
-The oil level may not drop below the - MIN - mark.
The upper mark - MAX - indicates the maximum oil level when all cylinders are fully retracted.
To check the maximum oil level, ensure that the following conditions are fulfilled: The hydraulic excavator is standing on level ground. The working attachment is placed on the ground, and the stick and the bucket tilt cylinder are fully retracted. The blade and/or outrigger supports are fully retracted (lifted).
- The oil level may not exceed the - MAX - mark. Check the oil level and add oil, if necessary.
5.12.2Releasing the pressure from the hydraulic system
Switch off the diesel engine. Operate the pilot control devices (joystick and pedals) in all directions (while the ignition key is in contact position).
5.12.3Releasing tank pressure
Fig. 5-26 Releasing tank pressure
Turn out the breather filter 1 by maximum one full turn. The pressure in the hydraulic tank is gradually reduced. The breather filter 1 can be rotated by hand when the safety pin 2 is inserted. If necessary, use an open-end spanner to open the filter.
5.12.4Emptying and refilling hydraulic tank
1 Breather filter 2 Return filter 3 Drain valves
Depressurise the hydraulic system including the tank. If possible, empty and refill the hydraulic system using a filler unit.
Draining oil:
Remove the lid from the return filter 2 Screw the drain hose onto the drain valves 3 at the bottom of the tank and let the oil drain into a suitable container.
Refilling hydraulic oil: Remove the lid from the return filter 2
Refill oil through the filter cartridge until it reaches the centre mark in the sight glass.
Tighten the breather filter 1
Replace the lid from the return filter 2
Note!
After each hydraulic oil change, bleed the hydraulic pumps.
Draining condensate:
Regularly drain the condensate from the system. Place a suitable container under the machine. Connect the drain hose to the drain valve 3 (see Fig. 5-27) until the oil flowing into the container does not contain any water.
5.12.5Changing return filter
The return filter is located inside the hydraulic tank and can be accessed when the cover 1 is removed.
At fixed intervals, the magnetic rods must be cleaned and the filter cartridges must be replaced.
Note!
In areas with excessive production of dust, observe the special instructions for the filter change.
Note!
LIEBHERR offers a bypass oil filter (optional equipment) for the return filter. Where environmentally friendly hydraulic oils are used, LIEBHERR prescribes the use of bypass oil filters.
The bypass oil filter is designed to remove small particles and water from the hydraulic system.
Changing the standard return filter:
1 Cover
2 Magnetic rods
3
4
5 Flat gasket
Depressurise the hydraulic system including the tank. Loosen the four screws of the cover 1 and lift off the cover with the magnetic rod 2
Carefully clean the magnetic rod 2 removing any persistent dirt. Remove the spent filter cartridge 3 holding it by the bracket.
Insert the new filter cartridge 3 into the tank, holding it by the bracket, and push it slightly down. Place the bracket to the side at the tank ring.
Ensure that the filter cartridge is positioned vertically in the tank.
Centre and place the cover 1 with the magnetic rod 2 carefully on the filter cartridge. Ensure that the flat gasket 5 is not damaged and positioned correctly.
Tighten the screws of the cover 1
After a filter change, you must also change the control oil filter.
Note!
The filling opening of the hydraulic tank is equipped with a protective cylinder 4 This prevents foreign bodies entering the hydraulic tank. If required, the protective cylinder can be removed from the filling opening.
Changing the return filter with bypass oil filter (optional equipment):
1 Cover
2 Magnetic rod
3 Filter cartridge (return filter)
4 Protective cylinder of return filter
5 Flat gasket
6 Filter cartridge (bypass oil filter)*
7 Protective cylinder of oil bypass filter*
8 Cover of bypass oil filter*
* only in conjunction with bypass oil filter (optional equipment)
Depressurise the hydraulic system including the tank.
Loosen the four screws of the cover 1 and lift off the cover with the magnetic rod 2
Remove the cover 1 from the magnetic rod 2
Remove the protective cylinder 7, lift off the cover 8 and remove the spent filter cartridge 6
Carefully clean the magnetic rod removing any persistent dirt.
Mount the protective cylinder 7 with the new filter cartridge 3 onto the magnetic rod. Replace the cover 8
Screw the cover 1 onto the magnetic rod 2
Remove the spent filter cartridge 3 holding it by the bracket.
Insert the new filter cartridge 3 into the tank, holding it by the bracket, and push it slightly down. Place the bracket to the side at the tank ring.
Ensure that the filter cartridge is positioned vertically in the tank.
Centre and place the cover 1 with the magnetic rod 2 carefully on the filter cartridge. Ensure that the flat gasket 5 is not damaged and positioned correctly.
Tighten the screws of the cover 1
After a filter change, you must also change the control oil filter.
Note!
The filling opening of the hydraulic tank is equipped with a protective cylinder 4 This prevents foreign bodies entering the hydraulic tank. If required, the protective cylinder can be removed from the filling opening.
5.12.6Changing control oil filter
1
2
3
5
6
7
8
The pressure filter 2 is an integral part of the control oil unit 1 located at the rear of the hydraulic tank.
Note!
The cleaning of the filter cartridge is prohibited! Each time you open the filter pot, replace the cartridge.
Depressurise the hydraulic system including the tank.
Remove the filter pot 6 of the pressure filter 2 and pull out the filter cartridge 4
Clean the filter pot.
Apply a little hydraulic oil to the threads and sealing faces at the filter pot 6 and at the control oil unit 1 as well as to the sealing rings 5 and 7
Carefully place the new filter cartridge 4 onto the mounting stud 2
Screw in the filter pot 6 to the stop and tighten it by hand.
5.12.7Checking the control circuit
The actuators do not require any special maintenance or servicing.
Regularly inspect the pipelines and the connections of all units (pumps, pressure accumulators, pressure-relief valve, pressure filter, etc.) for leakage.
Danger!
The pressure accumulator 8 (see Fig. 5-31) ensures that the control circuit remains pressurised after the diesel engine is shut down so that a number of movements remain possible.
Prior to interfering with the control pressure circuit, it must be depressurised:
To do this, place the attachment on the ground.
Switch off the engine.
Operate both joysticks (while the ignition key is in start position).
5.12.8Bleeding hydraulic pump
Hydraulic pump
After work on the hydraulic pump and after a hydraulic oil change, you must bleed the hydraulic pump.
Slightly loosen the hydraulic screw coupling of the leak oil hose 1 and let the air escape.
As soon as hydraulic oil begins to escape, close the hydraulic coupling. Before restarting the pump after a repair or replacement, fill the pump housing with hydraulic oil through the above fitting.
5.12.9Maintenance of hydraulic cylinders
5.12.9.1Checking piston rod bearing
Piston rod bearing
Note
If there is a leak at the piston rod bearing of a hydraulic cylinder (arrow), we recommend having the seal kit replaced by a LIEBHERR technician.
5.12.9.2Preservation of piston rods
Prior to standstills of more than 4 weeks, and in particular prior to any sea transport of the machine, carry out the following tasks:
If possible, position and transport the machine in such a way that the piston rods are fully retracted into the cylinders.
Exposed piston rods must be protected with a thick layer of acid-free corrosion protection grease.
Before loading the machine, check the piston rods again for proper preservation. Also apply corrosion protection grease to the piston rods, if the respective cylinder is rarely operated during work. Piston rods that are not frequently retracted and extended are not properly lubricated with hydraulic oil. Regularly check the preservation of rarely operated hydraulic cylinders.
5.12.10Replacing hydraulic hoses
Danger!
A defective hydraulic hose can cause accidents and injuries. Replace defective hydraulic hoses (bubbles, moisture, damaged top edge etc.) immediately.
Install new hydraulic hoses without torsion. Ensure that the hydraulic hose is not twisted when mounting.
Installed high pressure hoses with SAE connections have a nominal diameter of 16, 20 or 25.
Tighten the mounting screws of SAE fittings with the following tightening torques. :
5.13Changing the oil on components
5.13.1General
Notes
The machine must be in level position. Shut down the engine. Wait for a short time until the oil has collected in the oil pan.
If possible, drain the oil when it is at operating temperature.
Changing the oil on components
5.13.2Swin gear - oil change
To drain the oil:
Remove the cap 4
Unscrew the cover of the drain valve 1 via the opening on the base plate of the swing platform.
Screw the provided drain hose 2 on the drain valve and allow the oil to flow into a suitable container.
Remove the hose 2
Reinstall the cover of the drain valve 1
To add the oil:
Add the oil via the tank 3 until the level reaches the MAX mark.
Reinstall cover 4
5.13.3Transmission – oil change
To drain the oil:
Remove the oil filler plug 2
Remove the oil drain plug 1 Drain the oil into a suitable container. Install the oil drain plug 1
To add the oil: Add the oil until the oil level reaches bore 2 Install the oil filler plug 2
5.13.4Steering and rigid axle - oil change
To drain the oil:
Remove the oil filler plug 2
Remove the oil drain plug 1
Checking brake pads for wear
Drain the oil into a suitable container. Install the oil drain plug 1
To add the oil: Add the oil until the oil level reaches bore 2 Install the oil filler plug 2
5.13.5Wheel head – oil change
To drain the oil:
Turn the wheel head until the plug is located exactly vertically beneath the center of the wheel.
Remove the plug and drain the oil to flow into a suitable container. Reinstall the plug.
To add the oil:
Turn the wheel head until the level mark line is exactly horizontal. Add the oil up to the bottom edge of the bore. Reinstall the plug.
5.14Checking brake pads for wear
The LIEBHERR customer service department checks the brakes for wear and replaces worn brake pads.
Brake pads must be checked at least once every year. The check must also be carried out, if any of the following occur:
–Unusual brake noises
–Reduced brake force
–Reduced brake pressure
–Drop
5.15Electrical system
5.15.1Notes regarding the electrical system
Danger!
Risk of injury from sparks.
When charging batteries or carrying out other work on batteries, keep away from sparks and naked flames. Always wear goggles and protective gloves.
Regularly inspect the electrical system of the machine for defects. Identify the cause of blown fuses and broken incandescent lamps, eliminate it and replace the fuse or the lamp.
Defects such as loose connections, chaffed cables or poorly fixed clamps must be repaired without delay.
Before carrying out any work on the electrical system or carrying out electric arc welding work on the machine, disconnect the batteries.
Danger!
Risk of injury from sparks.
Disconnect the negative pole (-) first and reconnect it last.
5.15.2Battery main switch
Caution!
Do not interrupt the saving process of the engine control unit. After switching off the diesel engine, the engine control unit remains activated for approx. 40seconds in order to save system data. Switching off the battery main switch during saving might result in the loss of data so that the diesel engine cannot be restarted.
After switching off the diesel engine, wait for approx. 1minute before switching off the battery main switch to ensure that the saving process is properly completed.
Caution!
Special care is required in connection with machines with built-in auxiliary heater. Only switch off the battery main switch after the afterrun time of the auxiliary heater has lapsed.
Fig. 5-39 Battery main switch
Before carrying out any work on the electrical system or performing welding work on the machine, set the battery main switch to position 0 (off).
Before washing the machine, cover the electrical devices (in particular the alternator, generator, cabling, electrical components and measurement transducers) so that they are protected against splashing water.
When cleaning the engine with a water or steam jet, ensure that the measurement transducers (e.g. oil pressure switches) are not exposed to a direct water or steam jet.
Otherwise, water might penetrate the devices and cause corrosion of the contacts, leading to measuring failures.
Oil pressure switches cannot be designed as water-tight units due to the need for diaphragm ventilation.
Note!
The battery might discharge itself during prolonged standstills. Prior to prolonged standstills, set the battery main switch to position 0 (off).
5.15.3Battery care
To ensure that the batteries work properly at all times, keep them clean. Regularly clean the pole heads and cable terminals A and protect them with a thick layer of acid-proof grease, (see Fig. 5-40).
Danger
Kinked rubber hoses of the central gas release system lead to a higher risk of explosion!
The hydrogen produced in the battery may not collect in the battery box and must be released from the enclosure through the rubber hoses. When installing the hoses of the central gas release system, ensure that they are not kinked. Regularly check the hoses B for damage, especially after installation of the battery, (see Fig. 5-40).
The liquid level in the cells must be about 10 to 15 mm above the upper edge of the plate. If topping up is necessary, add only distilled water.
From time to time, check the acid density using a battery tester C
If the battery is fully charged, the density is 1.28 kg/l (31.5°Bé). If the battery tester shows a lower value, the battery is dischargedto some degree and might need to be recharged.
5.15.4Slip ring body (optional equipment)
Slip ring bodies are easily damaged by humidity, as oxide layers might form on the conducting surfaces, impairing electrical conductivity. As a consequence, the electrical consumers in the undercarriage are not sufficiently powered, which can result in malfunctions.
To prevent this, we recommend carrying out the following tasks every 500 operating hours:
Unscrew the lock nuts 1
Remove the slip ring housing 2.
Remove any oxidation from the slip ring body (use cleaning spray, if necessary). Replace damaged (corroded) fork terminals.
Apply Cramolin contact spray to all slip ring elements.
Replace the housing 1
Secure the housing 1 with the lock nuts 2 and tighten them all with the same torque.
