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. ularly 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.

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

e 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

fully, 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.

the event of malfunctions in the power supply.

pment may only be carried out by skilled 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.

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.

natural aging process. This restricts their duration of use.

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 15mm. 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. 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 of access doors

The machine has access doors for maintenance. The locks integrated in the handles must be unlocked before starting to drive.

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 doors

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 6kN. 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.

5.4Lubricants and operating fluids

5.4.1General information on changing lubricants and operating fluids

Note

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

After each oil change or refill, check the level in the relevant unit.

Note!

Adhering to regulations for lubrication, level checks and operating material changes 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.

For preference, drain off oil when it is at operating temperature.

Ensure that old oils are collected and disposed of in an environmentally acceptable manner using the removable oil filter cartridges.

Danger!

When checking and changing lubrication and operating materials, 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 electric motor switched off.

Whenever you reach into the electric motor compartment, always secure the cover and side doors against accidentally falling back or closing. Do not smoke and avoid naked flame.

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

5.4.2Lubricating chart

SymbolDisplay

Hydraulic system

Swing gear

Travel gear

Lifetime sealing interspace (optional)

Splitterbox

Greasing for bearings of electric motor

Grease / Swing ring teeth

Grease

Windshield washer

Check oil level

Oil change

First oil change

Oil analysis

(1) If filled with COB-2, COB-3 or COB-4 gear oil

(2) If filled with COB-1 gear oil

(3) Refer to the section «Lubricating and operating material specifications»

5.4.3Lubricant chart

Operating manual

Lubricants and operating fluids

DesignationMediumSymbolClassificationViscosityQuantity*

Swing ring roller bearing races and general lubrication points Lubricating grease

Swing ring teethLubricating grease

See section "Lubricating and operating material specifications".

See section "Lubricating and operating material specifications".

213 L

20 L

Track rollerAGIP DIESEL SIGMA S30 ISO 10016 x 2700 cc

Cold climate conditions: AGIP BLASIA ESB 220

Carrier rollerAGIP BLASIA 220ISO 2204 x 3350 cc

Cold climate conditions: AGIP BLASIA ESB 220

Idler WheelVARIAX - EP80W902 x 3300 cc

Cold climate conditions: AGIP BLASIA ESB 220

Hinges, joints, locksEngine oil----

Rubber seal on doors and trim panels Silicon spray or talc chart

Tab.

*The given quantities are only guidelines. Check fluid level after each change or refilling.

5.4.4Operating material chart

DesignationMediumSymbolQuantity* climate conditions)

Coolant mixture for cabin heater standard climate conditions).

Windshield washer system Commercially available windshield washer fluid or denatured alcohol

12,8 l. in container. 60 l. in full system.

30 L

*The given quantities are only guidelines. Check fluid level after each change or refilling.

5.4.5Service trap

For safety reasons and ease of maintenance, you must drain and fill the oil of the connected components only through the couplings of the service trap, which is installed below the machine uppercarriage.

These components also have oil drain valves. Refer to the oil change procedures of these components.

Lubricants and operating fluids

Description

Refer to the sections below for couplings adapters to use with each component.

Primary components couplings

SymbolComponentWiggins adapter (with maximum flow)

Swing gear To fill with oil: ONC2A (50 l/min)

To drain the oil: OSP2 (50 l/min)

Banlaw adapter (with maximum flow)

To fill with oil: Aus 34A (100 l/min)

To drain the oil: Aus 41A (100 l/min)

SplitterboxC-1807 (50 l/min)Aus 32W (100 l/min)

Hydraulic oil6000B12 (100 - 200 l/min)Aus 29W (100 l/min)

Couplings of the centralized lubrication system

Depending on the machines, the centralized lubrication system can be different. The system that is installed on your machine is given by:

Fig. 5-7 Configurations A and B of centralized lubrication systems

A Configuration "SKF / Lincoln" 1 Manual valves (2x)

B Configuration "Beka" 2 Gauges (2x)

Obey the applicable section given below.

Couplings of the "SKF / Lincoln" configuration (A) SKF / Lincoln" devices

SymbolComponentAdapter (with maximum flow)

Principal greaseWIGGINS OSP2 (15-30 L/min)

Pmini 100 bar

Grease for swing ring teeth WIGGINS 6000B12 (15-30 L/min)

Pmini 100 bar

Couplings of the "Beka" configuration (B) Beka" devices

SymbolComponentWiggins adapter (with maximum flow)

Principal grease6005A12 (15-30 l/min)

Grease for swing ring teeth

Pmax 160 bar

6000B12 (15-30 l/min)

Pmax 160 bar

1 with two gauges 2

Banlaw adapter (with maximum flow)

GTXNBN (31 l/min)

Pmax 160 bar

GTXRB (31 l/min)

Pmax 160 bar

In this case, you must also obey the procedure that follows to disconnect the couplings.

When the related pumps are stopped:

Open the two manual valves 1

On the two gauges 2, check that the hydraulic pressure is zero.

Lubricants and operating fluids

Disconnect the couplings. Close the two manual valves 2

Operate the service trap

The service trap is manually moved up and down from the ground level. As a help way, you can use the special lever 1, which is installed on the access ladder.

One more lever is installed in the cab elevation.

Move the service trap into lower position

1 Service trap lever Caution!

Risk of damage.

Only move down the service trap when the uppercarriage and the undercarriage are aligned.

1 Service trap lever

2 Locking hook

3 Handle

Put the service trap lever 1 into the locking hook 2

Push the lever 1 up to unlock the hook 2. You can also do it with your hands. The service trap moves down.

In option, the machine can have an opening rope. In this case, you must pull on it to unlock the hook 2

Lower the service trap fully with the handle 3. You can use your hands or the lever 1.

Lubricants

Move the service trap into upper position

Caution!

Risk of damage.

Make sure that the position of the locking hook 2 is correct. The locking hook 2 must be aligned with the vertical axis.

When the service trap gets its top position, the warning light H70 on the control board goes off.

Caution!

For safety reasons, the machine can only be operated if the service trap is locked in its top position. This means that the swing and travel movements remain locked.

This safety measure can be bypassed as long as the button S122 on the control board is activated.

Grease control

Grease control box

The open service trap lets also access to the control box E1043 which monitors the levels of attachment and swing ring greases.

Lubricants and operating fluids

E1043 Control box for greases levels

H58 Swing ring grease

H59 Attachment grease

When a grease level is maximum: The related warning light H58 or H59 goes off.

Grease warning light

The warning light H109 comes on if there is a fault of the grease system. It is installed next to the cab elevation door.

H109 Grease warning light

5.5Lubricating and operating material specifications

Liebherr-Mining Equipment Colmar SAS only gives approval for the Liebherr-branded lubricants and operating materials given in this manual.

For other lubricants, fluids or greases, Liebherr-Mining Equipment Colmar SAS gives technical specifications for their related applications. It is the responsibility of the lubricant, fluid or grease supplier to check, justify and ensure to the owner of the machine that the lubricant, fluid or grease obeys these specifications sustainably.

5.5.1Lubrication for the electric motor

Refer to the Manual of safety, installation and maintenance of the electric motor manufacturer.

5.5.2Hydraulic oil specifications for LIEBHERR Mining excavators

Hydraulic oils must meet the requirement outlined below (depending on temperature range).

Non-compliance with these requirements shall void all warranty and liability by LIEBHERR.

LIEBHERR recommends maintaining the hydraulic oil to a cleanliness level that meets contaminant code 20/18/15 according to ISO 4406.

Maximum water content of hydraulic oil : <0,1%.

Caution!

According to the oil type used for the hydraulic system, the fans speed regulation must be set specifically ("STANDARD", "COLD" or "EXTRA-COLD").

STANDARD" at delivery.

livered with an arctic kit, it is set to "COLD" at delivery.

Before first start of the excavator or if an oil type change is done afterwards, the fans speed regulation setting must be checked and corrected if necessary. Contact LIEBHERR Customer Service.

Lubricating and operating material specifications

LIEBHERR oils for hydraulic system

Requirements

A Ambient air temperature

B Operating range

C Extra-cold start range if excavator fitted with operating Liebherr arctic kit (with warm-up instruction)

Fans speed regulation settings

LIEBHERR oilfans speed regulation setting

Liebherr Hydraulic Plus"STANDARD"

Liebherr Hydraulic Basic 68"STANDARD"

Liebherr Hydraulic Basic 100"STANDARD"

Liebherr Hydraulic HVI"COLD"

Liebherr Hydraulic Plus Arctic"EXTRA-COLD"

Engine oils for hydraulic system

Requirements copyright © Liebherr-Mining Equipment Colmar SAS 2020

A Ambient air temperature

B Operating range

C Extra-cold start range if excavator fitted with operating Liebherr arctic kit (with warm-up instruction)

Caution!

Minimum ambient air temperature for extra-cold start depends on oil type and brand and equals to oil pourpoint temperature +5 degrees K.

Recommended and approved are mineral engine oils, which conform to one of the following specifications:

APIACEAMercedes-Benz

CK-4E7228.1

CJ-4E5228.3

CI-4E3228.5

CH-4E2

CF-4

Fans speed regulation settings

CF Engine oilfans speed regulation setting

SAE10W30"STANDARD"

SAE10W40"STANDARD"

SAE20W-20 (ISO VG68)

"STANDARD"

SAE15W40"STANDARD"

SAE30 (ISO VG100)

SAE 10W (ISO VG46)

Hydraulic oils for hydraulic system

Requirements

"STANDARD"

"EXTRA-COLD" or "COLD"

Lubricating and operating material specifications

A Ambient air temperature

B Operating range

C Extra-cold start range if excavator fitted with operating Liebherr arctic kit (with warm-up instruction)

Caution!

Minimum ambient air temperature for extra-cold start depends on oil type and brand and equals to oil pourpoint temperature +5 degrees K.

Hydraulic oils must contain dispersant and detergent additives and conform to one of the following specifications:

Diniso

51524-2 (HLP, HLP-D)ISO 11158 (HM)

51524-3 (HVLP, HVLP-D)ISO 11158 (HV)

Additional requirements:

Test/RequirementStandard/ReferenceRequired level/ Performance

Shear stabilityDIN 51350-6 CEC L 45-A-99

Fans speed regulation settings

KRL/C < 15%

Hydraulic oilfans speed regulation setting

ISO VG68"STANDARD"

ISO VG100"STANDARD"

ISO VG46"COLD"

ISO VG32"EXTRA-COLD"

Warm-up procedure

The black bar C indicates that the ambient temperatures are maximum 20 °C below the operating range B

In the event of a cold start at an ambient temperature included in range C, the following warm-up instruction applies to the hydraulic oil:

1. Start the electric motor. Carefully activate the working hydraulic circuits. Operate a hydraulic cylinder (Stick for example) and move them to the stop quickly and many times. After approx. 5 minutes, start the travel hydraulic circuits.

Warm-up duration: approx 10 minutes

For temperature below the limits A :

2. Preheat hydraulic oil in the tank before starting the electric motor.

Biodegradable hydraulic oils

The use of biodegradable hydraulic oils must in any case be discussed with LIEBHER MINING EQUIPMENT COLMAR SAS.

Do not mix biodegradable hydraulic oils from different suppliers and never mix with mineral oils.

Do not use vegetable oils as they do not possess the necessary thermal stability. Depending on the temperature range, LIEBHERR recommends its poly-alpha-olefin (PAO, HEPR) oils, that are biodegradable according to CEC-L-103-12 (21 days, > 60%, primary decomposition):

Liebherr Hydraulic Plus or Liebherr Hydraulic Plus Arctic

If these oils are not available locally or if further specifications are required, use one of the following oils (before choosing an oil, contact our Customer Service):

Fully saturated synthetic ester-based oils, HEES

Depending on the temperature range, the viscosity grade of the HEES oil must conform to the above specifications for hydraulic oils.

Caution!

LIEBHERR recommends to limit the use of HEES oils to areas where HEES oils are mandatory by local regulations.

Lifetime of components made out of rubber material such as hoses, seals, compensators might be reduced while using HEES oils!

When mixing ester-based biodegradable hydraulic oils with mineral oils, there is a risk of agressive chemical reactions, which might damage the hydraulic equipment.

Hydraulic oil selection for cold climate conditions

When a LIEBHERR Mining excavator works under cold climates conditions, in any case, the appropriate arctic kit must be installed.

Oil must match the above prescription for engine oils or hydraulic oils. ature must be at least 5 K below the minimal air ambient temperature.

> 160°C (recommended > 200°C).

The operating range of the arctic oil depends on the ambient air temperature and must be checked as follow:

+50°C (oil temperature) must be over 16 cst.

In this case, the fans speed regulation "EXTRA-COLD" must be selected.

+60°C (oil temperature) must be over 16 cst. In this case, the fans speed regulation "EXTRA-COLD" or "COLD" must be selected.

+70°C (oil temperature) must be over 16 cst. In this case, the fans speed regulation "COLD" must be selected.

Contact LIEBHERR Customer Service for additional questions about oil selection.

Oil mixing

In principle, oil mixing between two different oil types must be avoided. Mixing two different oil types leads to an unknown lubricant with resultant unknown physical copyright © Liebherr-Mining Equipment Colmar SAS 2020

Lubricating and operating material specifications properties (viscosity, pourpoint, flash point, ageing behaviour, lubricity, reaction with additives...).

However, if mixing is absolutely necessary, respect the following maximum mixing proportions: or LIEBHERR oils with mineral oils, or hydraulic oils with mineral oils, or two different mineral oils together, or two different hydraulic oils together: max. 10% max. 2% or mineral oils or LIEBHERR oils:

Hydraulic oil change intervals

Oil changes at pre-set intervals (mineral oils and PAO oils only)

This procedure is applicable only for mineral oils and PAO oils. If you use HEES biodegradable oil, refer to the next section.

A Mineral oils and PAO oils hOperating hours

Liebherr recommends that you sample the hydraulic oil every 500 operating hours (refer to the section "Condition monitoring with oil analysis"). Change the hydraulic oil every 2000 operating hours.

Oil changes at optimized intervals

This procedure is applicable for mineral oils, PAO oils and HEES biodegradable oils.

A Mineral oils and PAO oils

B HEES biodegradable oils h Operating hours

1 First oil sample

2 Second oil sample

3 Next oil samples at regular intervals

You can extend the oil change intervals (up to 6000 operating hours and possibly even more) as long as the properties of the oil are satisfactory. Get a sample of the new hydraulic oil.

If you use mineral oil or PAO oil, you must sample the hydraulic oil every 500 operating hours after the first 1500 operating hours.

If you use HEES biodegradable oil, you must sample the hydraulic oil every 250 operating hours.

Change the hydraulic oil immediately if the results of the analysis are not satisfactory (refer to the section "Condition monitoring with oil analysis").

5.5.3Swing and travel gear oils

Note!

For a given machine operating temperature range, and if different viscosity grades are approved according to the following specifications, always choose the lubricant with the highest viscosity grade.

Caution!

Gears flushing is necessary when switching from mineral oil to synthetic oil. Use new oil to flush the gear when switching from mineral oil to synthetic oil. Flushing with cleaning fluid or Diesel fuel is not permitted.

Use gear oil meeting following viscosity classes and specifications (depending on the ambient temperature):

Lubricating and operating material specifications

* COB-1: Gear oil according to DIN 51517, part 3, CLP-HC(1) (1) HC / Synthetic carbon hybrid (poly-alpha-olefin PAO)

TEST / REQUIREMENTSTANDARD / REFERENCE REQUIRED LEVEL / PERFORMANCE

Relative scuffing load-carrying capacity A/8.3/90DIN ISO 14635-1>14

Relative scuffing load-carrying capacity A/16.6/140DIN ISO 14635-1>12

FVA-FZG micro-pitting load capacity

GT-C/8.3/90FVA Information sheet no. 54/I-IV

GT-High

FE-8 roller bearing wear tests 7.5/80/80 and 7.5/100/80DIN 51819-3Pass (excellent)

FLENDER AG approval-Approved

Tab. 5-4

FVA = Forschungsvereinigung Antriebstechnik e.V. ("Research association for drive technologies")

FZG = Forschungsstelle für Zahnräder und Getriebebau der TU München ("Gear Research Center of the Technical University of Munich")

** COB-2: Gear oil according to DIN 51517, part 3, CLP

TEST / REQUIREMENTSTANDARD / REFERENCE REQUIRED LEVEL / PERFORMANCE

FVA-FZG micro-pitting load capacity GT-C/8.3/90FVA Information sheet no. 54/I-IV

GT-High

FE-8 roller bearing wear tests 7.5/80/80 and 7.5/100/80DIN 51819-3Pass (excellent)

FLENDER AG approval-Approved

Pour point temperatureISO 3016VG220: TPour point < -15°C

VG320: TPour point < -15°C

VG460: TPour point < -10°C

VG680: TPour point < -5°C

Tab. 5-5

*** COB-3: Gear oil according to API classification GL5

TEST / REQUIREMENTSTANDARD / REFERENCE REQUIRED LEVEL / PERFORMANCE

API classificationGL 5-

Scuffing load capacity FZG test A/8.3/90DIN ISO 14635-1>12

MIL-L2105 B/C/D-

MAN342 type M1-

Mercedes Benz235.0-

ZF FriedrichshafenTE-ML 05A, 16C, 17B, 19B, 21A -

Tab. 5-6

**** COB-4: Gear oil according to API classification GL5

TEST / REQUIREMENTSTANDARD / REFERENCE REQUIRED LEVEL / PERFORMANCE

Tab. 5-7

**** COB-4: Gear oil according to API classification GL5

API classificationGL 5Scuffing load capacity FZG test A/8.3/90DIN ISO 14635-1>12

MIL-L2105 D, PRF-2105EMAN342 type N-

ZF FriedrichshafenTE-ML 05A, 07A, 16D, 21A -

5.5.4Splitterbox oil

Use gear oil with viscosity classification SAE 90 or SAE 80W90 and meeting specifications API-GL-5 and MIL-L-2105 B, C or D.

5.5.5Lubricating grease

The machine has two lubrication systems: ing ring bearings, the attachment bushings and the swing gear bearings

For each of these systems, use grease that meets the specifications that follow. Specifications for standard applications (ambient temperature of more than -20°C)

Specification

MethodUnit

Swing ring bearings, attachment bushings, swing gear bearings

Swing ring teeth Temperature range-°C-20 to +120 NLGI grade--2

Lubricating and operating material specifications

Specification

Greases which use calcium simple soap as thickener are not permitted.

Grease selection for cold climate conditions grade must be adapted. variation over the year, copyright © Liebherr-Mining Equipment Colmar SAS 2020 entralized lubrication system must be tested at minimum ambient temperature of the application.

For application below -20°C: applications.

(below -20°C) and are mandatory for operations below -40°C.

Additional requirement:

Grease mixing

When the grease is changed from one type of grease to another, the basic recommendation is to remove all the old grease from the system. However, the full removal from the system is not possible especially in the swing ring and in the swing gear bearings.

The compatibility of two different greases is not given and can cause catastrophic lubrication failures. Lubricating greases made of different thickener base must never be mixed together. Not only the thickener type, but also the basic oil and the additives treatments have to be considered. The compatibility of greases should be evaluated according to ASTM D6185. Furthermore, a written statement of the lubricant supplier must justify greases compatibility.

5.5.6Other lubricants

Refer to the table that follows for other lubricants.

Contact spray for slip ringsCramolin Lubricant for pistons, piston nuts and piston bearing installations on the hydraulic cylinders

Special anti-corrosive material for installation areas of sealing elements on hydraulic cylinders

Anti-corrosion grease for open piston rods (cylinders that do not move often or transportation)