5Maintenance

5.1Maintaining the machine safely

5.1.1General Safety instructions

ied out by trained expert technicians. ods for repeat checks / inspections as outlined in the Operating manual. Always use appropriate tools to carry out maintenance work.

the end of these operating instructions clearly define who must/may perform which operations. The tasks listed under daily / weekly may be carried out by the machine operator or maintenance personnel after having received appropriate instructions. The remaining tasks may only be carried out by expert technicians with appropriate training.

rements set forth by the manufacturer. This is always ensured with Original spare parts. intaining the machine. For certain work, safety glasses and protective gloves are required, in addition to a hard hat and safety boots.

the machine during maintenance.

work. Make sure he knows the person who is in charge of the work.

with the working equipment lowered and the Diesel engine turned off, unless described otherwise in the operating instructions.

tenance operations, especially when working under the machine. Pull the ignition key and set the main battery switch to position 0. ain during maintenance and repairs.

re-attached and inspected directly upon conclusion of the operations.

5.1.2Cleaning

n the machine, especially connections and fittings to remove oil, fuel or cleaning substances. Do not use harsh cleaning products and use only lint-free cleaning cloths. eaning products or steam within the first two months after delivery (or after repainting).

cleaning products, ons and the swing ring to avoid infiltration of water and steam into the bearing points.

Maintaining the machine safely exposed to water, steam or cleaning products. This applies especially to electric motors, electric components, switch boxes, plug connections and air filters. the fire warning system and the fire extinguisher do not come in contact with hot cleaning fluids when cleaning the engine compartment. lines for leaks, loose connections, chafing and damage. infiltrated water or cleaning fluid.

The fire extinguishing system could be actuated.

5.1.3Crack inspection

depending on application, job site, duration of use and conditions of use. The different load conditions result in the different service life durations for various machines components. This could lead to cracks and loose connections, particularly on load bearing parts. This applies particularly in the case of 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.

ep the machine clean and to clean it regularly.

schedule, e personnel of the machine operator. tions with the machine supported, on firm and level ground, at changing loads with the attachment in length and crosswise direction. The currently valid accident prevention regulations must be adhered to. ly: er swing ring seating with tower and ball swing ring. th bearing block for boom and boom cylinder, upper swing ring seating, cab bearing, mounting of swing gear and counterweight. nts, e.g. boom, stick, quick change adapter, digging tool and grapple. and pin connections, steps, ladders and mounting elements. sually. To increase the level of inspection, if a crack is suspected or is in areas which are not easily visible, such as the swing ring seating, then the dye penetration procedure should be used to check for cracks. ely. Welding on load bearing parts of earth moving machines, material handling and transport units may only be made by especially trained expert personnel and only in accordance to accepted regulation of welding technology. In case of doubt, contact LIEBHERR Service to discuss suitable measures.

5.1.4Welding

rk on the machine only if this is explicitly permitted. Before any welding, torching and grinding tasks, clean the machine and the surrounding area to remove dust and flammable materials. Ensure sufficient ventilation. There is a danger of fire and / or explosion.

out any arc welding work on the machine. Disconnect the negative pole first, then the positive pole. Proceed in reverse order when reconnecting.

welding location.

5.1.5Operating and service fluids

applicable safety regulations for the corresponding product. disposal of operating and service fluids as well as exchange parts.

(Danger of burning and scalding).

5.1.6Repair

able lifting devices with sufficient load carrying capacity. When replacing individual parts and larger components, attach and secure them carefully to the lifting tackle, to avoid any danger. Use only suitable and technically sound lifting devices as well as load tackle with sufficient load carrying capacity. Do not stand or work under suspended loads. ciently sized lifting devices. Always wear work gloves when handling wire ropes.

The guide must position himself within view of the operator or be in voice contact with him.

forms.

Do not use parts of the machine as climbing devices, if they are not designed for this purpose.

Wear a harness when working in great heights. Keep handles, steps, railings, platforms, and ladders free of dirt, ice and snow. the machine is properly supported. Never use metal on metal support. is raised with the attachment, without being properly supported from below with hardwood beams.

ys that any shifting weight will not endanger the stability of the machine and avoid metal to metal contact.

ng systems may only be carried out by especially trained expert personnel.

ade, block the chains with wedges and secure the uppercarriage to the undercarriage with the locking pin.

onnel may work on the hydraulic system.

Maintaining the machine safely can have enough pressure to penetrate the skin.

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 relieve the pressure in the tank, as described in this operating manual.

5.1.7Electrical system

All defects, such as loose connections, burnt out fuses and bulbs, burnt or damaged wires or cables must be repaired immediately by an electrician or especially trained personnel.

gy supply, turn the machine off immediately.

sion of an electrician may work on the electrical equipment of the machine, according to the electro-technical guidelines.

emergency off or master switch with voltage release. Rope of the work area off with a red and white safety chain and a warning sign. Use only insulated tools. mponents, shut off the voltage and connect the supply cable to the ground and ground the components, such as the condenser, with a grounding rod.

truly free of current, ground them and short circuit them. Insulate adjacent, current carrying parts.

out any arc welding work on the machine. Disconnect the negative pole first, then the positive pole. Proceed in reverse order when reconnecting.

5.1.8Pressure accumulator

cidents.

erating instructions prior to working on ahydraulic accumulator.

chanical work on them.

The pressure accumulator can be damaged due to heat exposure and can rupture due to mechanical treatment. THERE IS A DANGER OF EXPLOSION!

is a DANGER OF EXPLOSION!

burning.

plication before use.

the pressure accumulators. Make sure that the marking remains visible.

5.1.9Hydraulic hoses and lines

d regularly, every 2weeks, in case of suspected intentional damage immediately for leaks and external visible damage! Any damaged parts must be replaced immediately! Escaping oil can cause injuries and fires.

ess. For that reason, their service live is limited. quent causes of failure.

standards, regulations and guidelines for hoses and lines at the job site must be observed. ranges of permitted use can shorten the service life ( for example in high temperatures, frequent work cycles, extremely high impulse frequencies, multi shift operation).

e following conditions are found during inspection: cracks); 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); allation instructions; which reduce the strength of the fitting or the hose / fitting connection; h reduces function and strength; pressure hoses, always attach the screws of half clamps or full flange on both ends of hose first and then tighten. with a bent fitting, always tighten the end with the bent fitting first when tightening the flanges, then the end with the straight fitting. and tightened thereafter. erly mounted. This prevents vibration and damage during operation. that chafing with other hoses or other structures is prevented. of the outer hose diameter to the other parts is recommended. The distance should not be less than 10 to 15mm. able parts (such as boom to stick), check before initial use, that there is not chafed area over the entire area of movement.

Maintaining the machine safely

5.1.10Rollover-protection features (ROPS) and falling-object protective systems (FOPS)

- ALIEBHERR dealer must be consulted prior to making any changes, in order to prevent aweakening of the roll-over protection or falling-object protective system.

- No objects may be attached to the safety devices (such as fire extinguishers, headlights, or such).Welding attachment parts or drilling holes on may weaken the structure.

- Damaging or weakening the structure may be caused by an accident, falling objects, etc.

- Any modification that has not been exclusively approved by LIEBHERR will render the permit of the roll-over protection or falling-object protective system invalid.

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

Side door, rightMechanical

5.2.2Door lock

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.

Danger!

Repair work on the wheels, e.g. removing tires from the rim or installing tires on the rim may only be carried out by expert personnel using the appropriate assembly tool.

If the tire inflator is operated incorrectly or carelessly, the following dangers can arise, leading to severe injury or even death:

Tires which have become flat may not be inflated. They must be repaired at a professional shop.

An incorrectly seated lock ring could burst off. Danger of injury.

When inflating the tires, use a tire inflator hose of a sufficient length with a self retaining hose valve.

When inflating the tires, stand outside of the danger zone. Do not use different tire sizes.

5.3.1Checking the tire pressure

The air pressure in the tires has a considerable influence on the overall operational behavior of the machine. For this reason, the tire pressure should be checked regularly and corrected if necessary.

When working on the tires, ensure that the machine is positioned safely and is secured with wedges to prevent it from rolling off.

Ensure that the correct nominal tire pressure values, corresponding to the mounted tire and the machine group, are available for the tires.

Take the nominal values from the chart below.

Attach measuring equipment and correct air pressure, if necessary.

5.3.1.1Tire pressures

5.3.1.2Tightening torque

Note!

Retighten the wheel lugs according to the inspection and maintenance schedule after each wheel change.

5.3.2Filling with foam

Note!

The running characteristics will be influenced by filling the tires with foam. Only LIEBHERR may fill the tires with foam.

5.4Lubricants and operating fluids

5.4.1General information to change lubricants and operating fluids

Note!

The quantities given in the lubrication and operating fluid chart as well as on the lubrication chart in the cab are only guide values.

Check the level in the corresponding component after each oil change or refill.

Note!

Adhering to regulations for lubrication, level checks and changing of operating fluids guarantees a high degree of reliability and a long service life for the machine. It is particularly important to adhere to the oil change intervals and use the specified type of lubricant.

Observe the following when using and checking lubricants and operating fluids: Note!

Cleanliness is of the utmost importance when changing oil. Clean all filler plugs, filler covers and drain plugs and their surroundings before opening.

If possible, drain the oil when it is at operating temperature. Ensure that old oils are collected and disposed of in an environmentally acceptable manner, including removable oil filter cartridges.

Danger!

When checking and changing lubricants and operating fluids, ensure that the following precautions are adhered to:

Unless otherwise indicated, carry out all work on the machine on level, solid ground and with the engine shut down.

Whenever you access the engine compartment, always secure the cover and side doors to prevent them from accidentally falling back or closing.

Only refuel the machine when the engine is shut down, do not smoke and avoid open flames.

Turn the battery master switch to position 0 (off) and remove the ignition key.

Lubricants

5.4.2Lubricating chart

SymbolMeaning

Diesel engine

Hydraulic tank

Swing gear

Transmission

Rigid axle

Rigid axle wheel hub

Steering axle

Steering axle wheel hub

General grease nipples

Checking the oil level

Oil change

First oil change

Greasing

Follow the operator's manual

Tab. 5-3 Legend

5.4.3Lubricant chart

DescriptionMediumSymbolClassificationViscosityQuantity the instructions provided by the gine manufacturer (see Deutz operator's manual).

Operating instructions

Lubricants and operating fluids

DescriptionMediumSymbolClassificationViscosityQuantity (litres)*

Tracks and gearing for slewing ring, attachment bearing

Hinges, joints, locksEngine oil----

Sealing rubber on doors and coversSilicon spray or talc----

* = Guide values

5.4.4Operating material chart

DescriptionMediumSymbolQuantity (litres)*

Fuel tankCommercially available diesel fuel with sulphur content <=0.5%290

CoolantAnti-corrosion and anti-freeze fluid25.0

Windscreen washer systemCommercially available windscreen washer fluid or methylated alcohol -3,0

Air conditioning system refrigerantR 134 a-1.7 kg

Refrigeration oil in a/c compressorZXL 100 PG-0.15

* = Guide values

5.5Lubricant and operating fluid specifications

5.5.1Lube oil for the Diesel engine

The information provided by the engine manufacturer applies (see Deutz operating instructions).

5.5.1.1Oil change intervals for the turbocharged engine

Conditions of useSulphur content in fuel Oil change interval dependent on oil viscosity:

Tab. 5-6 Oil change intervals for the turbocharged engine e zone, sulphur content in fuel and oil quality (see Tab. 5-6). and oil filter should be changed at least once a year.

Oil change intervals for Diesel engine depend on the following criteria: 500operating hours when using initial fill oil of quality E3-96.

5.5.2Fuel

Diesel fuels should meet the minimum requirements of the below listed, approved fuel specifications.

The sulphur content should not exceed 0.5 %. A higher sulphur content will affect the oil change intervals and the engine life.

5.5.2.1Lubricity

Decreasing sulphur content has raised the problem of Diesel fuel lubricity. It has been shown that Diesel fuels containing the maximum permitted European sulphur limit of 0.05 % can cause wear in the fuel injection system (particularly for distributortype injection pumps).

fuel lubricity must be <400 µm according to the HFFR (60°) test.

Suppliers should supply the additives as the responsible party for the fuel quality. It is not recommended that customers add secondary lubricity additives.

Lubricant and operating fluid specifications

Operating instructions

5.5.2.2Flow improvement by adding petrol (regular gasoline)

When ambient temperatures are below approx. 0°C, the flow properties of summer Diesel fuels can become insufficient due to paraffin separation.

The same also occurs in winter Diesel fuels used in temperatures below -15°C. Frequently, Diesel fuels with additives with a use temperature of up to -20°C are offered.

To avoid malfunctions, Diesel fuel must be mixed with normal gasoline or petroleum at lower temperatures.

Adding normal gasoline should be viewed as an emergency remedy and must not exceed 30% by volume.

Super petrol (Super or premium gasoline) may not be used for mixing. Engine performance can be reduced depending on the additives mixed in for cold weather conditions. For this reason, additions to the mixture should be kept as low as possible by taking the current ambient temperatures into account.

Danger!

For safety reasons, mix fuel only in the fuel tank.

Note!

When refuelling, the specifically lighter additional fuel should be added before the Diesel fuel. Then run the engine until the mixed fuel is distributed through the entire fuel system.

Approved fuel specifications

DIN EN 590

ASTM D 975 - 89a 1 D and 2

Mixing ratio Diesel fuel / regular gasoline

* If an addition of 50 % is required, use only petroleum (no regular gasoline).

5.5.2.3Additives

to Diesel fuel (flow improver)

Commercially available flow improvers can al cold weather conditions. When using them, follow the manufacturer dosage and usage requirements.

5.5.3Hydraulic oil

5.5.3.1Mineral

Oil

Engine oils corresponding to the following specifications and regulations are specified:

Single-grade oils: API - CD / CCMC - D4 / ACEA - E1

Mercedes-Benz regulations, Page no. 226.0 and 227.0

Multi grade oils: API - CD + SF / CCMC - D5 / ACEA - E3

Mercedes-Benz regulations, Page no. 227.5 and 228.3

Tab. 5-9 Specified engine oils for use as hydraulic oil

The engine oil for use as hydraulic oil can be selected according to the following chart.

Fig. 5-6 Engine oils for use as hydraulic oil

Warm-up guidelines

At temperatures up to 10°C below the given limit (black bar), the following warm-up guidelines apply:

After starting the engine, regulate the Diesel engine only to approx. 1/2of the rated speed. Operate the hydraulic cylinder and motors, move cylinder briefly against the stop. Warm-up duration approx.10minutes.

At even lower temperatures: Preheat the oil tank before starting the engine.

5.5.3.2Environmentally friendly hydraulic fluids

Note!

Mixing environmentally friendly hydraulic oils made by different manufacturers as well as mixing them with mineral oils must be avoided.

The environmentally friendly hydraulic oils recommended by LIEBHERR are limited to oils with a synthetic ester basis with a viscosity according to ISOVG46.

The initial oil fill is carried out at the factory according to an approved list. Use of an environmentally friendly hydraulic oil must first be coordinated with LIEBHERR.

Plant-based oils are not to be used due to their insufficient temperature properties. The use of bypass filters is required.

5.5.3.3Hydraulic oil monitoring

Note!

Environmentally friendly hydraulic fluids should generally be checked at regular intervals through an oil analysis. Oil analysis is recommended for mineral oils.

Machines in normal use: at least every 500operating hours

Machines in dust intensive use: at least every 250operating hours LIEBHERR recommends that oil analyses be carried out by the WEAR CHECK Company and that oil changes are performed on the basis of the lab report (see also customer service and product information).

5.5.3.4Hydraulic oil monitoring in normal use

hrs.operating hours

1 first oil sample

2 second oil sample

3 additional oil samples every 500 operating hours

Oil change according to analysis and lab report. Change intervals for hydraulic oil return filter (10µm): first after 500operating hours, additional changes every 1000operating hours.

5.5.3.5Hydraulic oil monitoring in dust intensive use

hrs.operating hours

1 first oil sample

2 second oil sample

3 additional oil samples every 250operating hours

Oil change according to analysis and lab report. Change intervals for hydraulic oil return filter (10µm): first after 500operating hours, additional changes every 500operating hours.

5.5.3.6Notes on reducing hydraulicoil contamination in heavy dust use

If the machine is generally operated with the hydraulic hammer, or if it is used under similar circumstances (heavy dust occurrence), there is the risk that the hydraulic oil will become contaminated more than usual.

To prevent early wear of hydraulic components, the oil change intervals (and intervals between oil samples) should be reduced and the following regulations should also be observed: ilter must be replaced every 500operating hours. must be replaced with a 2µm fine filter (fineness of standard filter is 7 µm).

5 µm filter cartridges.

Lubricant and operating fluid specifications

Operating instructions

every time the hydraulic oil is changed (every 500operating hours).

Note!

Machines fitted with a hydraulic hammer at the factory and retrofitted hydraulic hammer kits feature these 10-µm filter cartridges and 2-µm breather filters.

5.5.4Gear oil

Gear oils must correspond to the specifications

Engine oils used in gears must correspond to the specifications

For viscosity classes SAE80 and SAE90 according to MIL-L-2105 D, oil of viscosity class SAE80W90 can also be used.

5.5.5Lubricating grease and other lubricants

GreaseDescription / manufacturer

Lubricating grease for the swing ring / general lube points

The grease must correspond to specification KP2k, consistency 2 or NLGI grade according to DIN 51818 and DIN 51825 or EP 2 according to NF-T-60 132.

The grease must consist of a lithium complex and have a VKA value of at least 2300 N according to DIN 51350 and ASTM D 2596.

Contact spray for slip ringsCramolin

Lubricant for pistons, piston nuts and piston bearing installations on hydraulic cylinders

Special anti corrosion fluid for installation areas of sealingelements on hydraulic cylinders

Anti-corrosion grease for exposed piston rods (for cylinders that are not moved often or during transport)

Tab.

-

Gleitmo 800

Castrol-Tarp

Lubricating grease and other lubricants

5.5.6Coolant

To improve coolant quality, water filter attachments are used for LIEBHERR Diesel engines.

Due to this measure, the coolant is filtered again in the bypass flow and is cleaned of dirt and rust particles, which could result in leaks on the coolant pumps.

Ambient temperature to Part water in %Part anti-corrosion fluid / antifreeze in % -37 °C / -36.67 °C5050

-50 °C / -58 °F4060

The coolant must contain a minimum of 50percent by volume of anti-corrosion fluid/ antifreeze all year. This corresponds to an antifreeze protection up to -37°C and ensures sufficient protection from corrosion.

In case of coolant loss, it must be ensured, when adding coolant, that this amount does not fall short of 50 % by volume.

Note!

Do not use more than 60 % anti-corrosion fluid/antifreeze!

At a higher percentage, the cooling effect and antifreeze protection would actually be reduced.

When carrying out maintenance work, the mixing ratio of the coolant must be checked.

Note!

2 years

Before adding new coolant, make sure that the coolant system is clean and flush if necessary.

5.5.6.1Regulations for fresh water quality

To prepare the coolant, use clean water, which is not too hard. Often, but not always, drinking water meets these requirements. Sea water, brackish water, brine and industrial wastewater are not suitable.

ContentQuantity

Sum of alkaline earths (water hardness) 0.6 to 3,6mmol / l (3 to 20°d) ph value at 20 °C6.5 to 8.5

Chloride-ion contentmax.80 mg / l

Sum of chloride + sulphatemax.100 mg / l

Lubricant and operating fluid specifications

Operating instructions

5.5.6.2Approved anti-corrosion fluid and antifreeze

Concentrate, undiluted

Product descriptionManufacturerCountry

Agip Antifreeze PlusAgip Petrol S.p.A., RomeI

Agip Langzeit-FrostschutzAutol-Werke GmbH, WürzburgD

Antigel DB 486Sotragal S.A., St. PriestF

Aral Kühlerfrostschutz AAral AG, BochumD

Avia Frostschutz APN (G48-00)Deutsche Avia-Mineralöl GmbH, MunichD

BP Antifrost X 2270 ADeutsche BP AG, HamburgD

BP Napgel C 2270 / 1BP Chemicals LTD., LondonGB

Caltex Engine Coolant DB Caltex UK Ltd, LondonGB

Caltex Extended Life CoolantCaltex UK Ltd, LondonGB

Castrol Anti-Freeze ODeutsche Castrol Vertriebs GmbH, HamburgD

Century F.L. Anti-FreezeCentury Oils, Hanley, Stoke-on-TentGB

Chevron DEX-COOL Extended Life Anti-Freeze / Coolant Chevron Texaco, San Ramon, CAUSA

DEUTZ Kühlschutzmittel 0101 1490Deutz Service International GmbH, CologneD

Esso KühlerfrostschutzEsso AG, HamburgD

FircofinFuchs Mineralölwerke GmbH, MannheimD

Frostschutz Motorex (G48-00)Bucher & Cie, LangenthalCH

Frostschutz 500Mobil Oil AG, HamburgD

Glacelf Auto SupraTotal Nederland N.V., Den HaagNL

Glycoshell AF 405Shell Deutschland GmbH, HamburgD

Glycoshell NShell Deutschland GmbH, HamburgD

Glysantin (G 48-00)BASF AG, LudwigshafenD

Havoline XLCArteco, GentB

Havoline DEX-COOL Extended Life Anti-Freeze/ Coolant Chevron Texaco, San Ramon, CAUSA

Igol Antigel Type DBIgol France, ParisF

Labo FP 100Labo Industrie, NanterreF

Motul Anti-FreezeMotul SA, AubervillesF

OMV KühlerfrostschutzmittelOMV AG, SchwechatA

Product descriptionManufacturerCountry

OrganifreezeTotal Deutschland GmbH, DüsseldorfD

OZO Frostschutz STotal Deutschland GmbH, DüsseldorfD

Total Antigel S-MB 486Total Deutschland GmbH, DüsseldorfD

Total FrostfreiTotal Deutschland GmbH, DüsseldorfD

Veedol Anti-Freeze ODeutsche Veedol GmbH, DüsseldorfD

Wintershall KühlerschutzWintershall Mineralöl GmbH, DüsseldorfD

Tab. 5-13 Approved anti-corrosion fluid / antifreeze (concentrate, undiluted)

50:50 premix (water: anti-corrosion fluid / antifreeze)

Product descriptionManufacturerCountry

Liebherr Anti-Freeze APN Mix Ident-Nr. 8611045LiebherrD

Caltex Extended Life Coolant Pre-Mixed 50/50 (ready-to-use-version)

Chevron DEX-COOL Extended Life Prediluted 50/50 Anti-Freeze/Coolant

Caltex UK Ltd, LondonGB

Chevron Texaco, San Ramon, CAUSA

Havoline XLC, 50/50Arteco, GentB

Havoline DEX-COOL Extended Life Prediluted 50/50 Anti-Freeze/Coolant

Chevron Texaco, San Ramon, CAUSA

Organicool 50/50Total Deutschland GmbH, DüsseldorfD

Tab. 5-14 Approved anti-corrosion fluid / antifreeze / 50:50 premix

5.6Diesel engine

5.6.1Check oil level

Danger!

Danger of burning.

The engine oil is hot when at or near operating temperature. Do not allow your skin to come into contact with hot oil or components containing hot oil.

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.

Fig.

Check oil level

Check the oil level in the engine. The oil must leave a mark between the min and the max marks on the dipstick. If necessary, add engine oil at the oil filler fitting (see arrow) until the level has reached the upper mark MAX

5.6.2Changing the oil

For oil change, see the Deutz operating instructions.

Note!

Change the oil only if the engine is warm.

5.7Cooling system

5.7.1Checking and cleaning the cooling system

Cleaning the cooling fins

The machine is equipped with a combination oil / water cooler.

Optimum cooling can only be achieved if the cooler is kept clean.

Check the engine, fan and cooler for damage and clean if necessary.

Check the cooling system according to the maintenance schedule intervals. If required, clean the cooling fins with compressed air or a steam jet (from inside to the outside, see arrow).

Check the condition and seals of the connector hoses between the radiator and engine the as well as the coolant hoses regularly.

In case of leaks, change the pressure relief valve 1 (expansion tank lock ring).

5.7.2Checking the coolant level

Danger!

Danger of burns due to hot coolant. The engine cooling system is hot and pressurized when at or near operating temperature.

Avoid touching coolant or coolant-bearing parts. Check the coolant level only when the engine has cooled off sufficiently.

5-11 Expansion tank

Turn the cover (see arrow) a half turn. In this position, relieve any pressure that may be present. After equalizing the pressure, slowly open the cap all the way. The coolant must be between the MIN and MAX marks. Add coolant if necessary.

Close the cap.

After adding coolant, allow the engine to run for a short time with the heater turned on and then recheck the coolant level.

5.7.3Anti-corrosion fluid and antifreeze

The system must be filled with antifreeze year round.

At delivery, the coolant contains antifreeze for temperatures up to -37°C (this corresponds to approx. 50 % antifreeze).

When carrying out maintenance work, the mixing ratio of the coolant must be checked.

Quantity: see Lubrication Chart

Note!

Do not use more than 60 % anti-corrosion fluid/antifreeze! At a higher percentage, the cooling effect and antifreeze protection would actually be reduced.

5.7.4Changing water filters

The water filter must be replaced every 500 operating hours: Close the shut off valves (arrows) on the filter housing. Unscrew the filter element.

Lubricate the seal ring on the new filter element lightly with oil. Install the new filter element until the seal ring is touching on the filter head.

Note!

The filter element can be damaged. Do not use any tools to tighten the filter element.

Tighten the filter element by hand a 1/2 - 3/4 turn. Open the shut off valves again.

5.7.5Changing the coolant

Danger! Danger of burns due to hot coolant. Change the coolant only when the engine is cold.

When changing the coolant, observe the following points: ling circuit at least every two years. closed. rcuit after refilling. take place with the ignition key in the contact position.

5.7.5.1Draining the coolant

Open the cover of the expansion tank slowly. Remove the cover plate on the underside of the engine. Place a suitable container underneath.

Unscrew the cover of the drain valve 1 on the underside of the water cooler (see arrow) and attach the drain hose from the toolbox.

Open the water taps 2

5.7.5.2Refilling the coolant

Remove the drain hose on the underside of the water cooler and close the valve. Open the water taps 2

Pour coolant into the expansion tank until the coolant is visible in the filler neck. Turn the heater on and set it to its highest level; allow the Diesel engine to warm up.

Check the coolant level and add more coolant, if necessary.

5.8Fuel system

Danger!

Danger of explosion!

Avoid open flames when working on the fuel system and when refuelling. Do not smoke.

Unscrew tank cap 1 Add fuel via the strainer.

For refuelling and storing hoses, proceed as follows:

Connect the suction hose 1 and 2

Insert the free end 3 of the suction hose into the fuel supply tank.

Open the shut off valve 4

Use switch S25 (green) on the control unit 5 to turn the refuelling pump on and pump fuel into th

The pump turns off automatically as soon as the maximum fill level is reached. The refuelling pump can be turned off at any time using switch S59 (red).

Caution!

Do not let the pump run dry.

Ensure that the fuel level does not drop below the suction level of the suction hose.

Close the shut off valve 4

Make sure that there is no fuel in the suction hose 1 (2) before storing the hose. Roll up the suction hose and place it in the storage compartment. Close the cover again.

5.8.2Draining 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.

5.8.3Emptying 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.

5.8.4Fuel preliminary filter (type 2)

Drain the water:

Fig. 5-18 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.

5.8.5Replacing the fuel filter cartridge (fine filter)

Unscrew fuel filter cartridge 1

Lubricate the rubber seal ring on the new filter cartridge lightly.

Note

The filter cartridge could be damaged if it is tightened too much! Do not use any tools to tighten the filter.

Screw on the new filter cartridge and tighten by hand. It is not necessary to bleed the fuel system after changing the fine filter.

5.9Dry air filter

Maximum engine protection against premature wear due to dust is only possible if the air filter is serviced at regular intervals.

The dry air filter is designed in such a way that it offers maximum protection at long maintenance intervals.

For safety reasons, we do not recommend to wash out filter elements.

Fig. 5-20 Dust discharge valve extractor slot

Push the extractor slot on the dust discharge valve open by hand once a week to prevent it from sticking due to humidity and dust.

When the maximum vacuum pressure has been reached, the maintenance indicator on the filtered air connection (see arrow) actuates and the indicator light H13 (air filter contamination) lights up.

5.9.1Changing the main element

Caution!

Only replace the main element when the maximum permissible intake underpressure has been reached, or at least once a year.

Installing and removing the main element too often could damage the seals between the filter element and the filter housing.

Only replace the safety element after every third change of the main element, or at least once a year.

Before installing a new element, carefully clean the seal and the seal contact surface in the housing.

Remove the cover 1 with the engine shut down. Remove the contaminated main element 3

Clean the interior of the air filter housing and the sealing surface in the housing with a damp cloth.

Caution!

Dirt could enter the engine air intake!

Do not clean the housing by blowing it out with compressed air.

Insert the new main element and ensure that it seals and is positioned correctly. Close the filter housing 2 with cover 1

5.9.2Changing the safety element

Note!

Replace the safety element after replacing the main filter cartridge three times or at least once a year.

Replace the safety element immediately if a visual inspection has shown that the safety element is very dirty.

Remove the main element 3. Remove the safety element 4

Clean the interior of the air filter housing carefully with a damp cloth. Clean sealing surfaces in the housing and inspect for any damage.

Insert the new safety element 4 carefully.

Insert the main filter cartridge3 and ensure that it seals and is positioned correctly. Close the filter housing 2 with cover 1

5.9.3Checking the filtered air line

Fig. 5-23 Filtered air line

Check the filtered air line 1 between the filter outlet and the engine suction pipe for damage and leaks each time the filter element is replaced.

If necessary, retighten the tension clamp screws 2

5.10Hydraulic system

Maintenance work on the hydraulic system is restricted mainly to the hydraulic tank.

All other system components do not require special maintenance. The pipe and hose network should be checked at regular intervals for leaks.

Note!

Strict cleanliness is of particular importance for the hydraulic system. For this reason, the intervals given

5.10.1Checking the oil level in the hydraulic tank

The oil level is checked via the sight gauges on the rear of the hydraulic tank.

The lower eye - MIN - shows the minimum oil level if all cylinders are fully extended. When checking the minimum oil level, the following prerequisites must be met:

The hydraulic excavator must be standing on level ground.

The attachment must be fully raised and the adjustable boom cylinder, hydraulic cylinder, stick cylinder and bucket cylinder fully extended (stick and bucket curled in).

The blade and / or outrigger support must be fully extended or lowered. The oil level may not fall below - MIN - level.

The upper eye - MAX - shows the maximum oil level if all cylinders are fully retracted. When checking the maximum oil level, the following prerequisites must be met:

The hydraulic excavator must be standing on level ground. The attachment is placed on level ground, the stick and bucket cylinders are fully retracted.

The blade and / or outrigger support must be fully retracted or lowered. The oil level may not exceed - MAX - level.

Check the oil level and add more oil, if necessary.

5.10.2Relieving the pressure in the hydraulic system

Danger!

A fine stream of oil can penetrate the skin when under high pressure and cause serious injury.

Before working on the hydraulic system, always relieve the pressure. Do not check for leaks with bare hands.

Note the following points:

The machine must be in the position described above. Shut down the engine.

Move the pilot control devices (joystick and pedals) in all directions (with the ignition key in contact position).

Danger!

The hydraulic oil is hot when at operating temperature and could be pressurized. Do not allow your skin to come into contact with hot oil or components containing hot oil.

Fig. 5-25 Relieving the pressure in the hydraulic system

Back out the breather filter 1 by a maximum of one turn. The pressure in the hydraulic system is relieved.

The breather filter 1 can be turned manually if the safety pin 2 is inserted. An open end spanner can be used if the filter does not open easily.

5.10.3Emptying and refilling the hydraulic tank

1

If possible, always fill and empty the hydraulic system using a filler unit.

To drain the oil:

The pressure in the hydraulic system must be relieved. Back out the breather filter 1 by a maximum of one turn. The pressure in the hydraulic system is relieved.

Remove the cover of the return filter 2

Install the drain hose to the drain valves 3 in the tank bottom and let the oil flow out into a suitable container.

To refill the hydraulic oil:

Back out the breather filter 1 by a maximum of one turn. The pressure in the hydraulic system is relieved.

Remove the cover of the return filter 2

Refill the oil through the filter cartridge until the level reaches precisely the center mark on the sight gauge.

Tighten the breather filter 1

Install the cover of return filter 2

Caution!

After each hydraulic oil change, bleed the hydraulic pumps.

To drain the condensation: Drain the condensate regularly. Place a suitable container underneath the tank.

Keep the drain hose on the drain valves 3 (see Fig. 5-26) until oil contains no more water.

Interval: see Maintenance schedule

5.10.4Return filter

The return filter is located on the top of the hydraulic tank.

1 Cover

2 Hex head screw

3 Gasket

4 Bypass cage

5 Magnetic plug

6 Filter element

7 Protective cylinder

The magnetic rod 5 of the return filter must be cleaned at fixed intervals (see maintenance chart) and the glass fiber filter element 6 replaced.

Note!

When working in dust intensive conditions, please observe the special regulations for filter change.

To clean the magnetic rod or replace the filter element: The pressure in the hydraulic system must be relieved. Unscrew the four screws on the filter cover and lift out the cover 1 and magnetic rod 5

Carefully clean the magnetic rod to remove any dirt particles. Remove the used filter cartridge 5 using the bracket. Vertically insert the new filter cartridge into the tank, using the bracket and press down lightly. Then place the bracket on the side on the tank ring.

Caution!

Ensure that the filter cartridge is vertically positioned in the tank.

Center the cover unit and bypass cage 4 on the filter element 6 and set it on top. When doing this, ensure that the gasket 3 is positioned correctly and is in good condition.

Note!

The filling hole of the hydraulic tank is equipped with a protective cylinder 7. This prevents objects from getting into the hydraulic tank. The protective cylinder can be removed from the filling hole, if required.

Note!

Each time you replace the filter element 6, also replace the pressure filter integrated in the servo oil unit.

5.10.5Servo oil filter

The pressure filter 10 is part of the servo oil unit 1 which is located on the rear of the hydraulic tank.

Note!

It is not permitted to clean the filter element. Change the filter element each time the filter housing is opened.

To replace the filter element:

The pressure in the hydraulic system must be relieved. Unscrew the filter housing 14 from pressure filter 11 and remove filter element 12

Clean the filter housing.

Oil the thread and sealing surfaces on filter housing 14 and on servo oil unit 1 as well as seal rings 13 and 15 with hydraulic oil.

Push the filter element 12 carefully onto the mounting stud 2.

Screw filter housing 14 on completely and tighten by hand.

Note!

5.10.6Servo circuit

When replacing the filter element 12, also replace the filter element seal ring 13 Danger!

The joysticks do not require special maintenance. Inspect the pipe network as well as connections on all components (pressure accumulator, pressure limiting valve, pressure filter etc.) regularly for leaks.

The pressure accumulator 10 (see Fig. 5-28) ensures that the servo circuit has enough pressure for a few movements, even after the Diesel engine has been shut down.

Before working on the servo circuit, the control pressure must be relieved as follows:

Place the attachment on the ground. Shut down the engine.

Operate both joysticks (with ignition key in contact position).

5.10.7Bleeding the hydraulic pump

Fig. 5-29 Hydraulic pump

After working on the pump or after changing oil in the hydraulic system, the hydraulic pump must be bled.

Loosen the fitting of the leak oil hose 1 slightly and allow the air to escape. When hydraulic oil flows out, retighten the fitting.

Before using the pump for the first time or after repairs or replacement, the pump housing must be filled with hydraulic oil via the same connection.

5.10.8Bypass oil filter (optional extra)

The bypass oil filter has the task of filtering fine dirt and water out of the hydraulic system.

Replace the filter element whenever the return-line filter is changed. The filter should always be changed every six months.

Note!

LIEBHERR strictly requires the use of bypass oil filters when environmentallyfriendly hydraulic oils are used.

1

2

3

Replace filter element: Switch off the engine.

Depressurize the hydraulic system. Remove screw 1 and remove cover 3

4

5

6

Slightly turn the old filter element 5 in a clockwise direction using the support straps and lift at the same time.

Wait until the oil has drained and then remove filter element 5. Catch any dripping oil using a suitable container.

Check the inlet and outlet of filter housing 6 for dirt residues and clean if necessary.

Take the new filter element 5 out of the packaging without removing the cardboard shroud around the filter element.

Note!

Damaged packaging may have resulted in the ingress of humidity which can limit the life of the filter element.

Ensure that the packaging of the new filter element has not been damaged.

Insert the new filter element 5

Fill filter housing 6 with the same hydraulic oil as the machine.

Clean cover 3 and fit a new O-ring 4.

Attach the cover 3 and fasten with screw 1. Tighten to a torque of 50Nm. Start the engine and check whether the bypass oil filter is tight.

5.10.9Servicing the hydraulic cylinder

5.10.9.1Checking the piston rod bearing

Bearing

Note

When a leak occurs on the piston rod bearing of a hydraulic cylinder (arrow), then the seal kit must be replaced by a LIEBHERR mechanic.

5.10.9.2Protecting the piston rods

5-32 Machine with piston rods retracted

When the machine is out of service for more than 4 weeks and particularly for transport by sea, the following measures must be taken:

Position or transport the machine in such a way that the piston rods are fully retracted.

Cover any exposed piston rods with a thick layer of acid free anti-corrosion grease.

For sea transport, check the preservation of the piston rods again after loading. Cover piston rods with anti-corrosion grease also if a cylinder is used with a low stroke for certain applications, and the piston rod is not regularly covered with hydraulic oil (e.g. cylinder on basic boom when working above ground).

Regularly check the condition of little moved hydraulic cylinders.

Changing the oil on components

5.10.10Replacing 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. :

5.11Changing the oil on components

5.11.1General 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.

5.11.2Swin gear - oil change

1 Drain valve

2 Drain hose

To drain the oil:

Remove the cap 4

3 Oil container

4 Cap

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

Changing the oil on components

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

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

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.

Check the wear on the multi-disk brake at least once a year. The wear on the multi-disk brake can be checked without removing the planetary carrier or disks (see Service manual). Check brake wear also in case of the following problems:

5.13Electrical system

5.13.1Notes for electrical system

Danger!

Danger of injury due to spark formation.

Avoid sparks and open flame when charging batteries or working on the batteries.

Always wear safety glasses and protective gloves.

correct function at regular intervals.

Burnt out fuses and bulbs must be replaced immediately after the cause of the defect has been rectified. Fix any problems, such as loose connections, chaffed wires or incorrectly attached clamps immediately.

Disconnect the batteries when working on the electrical system or when carrying out electric arc welding on the machine.

Danger!

Danger of injury due to spark formation. Disconnect the negative terminal (-) first and connect it last.

5.13.2Battery master switch

Caution!

Be especially careful with machines with built-in auxiliary heater. Turn the battery master switch only off when the auxiliary heater's after-run is completed.

Fig. 5-38 Battery master switch

Before starting any work on the electrical system, including welding work on the machine, switch the battery master switch to position 0

When washing the machine, cover the electrical components (particularly the alternator, generator, wiring, electronic components and transmitters) to prevent moisture penetrating.

When cleaning the engine with a water / steam jet, do not hit electric sensors such as oil pressure switches directly with water or steam.

Otherwise moisture could penetrate and lead to contact corrosion and the failure of the transmitters.

Oil pressure switches are not watertight due to the necessary membrane ventilation.

Note!

Battery can discharge if the machine is out of service for longer periods of time. Before a longer down time, switch the battery master switch to position 0 (off).

5.13.3Battery care

The battery must always be kept clean to ensure proper function.

Especially the pole ends and battery terminals A must be cleaned regularly and then covered with a thick layer of acid free grease (see Fig. 5-39).

Danger!

Bent rubber hoses of central degasification increase the risk of explosion! The hydrogen created in the batteries may not be allowed to build up in the battery compartment and must be able to escape through the rubber hoses. The hoses of the central degasification must be routed without kinks.

Check the condition of the hoses B regularly, especially after installing a battery (see Fig. 5-39).

The fluid level in the cells should be 10 to 15 mm above the top of the plate. Use only distilled water when refilling.

From time to time, use an acid tester C to measure the acid concentration.

When the battery is fully charged, the unit weight is 1.28 kg/l (31.5°Bé). If the acid tester displays a lower value, then the battery is more orless discharged and must be recharged, if necessary.

5.13.4Slip ring assembly (option)

Slip ring assemblies are sensitive to moisture. An oxide layer can form on the conductive surfaces, which restricts the flow of current. Electrical users in the undercarriage will no longer be supplied sufficiently with current, which can lead to malfunctions.

To prevent this, it is recommended that the following work is carried out every 500 operating hours.

Unscrew the lock nuts 1

Remove the slip ring housing 2.

Clean the oxidation off the slip ring assembly (use a cleaning spray if necessary).

Replace damaged (corroded) wire lugs.

Spray "Cramolin" contact spray on all slip ring elements.

Replace the housing 1

Fasten the housing 1 evenly with lock nuts 2

Heating system / heating and air conditioning system (option)

5.14Heating system / heating and air conditioning system (option)

5.14.1Fresh air filter

The air flow in the heating and air conditioning system is reduced when the fresh air filter is dirty, which frequently results in the system icing up or shutting down.

rking in dust intensive conditions. without these filters, since the heat exchanger will be blocked quickly.

Remove the reservoir of the windshield washing fluid and deflector 2 Remove the fresh air filter 1

Note!

Never wash the filter elements with hot water or a steam jet. If damaged or in a bad condition, replace the filter elements.

Blow out the fresh air filter 1 with compressed air or clean in cold or luke warm water.

Heating system / heating and air conditioning system (option)

5.14.2Heating system

If the heater remains off for an extended period of time (e.g. in summer), the water taps (see arrows) on the Diesel engine should be closed. Carry out the following maintenance work on the heating system annually before the start of the heating period: oolant circuit, the hose connections on the heat exchanger, the seals on the shut off valves and the hose clamps. anti corrosion fluid and antifreeze in the coolant.

To check the heat exchanger / evaporator: Check the fins on the heat exchanger 1 and evaporator 2 (air conditioning system) annually for damage. Blow out with compressed air if dirty. Align the fins, if necessary.

5.14.3Air conditioning system (option)

Switch on the air conditioning system for approx. 10 minutes every 2 or 3 weeks, regardless of the season.

Heating system / heating and air conditioning system (option)

During the operating period, the following maintenance work must be carried out every 500 operating hours:

To check the condenser:

If heavily contaminated, overpressure forms in the air conditioning circuit and the air conditioning system turns off automatically.

Remove cover 1

Check the condenser 2 for contamination.

If necessary, blow out the condensor 3 with compressed air from the front through the mesh guard 4 of the fan motors. Remove the fan motors, if necessary. Make sure that the condenser fins are clean.

To check the A/C compressor:

Tighten the mounting screws of the A/C compressor (see arrow) and retainer on the Diesel engine.

Check the condition of the compressor V-belt.

Heating system / heating and air conditioning system (option)

To check the dryer-accumulator unit:

With the Diesel engine running and the air conditioning system turned on, check the refrigerant level in the sight gauge a of the dryer accumulator unit 5

Note!

If there is insufficient refrigerant, the white floater ball 6 is at the bottom of the sight gauge.

If the cooling effect is diminishing, have the system refilled by a refrigeration technician.

Determine the degree of moisture of the desiccant in dryer accumulator unit 5

To do this, check the color of the indicator pearl 7 in the sight gauge a

If the pearl is blue, the degree of moisture in the air conditioning circuit is OK. If, however, the pearl is pink, then the dryer-accumulator unit is saturated with moisture.

Change dryer-accumulator unit 5 immediately.

Check the condition of the of dryer accumulator unit visually.

If you notice that the refrigerant collector is rusty or damaged (e.g. on the panel mounting, on the hose connection), replace the refrigerant collector (pressure tank).

In the last two cases and at least once a year, the dryer-accumulator unit 5 must be replaced by a technician trained in air conditioning systems.

The A/C circuit must be emptied, checked for leaks and refilled. Check the hose lines for abrasion, replace and, if necessary, retighten the hose connections.

Additional maintenance work:

The following maintenance work must also be carried out at least once a year by a technician trained in air conditioning systems:

Check the function of the fan motor M65.

Check the function of the air flaps in the heating / air-conditioning system.

Check the electrical connections for tight seating (good contact).

Check the electrical lines for abrasions.

Check the defrost thermostat B295 (for function, correct positioning and for damage).

Check the function of the pressure switch B294 on the dryer-accumulator unit 9 (see Fig. 5-46).

5.15Lubricating the machine

Note!

When lubricating the machine with a manual grease gun, the required effort is reduced significantly if the grease is pumped in slowly.

5.15.1Lubricating the swing gear

Lubrication is carried out at the grease bar. The grease bar is located under the swing platform. Lubrication must be carried out daily in multi-shift operation.

To grease the swing race a, use the manual grease gun to pump two strokes of grease into grease fittings 1 and 2

Lubricating the machine

A housing (see arrow) which surrounds the swing gear pinion provides a virtually sealed grease reserve for gear lubrication on the swing ring. Lubrication ensures partial replacement of this reserve.

For partial replacement of the grease reserve, pump 20 strokes of grease into grease fitting 3 with the manual grease gun.

5.15.2Lubricating the attachment

Each lube point on the attachment must be lubricated every 10 to 50 operating hours (depending on use and multi-shift, daily or for each shift).

5.15.3Lubricate steering knuckle bearing, oscillating bolt

Caution!

The steering knuckle mounts should not be over-greased. Grease each bearing with two grease strokes.

The bearing positions should be greased using a hand grease gun. Grease steering knuckle mounts A using the grease nipples.

Grease oscillating bolt B using the lubrication lines at the side, until clean grease exits from the bearing positions.

5.15.4Lubricating the digging tool / bucket tilt device

The lubrication points on the digging tool or change over lever / connector link must be lubricated regularly. The corresponding lube points are marked in red.

Lubrication of digging tool

In normal use, each lube point must be greased weekly until clean grease emerges on the corresponding bearing point.

In severe applications, for example when handling material that causes wear, when working under water or in multiple shifts, the lubrication must be made daily or for each shift.

5.15.5Lubricating the grapple (option)

The grapple must be lubricated regularly. The corresponding lube points are marked in red.

5-52 Lubrication of grapple

In normal use, each lube point must be greased daily or per shift until clean grease emerges on the corresponding bearing point. In severe applications, the lubrication interval should be shorted accordingly.

5.16Quick change systems

5.16.1Lubricate the mechanical quick change adapter (option)

The mechanical quick change adapter is not lubricated via the central lubrication system. The bearing points must be greased using the grease gun.

Fig. 5-53 Lubrication of mechanical quick change adapter

Grease the bearing points via the grease fitting with a grease gun.

Note!

If the mechanical quick change adapter is greased when the pin is extended, the hollow area between the locking pins fills with grease and the pins can no longer be retracted.

Make sure that the locking pins are retracted during the lubrication procedure.

5.16.2Hydraulic quick change adapter (option)

Lubricating the quick change adapter:

The hydraulic quick change adapter is not greased via the central lubrication system. The bearing points must be greased using the grease gun.

Grease the locking pins 1 via the grease fitting with a grease gun.

Note!

The hydraulic quick change adapter cannot be sufficiently greased if the locking pins are extended.

Make sure that the locking pins are retracted during the lubrication procedure.

Cleaning the strainer:

Quick change systems

The filter disc 12 in the fittings between the connecting hoses and the hydraulic cylinder must be checked for blockages and cleaned, if necessary, every 2000operating hours.

Remove the cover 20 and the screws 21 from the quick change adapter. Remove the fittings and hydraulic hoses from the hydraulic cylinder 10

Screw out the outer mounting assembly 13 using a suitable tool (eg. a tack).

Remove the filter disc 12, check it and clean or replace it, if necessary.

Place the filter disc 12 on the inner mounting assembly 11 and mount the outer mounting assembly 13

Connect the fittings and hydraulic hoses to hydraulic cylinder 10.

Attach the cover 20 with the screws 21 on the quick change adapter.

5.16.3LIKUFIX (option)

5.16.3.1Cleaning LIKUFIX

The LIKUFIX hydraulic coupling system is mostly maintenance-free. We recommend to clean the system at regular intervals and spray it with lubricant (see Service manual). This will prevent dirt adhering and icing up.

If the system is kept properly clean, the seals are very durable.

5.16.3.2Replacing the seal ring

Replacing the seal

If leaks occur at the coupler plugs (A, see arrows), replace the seal rings.

Use a screwdriver to push down the seal plate on the coupler plug and lift out the defective seal ring with a pointed object (B).

Press the new seal ring together and place it on the seal plate with open side down (C).

Press down the washer as far as the groove, place the screwdriver in the middle of the seal ring and move your hand away ( D).

Allow the seal ring to snap into the groove (E).

Remove the screwdriver (F).

The seal plate must move upwards. If necessary, press the seal ring down again until the seal plate is moveable.

5.17Parking and swing gear brake

Both the parking brake on the transmission and the swing gear brake are negative acting, wet multi-disk brakes.

They are vented hydraulically and are fully sealed and integrated in the transmission or swing gear.

Their usage purely as parking brakes makes them wear-free and therefore maintenance free.

5.18General Maintenance points

5.18.1Replacing wear parts

In addition to the normal maintenance and service work, which have to be carried out in the given intervals, the following repairs can also be made by the machine operator or maintenance personnel: the pipe and hose system and on connections of hydraulic components (but not on pressure relief valves which are sealed with a lead seal at the factory). lic lines and fittings on the hydraulic system can be replaced.

It should be noted that only original LIEBHERR spare parts are to be used. This is particularly true for hoses and hydraulic lines, which must be preassembled at the factory. For all other repairs, particularly when removing the counterweight, factory or dealer mechanics must be consulted.

5.18.2Replacing the teeth on the digging tool

Determine the degree of wear of the teeth visually.

With heavily worn teeth, considerably greater force will be required for the digging tool to penetrate the digging material. The teeth must be replaced in time to prevent damage to the tooth adapter.

Do not work with the machine if teeth on the digging tool are missing or are heavily worn.

To attach and remove teeth with wedge retainers:

Fig. 5-57 Replacing the teeth

Use a hammer and driver 1 to knock out the wedge 2 (A ).

Remove the old tooth.

Place a new rubber wedge retainer 3 on the tooth retainer (B).

Push the new tooth on the adapter.

Use the hammer to knock in the wedge 2 (C).

To attach and remove teeth with tension pin retainer:

Use a hammer and driver 1 to knock out the tension pin 2 (A).

Remove the old tooth.

Push the new tooth onto the adapter (B).

Knock in the tension pin 2 with the hammer (C).

5.18.3Welding work on the machine

Welding work on all main components serving for power transmission (such as the undercarriage frame, swing platform, attachment parts etc.) may only be carried out by the manufacturer or by an authorized workshop.

Disconnect the battery before starting any electric arc welding work on the machine.

Always disconnect the negative terminal (-) first and reconnect it last. Turn the battery master switch off!

Caution!

If high currents flow through the bearings or sealing elements, they could be burnt. Move the grounding cable of the welding tool as close as possible to the welding area, so that the welding current cannot flow over parts, such as the swing ring, joints, bearings, bushings, rubber elements or seals.

5.19Inspection and maintenance plan

Caution!

Careful maintenance can only be carried out when the machine is clean. In particular, visual checks such as crack testing are only possible on a clean machine. Clean the machine before you start maintenance work (see also the chapter

Note!

The daily maintenance work carried out by the equipment operator comprises a functional check of the brakes (slewing gear brake, service brake and parking brake), steering and the electrical and hydraulic systems. In addition, a daily inspection must be performed to check for leaks from the engine, hydraulic system, transmission and axles.

Diesel Engine

Check oil level and oil pressure in engine

Check coolant level and coolant temperature

Check air filter on maintenance display

Check and drain water separator on fuel filter

Drain off water and sediment in fuel tank

Inspection and maintenance plan

Maintenance by maintenance personnel (machine operator)

WORK TO BE CARRIED OUT

A 312 / A 314 / A 316 Litronic first and only interval repeat interval special interval every 250hours

Operating instructions

by authorized specialist personnel

Note first and only interval repeat interval

Empty dust collection container on air filter (shorten or extend interval as required)

Check and clean cooler, pressure relief valve, coolant hose, ventilator

Replace lubricating oil filter cartridge

Replace engine oil1)

Check oil-, cooling- and fuel system for leaks and its overall condition

Replace water filter cartridge (at least 1xyearly)

Check and set engine speed adjustment

Check anti-corrosion fluid / antifreeze in coolant (replace coolant every 2years)

Check condition and tension (using a testing device at operating temperature) of the V-belt (replace every 2 years)

Check / adjust valve play, replace valve cover seal

Check engine bracket and oil sump mounts, clamps etc.

Check flexible fuel leakage oil line (change at least every 2 years)

Check intake and exhaust system for leaks and verify its overall condition

Replace fuel fine filter cartridge (or as required)4)

Replace preliminary fuel filter cartridge (or as required)4)

Replace main air filter element (according to maintenance display / annually)

Replace air filter safety element (every thirdchange of main element / annually) Never clean!

Check clean-air line (during filter maintenance)

Check / adjust injection valves every 3000 op. hours (when performance diminishes)

Hydraulic System

Check oil level in hydraulic tank

Clean magnetic rod in return-line filter (daily during first 300op. hours)

Replace filter insert in return-line filter (first time at 500op. hours)2)

Replace filter element in bypass flow filter (every 250 op. hours for dust intensive applications)

Maintenance by maintenance personnel (machine operator)

WORK TO BE CARRIED OUT

A 312 / A 314 / A 316 Litronic first and only interval repeat interval special interval every 250hours

Replace filter insert on control oil unit

Check component mounts by authorized specialist personnel

Note first and only interval repeat interval

Clean hydraulic oil cooler (and as required)

Drain off water in hydraulic tank (when using environmentally-friendly fluids, max. 0.1% water content permitted, insert bypass flow filter, take oil sample)

Check hydraulic system for leaks and its corrent function

Check / adjust servo pressures, secondary pressures and pressure cut-off

Replace hydraulic oil in tank (or optimise interval using oil analyses)2), 3)

Replace ventilation and vent filters on hydraulic tank2)

Electrical System

Check indicator lights and display devices when switching on Check lighting

Check acid concentration and level, cable terminals and terminal posts on batteries, as well as all plug connections

Spray slip rings on slewing gear connection (if present) with Cramolin contact spray

Check function of entire system and its components

Slewing Gear Transmission

Check oil level and tightness against leaks

Check function and operation of slewing gear brake

Check transmission and oil motor mounts

Replace transmission oil (first time at 500op. hours)

Slewing Rim

Renew lubrication on gearing

Renew lubrication on ball race

Inspection and maintenance plan

Maintenance / inspection during

WORK TO BE CARRIED OUT

Operating instructions

by authorized specialist personnel Note interval repeat

AXLE TRANSMISSION

Check oil level and tightness against leaks

Check function of gear change and parking brake

Check transmission, oil motor and drive shaft mounts

Replace transmission oil (first time at 500op. hours)

Axles

Check oil level and tightness against leaks. Also check that wheel nuts are tight.

Check axle mounts

Lubricate steering knuckle bearings (weekly / monthly according to use)

Lubricate oscillating axle bearing (weekly / monthly according to use)

Replace oil from axle housing and planetary drive, front and rear (first time at 500op. hours)

Check wear on multi-disc brake (1xyearly or as required)

Steering

Check function and tightness against leaks

Check component and steering part mounts

OSCILLATING AXLE SUPPORT

Check function and tightness against leaks

Check cylinder mounts

BRAKE SYSTEM

Check system for leaks

Check function and operation

Check accumulator pressure and brake pressure as well as monitoring switches

Maintenance / inspection during operating hours

WORK TO BE CARRIED OUT

A 312 / A 314 / A 316 Litronic by maintenance personnel (machine operator) first and only interval repeat interval special interval every 250hours by authorized specialist personnel first and only interval repeat interval

CAB + HEATING

Check / refill washing fluid in windscreen washer system container

Check heating function (before start of winter)

Check heating system for leaks

Check door and window hinges and locks

Check function of water inlet valve. Check for dirt and clean if necessary

AIR-CONDITIONING SYSTEM

Regularly switch on air-conditioning system (at least 1x every twoweeks)

Check condenser for contamination, blow out if required

Check mounting screws and compressor drive belt

Check dryer-collector unit (moisture, filling and condition), replace if required (at least every 2 years)

Clean fresh air filter (at least 1 x monthly, weekly for dust intensive appliations)

Replace fresh air filter (shorten change interval for dust-intensive applications)

Check air-conditioning system mounting, hose connections and electrical contacts (at least 1 x yearly)

UNDERCARRIAGE + UPPERCARRIAGE + WORKING ATTACHMENT

Lubricate bearing points on working attachment

Visually check wear condition of teeth

Lubricate bearing points on undercarriage (depending on use; daily for multiple shift operation)

Check parts for cracks

Check ballast weight and tank mounts

Check that line and screw connections are tight

Check trim panel hinges, quick-release fasteners and gas pressure springs on hatches

Indicate appropriate use of equipment

Note