5Maintenance

5.1Servicing the machine safely

General safety instructions

nel.

given in the operating instructions for repeat tests / inspections. It is imperative that a suitably equipped workshop is available in order to carry out maintenance work.

ven at the end of these operating instructions defines precisely who is required / permitted to carry out what work. Jobs listed as daily / weekly work may be carried out by the machine's driver or maintenance personnel when they have received appropriate instruction. The remaining work may only be carried out by specialist personnel with appropriate training.

the manufacturer. Original replacement parts are always guaranteed to meet these criteria.

rrying out maintenance work. Avoid the wearing of rings, wrist watches, ties, scarves, open jackets, baggy clothing etc... There is a risk of injury from, for example, getting caught up or being drawn in. Protective goggles, safety helmets, safety shoes and gloves, reflective vests and ear protection etc. are required for specific jobs.

diesel engine while the diesel engine is running.

Persons with pacemakers should not approach within 20 cm of the running diesel engine.

Do not touch voltage-carrying parts on the electrical connection of the individual solenoid injection pumps (Unit Pumps UP) while the diesel engine is running. nance work.

pair work. Designate persons in charge of supervision.

maintenance work on the machine on level, firm ground with the working equipment set aside and the engine switched off.

every maintenance locations on the uppercarriage, is when the uppercarriage is aligned with the undercarriage so that the sprockets locate at the back-end. The ladder situated on the undercarriage only corresponds with the uppercar- ons during maintenance and repair work. ents, of the hydraulic hoses and of the counterweight must be replaced after every removal. work, they must be immediately reinstalled and checked at the end of the work. arly when working under the machine, early visible position on the control panel. Pull out the start key and shut off the main battery switch. ated heaters only in well ventilated areas. Before operating these units, check ventilation. applicable local regulations.

Cleaning

he machine before starting maintenance or repair work and pay particular attention to connections and screw fittings. Do not use aggressive cleaning products and use lint-free cleaning cloths.

chine for the first two months after initial set-up of the machine (or after repainting).

other cleaning materials: ons and the rim bearing to prevent water or steam entering the bearing points. or steam may not be permitted to enter. Electric motors, electrical components, control boxes, plug connections and air filters are particularly at risk. into contact with hot cleaning products during cleaning work. The fire extinguisher could start. observe following recommendations: er than 20 inches neutral cleaning agents such as customary car shampoos diluted to 2 or 3 percent maximum chafing and damage. ons and the rim bearing to displace any water or cleaning products that may have entered.

Corrosion protection

ne must be inspected and renewed at regular intervals. For further information, refer to the Maintenance manual for corrosion protection.

Field of view

evitably reinstalled and correctly adjusted before the initial set-up of the machine.

correctly adjusted.

ing operation or when travelling.

ge on the machine, the sight conditions must be maintained. These conditions must otherwise be checked according to ISO 5006. must always be clean.

dangers due to a restricted field of view are minimized, particularly for machines with an operating weight which is superior to 40 tons.

Crack testing

erated carefully, there is a possibility of individual cases of overloading occurring, which could lead to cracks or loose connections. The machine should therefore be checked regularly for cracks, loose connections or other visible damage to maintain operational safety.

is essential that the machine is kept clean and cleaned regularly.

nance plan: supported, on firm, horizontal substrate, with the equipment in longitudinal and cross direction for variable loads. Current accident prevention regulations must be adhered to. axle and gearbox storage, support outriger, lower slewing ring support with tower and slewing ring. per slewing ring support, cab suspension, mounting for slewing gear and counter weight. ttachments, e.g. boom, stick, quick change adapter, digging tool and grapple. ns and pin connections, ascents, ladders and mounting elements. ally. If a crack is suspected, the dye penetration test should be carried out as a crack test on areas which do not have good visibility, such as the ring bearing support, in order to increase testing safety. diately. Welding work on load-bearing parts of the earth-moving machinery, loading devices and transport devices may only be carried out by trained specialist personnel and only in accordance with the accepted rules of welding engineering. In case of doubt, contact the LIEBHERR customer support service to discuss suitable remedies.

Welding, drilling, firing and grinding work

undercarriage, uppercarriage, equipment this rule is neglected, the warranty is voided. d grinding work on the machine with express authorization. Clean dust and combustible materials off the machine and its surrounding areas before welding, drilling, firing or grinding. Ensure adequate ventilation. Risk of fire or explosion. move the negative terminal first and reconnect it last. pair should be done on components which may contain inflammable gases (welded counterweight, components must be previously and sufficiently ventilated with pressurized air to avoid all fire or explosion hazard point, so the welding current will not run through parts like the swing ring, rotary connection, gears, bushings, bearings, hinges, joints, hydraulic hoses, sockets, rubber parts or seals.

Process materials

chemical substances, observe the appropriate current safety regulations for the product. ement parts are disposed of in a safe and environmentally acceptable manner.

(Risk of burning and scalding).

Repair work

parts. Use devices which are suitable for this purpose and which have sufficient load capacity. When replacing single parts and larger subassemblies, carefully secure them on lifting devices so that they do not present a risk. Only use suitable and correctly functioning lifting devices and load takeup devices with adequate load capacity. Do not stand or work under swinging loads.

rying capacity.

Wear work gloves when working with wire cables.

him. forms which are appropriate for the job. Do not use machine parts as climbing devices if they are not designed for this purpose.

When working at height, wear a harness to prevent falling.

For further information, see section "Maintenance anchor points" or contact Liebherr customer service.

rms and ladders are free of dirt, snow and ice.

carefully, so that pneumatic cylinders do not hit their stops, because this could cause mechanical damages.

operate is securely supported before working (e.g. replacing teeth). Prevent metal touching metal when doing this.

ly totally released the pretension of the chain tensioning unit. securely supported with appropriate supports.

jeopardize stability and prevent metal touching metal while doing this. trained specialist personnel.

connect the upper structure to the chassis using stop bolts. ment.

pressure can penetrate the skin.

ment, switched off the engine and depressurized the hydraulic system. After switching off the engine, with the start key in contact position and with the safety lever down into its lowest position, you must operate all pilot control devices (joystick and pedals) in all directions in order to reduce the actuating and dynamic pressures in the work circuits. You must then reduce the internal tank pressure as described in these operating instructions.

Electrical system

Have all faults, such as loose connections, blown fuses and lamps and clogged or abraded cables rectified by personnel.

e event of malfunctions in the power supply.

electrical personnel or by trained personnel under the supervision of an electrician in accordance with electrical regulations.

second person is available to operate the emergency-off or the main switch and overvoltage release. Cordon off the working area with a red and white safety chain and a warning sign. Only use insulated tools.

voltage, briefly disconnect the supply cable at earth and electronic devices such as capacitors using an earthing rod.

that they are off circuit, earth them and then disconnect them briefly. Insulate adjacent live parts.

electric arc welding on the machine. First disconnect the negative, then the positive pole. When reconnecting, proceed in the reverse order.

Hydraulic accumulator

personnel.

lic accumulators can cause serious accidents.

you must reduce the pressure in the hydraulic system (hydraulic system including hydraulic tank), as described in these operating instructions.

accumulator.

The hydraulic accumulator can be damaged by heat penetration and can be made to rupture by mechanical working. RISK OF EXPLOSION!

SION if oxygen or air is used.

purpose of use before installation.

on hydraulic accumulators. Ensure that this marking remains visible.

Hydraulic lines and hoses

work on hydraulic lines and hoses!

ible damage and any possible damage must be immediately checked for leakage. else.

and burns.

oad, lines and hoses are subject to the natural aging process. This restricts their duration of use. and unauthorized load are the most common causes of failure.

ing to lines and hoses at place of use must be adhered to. temperatures, frequent movement cycles, extremely high pulse frequencies, multiple shift usage).

the following are found during inspection: ure formation in hose material); whether in a unpressurized or pressurized state or on bends e.g. sheath separation, blistering; ings which reduce the tightness of the fittings or the hose / fitting connection; tly. Do not mix up the connections. pressure hoses, the screws from the half-clamps or full flange must always be attached to both hose ends and should only be tightened afterwards. ssure lines and hoses with bent fittings, the side with the bent fitting must always be tightened first and then the side with the straight fitting tightened afterwards. attached and tightened subsequently. , covers and protective devices are properly fastened. Doing this will prevent vibration and damage during operation. hoses or parts. prox. half the exterior diameter of the hose is recommended. The distance should not, however, be less than 10 to 15 mm. stick), check before initial start-up that there are no chafing areas in the entire area of movement.

Disposal

Disposal of the machine of the machine are disposed of correctly after the service life in accordance with all applicable national, regional or local regulations for waste disposal and environmental protection. uids from all components before disposal.

Disposal of gas tanks and pressurized tanks ds disposed of in an applicable recycling point. trained air-conditioning and refrigeration technician. ts and operating fluids manufacturer for disposal. of in an applicable recycling point.

Disposal of fuel, lubricants, operating fluids and consumables perating fluids in applicable containers before disposal.

5.2Maintenance access doors

5.2.1Overview

Caution!

For oil coolers access, use an external safety device (e.g. a ladder or stepladder).

Caution!

Access doors can close accidentally and trap the operator or maintenance personnel.

When you have opened the access doors, latch them using the retainer.

Access doorLockAccess to:

Electric motor coverGas pressure spring, auxiliary mechanical retainer

5.2.2Oil cooler access

Remove the screws 4 Turn the stairs 5 access to the oil cooler.

5.2.3Door

To stop the access doors from moving unintentionally (e.g. due to wind), open them fully and allow the door lock (see arrow) to latch in.

5.3Maintenance anchor points

You must always access to the machine through the access provided. For installation, maintenance and repair work, it is possible that the service personnel is obliged to remove fall protection elements such as handrails to get access to or to remove some parts of the machine.

Danger!

Risk of falling when fall protection elements are removed.

The machine has anchor points for safe installation, maintenance and repair work. Even if appropriate fall-arrest equipment is installed to the anchor points, fall-arrest equipment cannot prevent falls. Common sense and fall hazard awareness are important safety precautions for work that is done from above the ground.

5.3.1Approved anchor points

There are four types of approved anchor points on the machine:

The welded and the drilled anchor points have a specific label (see § "Signs on the machine"). To be easily identified, the welded and the drilled anchor points are also painted in blue (in white if the excavator is blue).

The lifting points given in the section "Transport drawings" can also be used as anchor points.

The horizontal middle bar on handrails can also be used as anchor point (as illustrated below). The used handrail must have at least two vertical posts.

Welded anchor points

Drilled anchor points

5.3.2Use the anchor points

Before you use an anchor point, always do a check of its condition. If an anchor point has been used to arrest a fall, or if you are not sure about its safe condition, do not use this anchor point until it has been inspected and, if necessary, tested by a competent person.

Always use the anchor points with applicable fall-arrest equipment.

Use a harness with a maximum arrest force of 6 kN.

Only attach to approved anchor points.

Never attach more than three persons to a lifeline.

Never attach more than one person to another type of approved anchor point. If several persons must attach themselves to the machine, they must use different anchor points.

Never use an anchor point to attach parts or material.

Persons who must work with fall-arrest equipment must be specially trained. All the anchor points and the tightening of the handrails mounting screws must be examined by authorized specialist personnel. For maintenance intervals, refer to the control and maintenance chart.