system

5.15.1Ambient air filter

Ambient air filter

If the ambient air filter is dirty, the air flow is reduced. This in turn affects its performance and can result in frequent icing or shut-down of the a/c system (optional equipment).

Never operate the machine without filter, even for short periods, as this might result in blockage of the heat exchanger.

The ambient air filter must be cleaned or replaced every 500 operating hours (shorten interval, if the machine is operated in a particularly dusty environment).

Remove the windscreen detergent tank and the deflector 2

Remove the ambient air filter 1.

Note!

Incorrect cleaning of the filter might damage it.

Never clean the filter elements with hot water of steam!

If the ambient air filter is damaged or in poor state, replace it.

Clean the ambient air filter 1 with compressed air or wash it with cold or tepid water.

5.15.2Heating system

5-45 Water taps on the diesel engine

If the heating remains switched off for a prolonged period of time (e.g. during the summer), close the water taps at the diesel engine (see arrows).

Every year at the start of the heating period, complete the following maintenance routine.

Check the entire coolant circuit for leakage.

Retighten the connections in the coolant circuit, the hose connections at the heat exchanger, the seals of the stop valves and the hose clamps.

The system may only be operated with coolant containing a suitable corrosion inhibitor and antifreeze agent.

Fig. 5-46 Combined heating-a/c system

Inspection of the heat exchanger

Check the fins of the heat exchanger1 and the evaporator2 (a/c system, optional equipment) for damage.

If they are dirty, clean them with compressed air.

If necessary, realign the fins.

5.15.3Air-conditioning system (optional equipment)

Switch on the a/c system every two to three weeks for about 10 minutes, irrespective of the season.

During the operating period, the following maintenance tasks must be carried out every 500 operating hours by a technician specialising in a/c systems:

–Testing of thermostat, blower and pressure switch

–Inspection of the electrical lines

–Testing of the condenser (if necessary: cleaning)

–Testing of a/c compressor

–Testing of dryer-collector unit and replacement, if necessary (minimum once annually).

For this purpose, the a/c system must be drained, inspected for leakage and refilled. Check the hose lines for chaffing and replace them, if necessary. If required, retighten the hose connections.

5.16Automatic lubrication of the machine

5.16.1Fully automatic central lubrication system (optional equipment)

If desired, the machine can be equipped with a fully automatic central lubrication system.

In such machines, the uppercarriage and the boom cylinder of the attachment do not need to be lubricated manually.

Depending on the actual equipment, the attachment can be connected fully, or partly to the central lubrication system. The connected components do not need to be lubricated manually.

The undercarriage, on the other hand, is not connected to the central lubrication system and must be greased manually.

1 Grease tank

2 Adapter (filling of grease tank with filling pump 9)

3 Lubrication nipple, filling of grease tank

4 Lubrication nipple for manual interim lubrication

5 Safety valve

6 Filling pump

7/8 LED green / red

The lubrication process is started automatically after a defined delay and is automatically halted when all bearing points are fully lubricated. No operator intervention is required in this process.

During the lubrication process, the switch S84 and the green LED 7 are on.

In the event of a fault, the switch S84 and the two LEDs 7 and 8 flash. Faults might be caused by:

–Blockage or kinking of the feed line (grease escapes at the safety valve 6).

–Proximity switch (or its supply cable) defective.

–High grease viscosity due to low temperature.

–Insufficient product in grease tank.

–Fault in motor power circuit.

Identify and eliminate the cause of the fault.

If required, and provided that the lubrication system is ready for operation, the operator can press the button S84 in the right control console to start an additional lubrication process.

If the lubricating pump is defective, the lube points connected to the lubrication system can be greased centrally with a lubricating pump at the lubrication nipple 4

Adding grease to the grease tank: Check the grease tank once weekly and add product, if necessary.

Note!

In order to prevent contamination and damage to the product, keep the grease tank closed.

Do not remove the lid of the tank to add product.

To add product to the grease tank, use the adapter 2

Insert the grease cartridge into the supplied filling pump 5, connect it to the adapter 2 and press the cartridge content into the tank.

If the filling pump 5 or the grease cartridge are not available, use a grease gun or a lubricating pump to fill the tank, connecting them to the lubrication nipple 3 After the grease tank has been refilled, complete an interim lubrication procedure.

Interim lubrication:

Automatic: Press the button S84

The central lubrication system is automatic started and stopped after a preset interval.

- alternatively -

Manual (with grease gun): Apply grease to the lubrication nipple 4

Continue the manual interim lubrication until grease escapes at the base of the boom cylinders.

5.17Manual lubrication of the machine

Certain parts of the working tools, attachments and the undercarriage are lubricated manually. The affected lubricating points are equipped with lubricating nipples.

Note!

We recommend using a grease gun, as it reduces the force required and ensures that the grease is squeezed in slowly.

5.17.1Central slewing gear lube point

The machine is equipped with a central lube point saving operators considerable time every day.

Lube points at the uppercarriage (slewing ring, slewing gear pinion) are permanently connected to the lubrication system.

5-48 Central lubrication nipple

The central lubrication nipple is located behind the right-hand door. The central lubrication requires approx. 3 cm³ of grease per working hour. For an average 8-hour day, the system thus distributes approx. 24 cm³ of grease in total A conventional hand grease gun applies at about 1.5 cm³ of grease per stroke. Lubrication with 24 cm³ of grease would thus require about 16 hand gun strokes. The required grease should be ideally added to the system every half day, or at least once per shift (i.e. every 8 to 10 hours): per shift, add about 16 hand gun strokes of grease through the central lubrication nipple.

- alternatively - twice per shift, add about 8 hand gun strokes of grease through the central lubrication nipple.

If it is not possible to press in grease, this is likely due to one of the following: –Blockage or kinking of the supply line

–High grease viscosity due to cold temperature. –Grease filter at the central lubrication nipple blocked Identify and eliminate the cause.

5.17.2Lubricating 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).

5.17.3Digging buckets / bucket tilting device

5-49 Lubricating bucket tilting device

The bucket tilting device and the digging buckets are not lubricated by the central lubrication system. The lube points of the digging bucket, switching lever and connecting link must be lubricated manually. The respective lube points are marked in red.

During normal operation, each lube point must be lubricated once per week. If the machine is operated under adverse conditions, the parts must be lubricated more frequently, for example once daily or once per shift.

Examples of adverse operating conditions:

–Multiple-shift operation

–Use in extremely abrasive material

–Frequent contact with water or corrosive substances

Lubricate the components with a grease gun until clear grease escapes at the bearing points.

5.17.4Attachments (optional equipment)

The attachments (e.g. grapple, quick-change adapter systems) must be lubricated manually. In grapples, the respective lubricating points are labelled. For normal operation, the grapple must be lubricated daily or once per shift. Other working tools must be lubricated at weekly intervals.

Machines operated under adverse conditions (e.g. in contact with water or corrosive substances) should be lubricated more frequently.

Examine the attachment to detect all lubricating nipples.

Lubricate the attachment, using a grease gun. Press in grease until clean grease escapes at the respective bearing point (unless instructed otherwise).

If the attachment is equipped with a rotator, the moving parts must also be lubricated. Lubricate the rotator (bearing, crown gear, pinion) using a grease gun, until clean grease escapes at the respective bearing point (approx. 2 lubricating strokes). If the rotator is not equipped with a separate lubricating nipple, apply grease to the crown gear and the pinion.

5.17.5Hydraulic 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 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.

5.17.6Mechanical quick-change adapter

The mechanical quick-change adapter is not lubricated by the central lubrication system. The respective bearing points must therefore be manually lubricated with a grease gun.

Lubricate the lube points through the lubrication nipple, using a grease gun.

Note!

If the mechanical quick-change adapter is lubricated while the bolt is extended, the cavity between the locking bolts is filled with grease, so that they cannot be retracted.

Therefore lubricate the system only, if the locking bolts are retracted.

5.18Couplings of the quick-change adapter systems (optional equipment)

5.18.1Hydraulic coupling

The LIKUFIX hydraulic coupling system and the multi-coupling system are equipped with hydraulic coupling plugs (see arrows). The coupling plugs are maintenance-free. We recommend cleaning the system regularly. This prevents caking of dirt and icing up in winter. With regular cleaning, the seals of the system have a long service life.

Cleaning:

Remove dirt and clean all coupling parts and sealing surfaces with a clean cloth and oil.

Changing seal ring:

Couplings of the quick-change adapter systems (optional equipment)

Caution!

The hydraulic lines are under pressure. Before changing the seal ring, depressurise the system using the joystick (switch off diesel engine, turn ignition key to contact position, operate the joystick).

In the event of leakage at the coupling plugs (A), change the seal rings. Hold down the seal washer of the coupling plug with a screwdriver and lever out the defective seal ring using a pointed tool (B).

Squeeze the new seal ring and place it with its open side facing downwards onto the seal washer (C).

Push the washer into the groove, place the screwdriver onto the centre of the seal ring and remove your hand (D).

Let the seal ring expand into the groove (E). Remove the screwdriver (F). The seal washer must move upwards.

If this is not the case, push the seal ring into the groove until the seal washer can move.

5.18.2LIKUFIX electric coupling

The LIKUFIX hydraulic coupling system is equipped with an additional electric coupling (e.g. for the operation of a magnet system). This coupling must be regularly inspected and cleaned.

Switch off the magnet system (if installed). Remove the working tool, if required.

Switch off the diesel engine.

Check the contacts for corrosion and wear (e.g. burn marks).

Clean the contacts of the electric couplings 1 and 2 with a dry cloth and apply contact spray (Cramolin), if necessary.

Check the electric couplings and the screwed connections for proper fixture.

Check the contacts of the top section 1 for play: it must be possible to push in the contacts against the spring force.

Check whether the seals at the contacts of the electric couplings (see arrows) are properly installed and undamaged. Repair any damage and replace defective parts.

5.19Travel and swing brakes

Both the travel as well as the swing brakes are spring applied, pressure released multi-disk brakes. They are vented hydraulically and are fully sealed and integrated in the travel or swing gear.

Their use purely as a parking brake makes them wear free and therefore maintenance free.

5.20General maintenance tasks

5.20.1Replacing wear parts

Apart from maintenance and care tasks that must be carried out at prescribed intervals, the following minor repairs can be made by the machine operator or a maintenance technician:

–Replacement of worn teeth on digging tool.

–Replacement of defective seals on pipe and hose lines and at connections of the hydraulic units (with the exception of the pressure-relief valves, which are factorysealed).

–Replacement of high-pressure hoses, hydraulic lines and screw connections of the hydraulic unit.

Only use original LIEBHERR spare parts. This applies in particular to hoses and hydraulic lines that must be factory-mounted.

All other repairs, and in particular the removal of the counter weight, must be carried out by authorised specialist technicians.

5.20.2Replacing teeth on digging tool

If the teeth are heavily worn, excess force is required to move the digging tool into the material to be excavated. This can lead to damage to the tooth adapters. Therefore replace worn teeth in due course.

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

U system:

Drive out the roll pin 2 using a hammer and mandrel 1 (A).

Remove the old tooth.

Place the new tooth on the adapter (B).

Drive in the roll pin 2 using a hammer (C).

Z system:

Remove the plug 1 from the square recess of the locking bolt 2 (A).

Turn the locking bolt with the square spanner 3 counter-clockwise (a - turn by approx. 30°).

Drive out the locking bolt from the opposite side (B).

Take off the tooth 4 from the tooth adapter 5 and remove the locking piece 6 (C).

Note!

Before mounting a new tooth, check the state of the locking bolt and locking piece. Replace any deformed or corroded parts.

Mounting teeth on digging tool - Z system

Insert the locking piece 6 into the recess of the tooth adapter 5 so that the flat locking piece side touches the tooth adapter (D).

Insert the new tooth into the tooth adapter.

Insert the locking bolt to the stop (E).

Turn the locking bolt with the square spanner -clockwise (b - turn by approx. 30°) (F).

The nose 2a of the locking bolt slides across the protruding part 6a of the locking piece and engages.

Insert the plug into the square recess of the locking bolt.

5.20.3Welded parts on the machine

All welding work on all main power-transmitting components (e.g. undercarriage frame, revolving deck, attachment parts, etc.) must be executed by the manufacturer or an authorised specialist workshop.

Before carrying out any arc welding work, disconnect the machine from the battery.

The negative pole (-) must be disconnected first and reconnected last. Also switch off the battery main switch!

Caution!

Bearings or sealing elements might be damaged (scorched) by high electric currents!

When carrying out welding work, connect the earth cable as close as possible to the welding point so that the welding current does not travel through machine parts such as the slewing ring, joints, bearings, bushes, rubber elements or seals.

Maintenance and inspection schedule

5.21Maintenance and inspection schedule

Note!

Careful maintenance is only possible, if the machine is clean. Especially visual inspections, e.g. for cracks can only be carried out properly on a clean machine. Therefore clean the machine thoroughly before starting any maintenance work (see also chapter "Safe maintenance of machine", subchapters "Cleaning" and "Crack inspection").

Note!

The daily maintenance tasks of the machine operator include a functional test of the brakes (slewing gear brake, chassis brake) and the electrical and hydraulic system. Also to be carried out is a daily visual inspection of the motor, hydraulic system and gearbox for leakage

Maintenance/inspection at operating hours

Work To Be Carried Out

Type 1038, 1042, 1043 by maintenance personnel (machine operator)

Initial and single interval

Repeat interval

Annually, at the start of the cold season When required

Diesel Engine

Check the oil level

Visual inspection (leakage, dirt, damage)

1) Change diesel engine oil together with authorised specialist technicians

Initial and single interval Repeat interval

Change oil filter insert (at least once a year)

Belt drive: Check the belt for wear or damage; check the belt tension and adjust it, if necessary (change belt every two years)

Check / adjust valve play, replace valve lid seal

Check intake and exhaust systems for general condition, fixture and leakage

Check oil pan, engine bearings, diesel engine brackets and clamps for proper fixture

3000 Check vibration dampers for deformation

RADIATOR

Check coolant level

Check cooling and heating systems for general condition and leakage

Maintenance/inspection at operating hours

Work To Be Carried Out

Type 1038, 1042, 1043 by maintenance personnel (machine operator)

Initial and single interval

Repeat interval

Annually, at the start of the cold season

When required together with authorised specialist technicians

Initial and single interval

Repeat interval

Check corrosion inhibitor and antifreeze agent concentration in coolant

3000 Change coolant (at least every 2 years)

Fuel System

Check water separator at the fuel pre-filter and drain off water, if necessary

Drain water and deposit from fuel tank

4) Check fuel system for leakage and general state

4) Change fuel pre-filter (also in the event of a drop in performance)

Change fuel fine filter

Bleed fuel system

Air Filter

Check underpressure indicator of the air filter

Clean dust removal valve of the air filter

Change main element of the dry air filter (according to counterpressure indication / annually)

Change safety element of the dry air filter (at every third main element change / annually) - do not clean or reuse!

Check clean air line (during maintenance of filters)

Electrical System Of The Diesel Engine

Check control device bearing for general condition

Check sensor devices and cable connections

DIESEL ENGINE - EXHAUST GAS SYSTEM WITH PARTICLE FILTER (optional equipment)

Drain off condensate at the condensate trap

Condensate trap: check and clean sintered metal filter, check connecting clamps for proper seat

Condensate trap: replace sintered metal filter

Clean particle filter and pre-filter; if required, clean before prescribed interval has lapsed

Maintenance and inspection schedule

Maintenance/inspection at operating hours

Work To Be Carried Out

Type 1038, 1042, 1043 by maintenance personnel (machine operator)

Initial and single interval

Repeat interval

Annually, at the start of the cold season

When required

Hydraulic System

Check oil level in hydraulic tank together with authorised specialist technicians

Initial and single interval

Repeat interval

Check degree of contamination of the bypass oil filter (special equipment); if required, change filter element

Clean magnetic rod in return filter (daily during first 300operating hours)

2) Replace filter insert in return filter

Replace filter cartridge in control oil unit

Check components for proper mounting

Check the hydraulic oil cooler for dirt; clean it, if necessary

Drain water from hydraulic tank (max. permissible water content for environmentally friendly fluids: 0.1%; insert bypass filter, take oil sample)

Check hydraulic system for leakage; complete functional test

Check / readjust servo, primary and secondary pressures

2), 3) Change hydraulic oil in tank (optimise interval by carrying out oil analyses)

2) Change breather filter on hydraulic tank

Electrical System

Check indicator lights and indicating devices upon start-up

Check lighting

Check acid density and level, wire terminals and terminal ports of the batteries, and all the plug connections

Spray slip rings of the slewing gear connection with Cramolin contact spray

Carry out functional tests of entire unit and all components

Slewing Gear Mechanism

Check oil level; check system for leakage

Carry out functional test of slewing gear brake

Check gearbox and oil motor for proper mounting

Change gear oil

Maintenance/inspection at operating hours

WORK TO BE CARRIED OUT

Type 1038, 1042, 1043 by maintenance personnel (machine operator)

Initial and single interval

Repeat interval

Annually, at the start of the cold season

When required

Slewing Ring

together with authorised specialist technicians

Initial and single interval

Repeat interval

Check mounting bolts for press fit; slewing gear pining meshing

Travel Gear

Check oil level; check system for leakage

Carry out functional test of travel brake

Check gearbox and oil motor for proper mounting

Change gear oil

Chassis

Visually check tension of chain; regulate, if necessary

Clean chain (after work)

Check base plates and tumbler wheels for proper mounting

Clean and lubricate slide faces of tensioning mechanism

Check idlers, support and running rollers for tightness

OPERATOR'S CAB + HEATING

Check / add detergent solution in windscreen washer tank

Treat rubber seals of the operator's cab with silicone or talcum powder

Treat rubber seals of the access doors in the uppercarriage with silicone or talcum powder

Check function of heating

Check heating system for leakage

Check door and window hinges as well as locks

Check water inlet valve for contamination, and clean, if necessary; carry out functional test of valve

AIR-CONDITIONING SYSTEM

Regularly switch on air-conditioning system (at least 1x every 14days)

Maintenance and inspection schedule

Maintenance/inspection at operating hours

Work To Be Carried Out

Type 1038, 1042, 1043 by maintenance personnel (machine operator)

Initial and single interval

Repeat interval

Annually, at the start of the cold season When required together with authorised specialist technicians

Initial and single interval

Repeat interval

Check condenser for contamination; blow clean, if necessary

Clean re-circulated air / fresh air filter; replace, if necessary; shorten interval if there is excessive generation of dust

Check compressor mounting bolts and drive belts

Check dryer-collector unit (humidity, fill level); replace, if necessary

Check evaporator unit; clean, if necessary

Check electrical lines for chafe marks; check plug connections

Complete functional test of excess pressure switch

Check cooling performance

Replace dryer-collector unit every 12 months; also check cooling circuit for leakage and change coolant and refrigeration oil.

Every 12 months, employ a refrigeration technician to carry out a functional test of the air flaps and the defrost thermostat

UNDERCARRIAGE + UPPERCARRIAGE + WORKING ATTACHMENTS

Lubricate bearing points, using the semi-automatic central lubrication system; exception: not required in units with fully automatic central lubrication system (optional equipment)

Check grease level in the central lubrication system tank; add grease, if required

Lubricate bearing positions (undercarriage and working attachments)

Lubricate daily when required due to type of use and/or shift operation

Inspect teeth for wear

250 Check parts for cracks

250 Check counter weight and tank for proper mounting

Check lines and screwed connections for proper fit

Check panelling hinges, quick fasteners and gas pressure springs of the caps

Instruct operators in the proper use of the equipment

Instruct the operator on how the machine must be lubricated according to the lubricating chart and make him aware of potential operator errors

Hydraulic Quick Change Adapter

Carry out a functional test of the visual and acoustic warning systems