5Maintenance

5.1Safety instructions

5.1.1General safety instructions

ied out by trained expert technicians. spections as contained in this operating manual.

op is available to perform these tasks, and note the designated qualifications of the personnel responsible for each inspection.

allowed to carry out which jobs. The machine operator (and his staff) are allowed to carry out certain jobs, but other jobs must be carried out only by qualified and trained staff. rements set forth by the manufacturer. This is always ensured with original spare parts. Spare parts that do not meet the technical requirements of the manufacturer might impair the safety and proper operation of the machine.

addition to a protective helmet and safety boots, for certain jobs protective goggles and gloves are also necessary.

om 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 manual.

maintenance operations, especially when working under the machine. Remove the ignition key and set the main battery switch to position 0. required torque specification.

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

5.1.2Checking for cracks

, depending on application, job site, duration of use and conditions of use. The different load conditions result in different service lives for various machines components. This could lead to cracks and loose connections, particularly on load-bearing parts. This applies particularly to machines used in material handling or industrial applications or for machines with special equipment, such as demolition excavators. To ensure that operating safety is maintained, the machine must be checked regularly for cracks, loose connections or other visible damage.

keep the machine clean and to clean it regularly.

schedule.

tions with the machine supported, on firm and level ground.

slewing ring seating with tower and slewing ring. cylinder, upper slewing ring seating, cab bearing, mounting of slewing gear and counterweight.

e.g. boom, stick, quick change adapter, digging tool and grapple. and pin connections, steps, ladders and mounting elements.

spected or is in areas which are not easily visible, such as the slewing ring seating, then the dye penetration procedure should be used to check for cracks.

ately. Welding on load-bearing parts of earth moving machines, material handling and transport units may only be made by certified welders in accordance with acceptable welding practices. Contact LIEBHERR Service to discuss suitable measures.

5.1.3Welding

LIEBHERR. Prior to any welding, cutting or grinding, clean the machine and surrounding area to remove dust and flammable materials.

5.1.4Fuels, lubricants and process chemicals

emical substances, always observe the applicable safety regulations for the corresponding product. disposal of operating and service fluids as well as exchange parts. scalding).

5.1.5Repair

fting devices with sufficient load carrying capacity. When replacing parts or large sub-assemblies, use appropriate and functioning lifting devices and adequate load carrying capacity to insure safe movement during installation. Never stand or work under suspended loads.

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

platforms.

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

Wear a harness when working at great heights. Keep handles, steps, railings, platforms, and ladders free of dirt, ice and snow. the machine is properly supported. Never use metal-on-metal support. equipment unless it has been properly and securely supported. ways that any shifting weight will not endanger the stability of the machine and avoid metal to metal contact. specially trained expert personnel.

and secure the uppercarriage to the undercarriage with the locking pin.

to detect leaks. Wear work gloves.

diesel engine and relieving the hydraulic system. After the diesel engine has been turned off, you must move all pilot controls (right handed joystick and pedals) into all directions to reduce the control pressure and the dynamic pressure in the work cycles. Then release the pressure in the tank, as described in this operating manual.

5.1.6Electrical system

All defects, such as loose connections, burnt out fuses and bulbs, burnt or damaged wires or cables must be repair ed immediately by an electrician or specially trained personnel. voltage systems.

connect the supply cable to the ground to discharge any stored energy. short circuit them. Insulate adjacent, current carrying parts. out any arc welding work on the machine.

5.1.7Pressure accumulator

ergy and operate at high pressures. Only specially trained personnel may work on pressure accumulators. operating manual prior to working on ahydraulic accumulator.

mechanical work on them.

burning. application before use.

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

5.1.8Hydraulic hoses and lines

ecked every two weeks for leaks and visible damage. Damaged parts must be replaced immediately. Remember that escaping high pressure oil can penetrate skin. Escaping oil can also cause fires.

process. For that reason, their service life is limited. and impermissible use are the most frequent causes of failure.

ranges of permitted use can shorten the service life (for example in high temperatures, frequent work cycles, extremely high impulse frequencies, multi shift operation).

inspection: and cracks); under pressure or not under pressure, or in bends (e.g. separation of layers, blisters or bubbles); allation instructions; ich reduce the strength of the fitting or the hose / fitting connection; h reduces function and strength; y, observe correct connection points. pressure hoses, always attach the screws of half clamps or full flange on both ends of hose first and then tighten. end with the bent fitting first when tightening the flanges, then the end with the straight fitting. ntre of the hose may only be installed and tightened thereafter. ps, covers and protective devices are properly mounted. This prevents vibration and damage during operation. structures is prevented. the outer hose diameter to the other parts is recommended. The distance should not be less than 10 to 15mm (1/2 inch). able parts (e.g. from boom to stick), check for hose interference and kinking over the complete range of motion.

5.1.9Cab protection (FOPS)

For certain machine applications LIEBHERR offers optional cab protection systems of various designs. These systems consist of a full length FOPS (falling objects protective structure) or a top guard and front guard to protect the operator's cab and windscreen area from falling objects (for example rocks or debris).

The full length FOPS wraps around the operator's cab, is mounted to the uppercarriage and is a stand-alone system.

The top and front guards are either bolted individually or in combination to the cab structure. In that case the operator's cab is also part of the cab protection system and is subject to the following instructions.

or example welding, cutting or drilling) any kind are prohibited without the expressed, written approval of LIEBHERR.

5.2Access points for maintenance

5.2.1Uppercarriage

No.Access pointAccess to:

1Engine bonnetDiesel engine, radiator

2Engine bonnetDiesel engine, radiator, control valve block, control oil unit

3BonnetCompensation vessel of cooling system

4Hydraulic tankReturn filter, breather filter

5Lubrication boxGrease tank, pump unit and compressed air system components of central lubrication system

6Engine compartment doorDiesel engine, hydraulic pumps

7Engine compartment doorBypass oil filter

8Battery compartment doorBatteries, battery main switch, dry air filter, compressed air system components of central lubrication system

9Radiator doorRadiator

10Fuel tankTank lid

The machine is equipped with several access doors for maintenance. Some of the access doors are secured with locking handles or screws. For fast intervention in the event of an emergency, the locks in the handles must be opened prior to starting the machine.

Caution!

Access doors might inadvertently close and cause injury to persons. After opening the access doors, lock them in position, using the holder.

In order to prevent inadvertent movement of the access doors (e.g. by wind), they must be fully opened and locked (arrow) with the locking mechanism.

Open the locks 1, open the bonnet and fold it up. Secure the bonnet with the holder 2

Caution!

All bonnets are held in place with gas pressure springs. Older gas pressure springs might become weak, so that the bonnet might close inadvertently. Therefore always secure the open bonnet with the locking mechanism 2

5.2.2Bottom

3

4

Some of the drain valves of the units cannot be reached from the engine compartment. They are however accessible through openings in the base of the uppercarriage. To access them, remove the respective cover plate and secure it again after the maintenance task is completed.

If necessary remove the cover plates and replace them after completion of the maintenance tasks

5.2.3Undercarriage

1 Refuelling system control device 2 Clutch drain hose

3 Compressed air connection

The service unit s located to the side of the tower superstructure and is accessible from the platform. Several connections are combined:

1. Refuelling system control device: fuel connection, control unit and electrical connection (see chapter "Refuelling system").

2. Drain hose connection: In the following chapters, a drain hose is referred to, used for the draining of lubricants and other media. We recommend connecting one end of the drain hose to the respective unit and the other to this coupling point.

The line ends in the undercarriage where you should place a collecting vessel of suitable dimensions to collect the drained off substances.

3. Compressed air connection: An external compressed air compressor can be connected at the undercarriage. This line connects the platform to the compressor.

5.2.5Electric slewing crane (special equipment)

5.2.5.1Operating instructions

The slewing crane is designed for the movement of loads during repair and maintenance work on the machine. Any other use, for example the pulling of loads, is deemed improper.

Proper use includes compliance with the instructions in the operating manual and the inspection and maintenance schedules.

5.2.5.2Commissioning, testing

Before commissioning the slewing crane, the operator must have it approved for use according to the applicable statutory regulations. In certain countries, these regulations might require that the crane be inspected and tested at specific intervals, and these regulations must be complied with.

The enclosed crane test log must be properly completed to document the inspections and tests that have been carried out.

5.2.5.3Power source

The power source of the crane (mains power, generator on the platform) must meet the following requirements: lation monitored frame)

5.2.5.4Operation

During machine operation, the slewing crane must be in parking position and the crane trolley must be secured. Do not start the machine while working with the

Danger!

Incorrect or improper use of the slewing crane can lead to serious injury or even death.

Switch the machine off and tilt the safety lever upwards before operating the slewing crane.

Never allow anyone to remain in the danger zone near and under suspended loads.

Preparing slewing crane for operation:

Take the connecting cable from the storage box and connect it to the power source.

Take the control unit from the storage box and position it so that you can see the crane while operating the control unit. Release the crane brake locking mechanism.

Turn the mains switch to position ON

Release the crane trolley.

Moving the crane to its parking position:

Turn the basic boom towards the crane brake.

Engage the locking mechanism of the crane brake. Secure the crane trolley: Fully retract the crane trolley and secure the load lift hook with the endless sling and the shackle to the crane tower.

Lift the chain and tighten it slightly.

Turn the mains switch to OFF and secure it with the padlock, if necessary. Switch off the power source and disconnect the power cable. Stow away the connecting cable and the control unit in the storage box.

Operating slewing crane:

AEmergency-stop

BLifting chain (2-stage operation)

CLowering chain (2-stage operation)

DCrane trolley forward

ECrane trolley back

FSwivelling right (2-stage operation)

GSwivelling left (2-stage operation)

For detailed information, refer to the operating manual of the crane manufacturer.

5.2.6Mechanical slewing crane (special equipment)

5.2.6.1Operating instructions

The slewing crane is designed for the movement of loads during repair and maintenance work on the machine. Application example: Lifting fuel tank nozzle onto the uppercarriage to refill the fuel tank. Any other use, for example the pulling of loads, is deemed improper.

Proper use includes compliance with the instructions in the operating manual and the inspection and maintenance schedules.

5.2.6.2Commissioning, testing

Before commissioning the slewing crane, the operator must have it approved for use according to the applicable statutory regulations. In certain countries, these regulations might require that the crane be inspected and tested at specific intervals, and these regulations must be complied with.

The enclosed crane test log must be properly completed to document the inspections and tests that have been carried out.

5.2.6.3Operation

During machine operation, the crane must be secured to the railing. Do not start the machine while working with the slewing crane.

Danger!

Incorrect or improper use of the slewing crane can lead to serious injury or even death.

Switch the machine off and tilt the safety lever upwards before operating the slewing crane.

Never allow anyone to remain in the danger zone near and under suspended loads.

Operating slewing crane:

Lift or low the cable by turning the hand crank to lift or lower the cable. Move the slewing crane by hand to the desired position.

Securing slewing crane:

Swivel the slewing crane across the railing. Attach the load lift hook with the endless sling to the railing. Lift the cable and tighten it slightly.

Releasing slewing crane: Release the cable.

Remove the load lift hook from the endless sling. For detailed information, refer to the operating manual of the crane manufacturer.

5.2.7Attachment points for fall-arrest equipment

The machine must always be accessed through the access and climbing aids provided.

For installation, maintenance and cleaning work, persons might need to access parts of the machine that forces them to stand outside the railings and designated access areas.

As there is a danger of falling, persons must always use fall-arrest equipment secured to the attachment points provided.

This also applies to persons that walk on the machine in areas where there is insufficient protection against falling from railings (e.g. cleaning of the operator's cab windscreen and roof).

Abseiling from the machine is only possible with suitable fall-arrest equipment and the necessary skills. Persons who must carry out work that requires abseiling must be trained in the use of fall-arrest equipment.

The attachment points at the machine are clearly identified with signs (see Fig. 5-11). An attachment point must only be used to secure one person at a time. If several persons must attach themselves to the machine, they must used different attachment points.

5.3Cleaning machine

The machine should be cleaned before carrying out any maintenance or repair work. In particular, the connections and screws should be cleaned of oil, fuel and residue of cleaning agents.

Note!

High-pressure water jet cleaners (steam cleaners) can damage the coating. Do not use high-pressure water jet cleaners during the first two months after commissioning (or after recoating). Observe the prescribed safety distances.

Before cleaning the machine:

Before cleaning the machine with water or with a steam cleaner (high-pressure water jet cleaner), carry out the following tasks to protect the equipment against penetrating water.

Lubricate all bearing points, bolt connections and the slewing ring; if necessary, use the central lubrication system to do this.

Cover or seal all openings that must be protected against penetrating water for safety reasons (particularly at risk of damage are electric motors, electric components, switch cabinets, plug connections, measuring sensors and air filters).

Cleaning:

Use flint-free cleaning cloths.

Do not use aggressive detergents or flammable liquids.

When cleaning the engine compartment, ensure that the temperature sensor of the fire alarm and extinguishing systems (if installed) are not accidentally brought into contact with the hot cleaning solution,

After cleaning:

Remove all seals and covers.

Check all fuel, engine oil and hydraulic lines for leakage, loose connections, chaffing and damage.

Repair any defects without delay.

Lubricate all bearing points, pin connections and the slewing ring to remove any water that might have been penetrated.

If required, renew the preservation layer (anti-corrosion protection) on components and surfaces.

5.4Care for rubber components

The service life of rubber seals can be prolonged by treating them with a rubber care product.

Clean and regularly treat the rubber seals on doors and panelling elements with a care product. This helps prevent premature wear and protects the rubber seals during the cold season.

Recommended care products: Silicone, talcum powder, deer tallow

5.5Fuels, lubricants and process chemicals

5.5.1General information

Observe the instructions for lubricants and process chemicals. Lubricate the machine and change the oils at the prescribed intervals. For more information, see lubrication chart and inspection and maintenance schedule.

Keep workplaces for these activities clean. This enhances the service life and reliability of the machine.

All work on the machine must be carried out while it is standing on firm and level ground.

Switch off the diesel engine, remove the ignition key and set the battery main switch to position 0 (OFF).

Clean lubricating nipples before adding grease.

Clean all filling points and the area around them before opening the caps and screws.

The oil should be changed while it is at operating temperature.

After each oil change or refilling, check the fill level in the respective unit (the specified fill levels are guide values).

Collect old oil and chemicals in suitable containers and dispose of them according to the applicable statutory regulations.

Fuels,

5.5.2Filling volumes, lubricating chart

5.5.2.1Recommended lubricants

Central lubrication system, lube points on machine and attachment

Universalfett 9900Lubrication system of slewing gearLiebherr spray paste-Hinges, joints, locksEngine oil--

* = guide values

5.5.2.2Recommended fuels and chemicals

* = guide values copyright by

5.5.2.3Lubricating chart

SymbolDescription

Diesel engine, check oil level

Gearbox, check oil level

Hydraulic tank, check oil level

Carry out first oil change

Change oil

Lubricate machine

Lube point

Medium filling point

Observe operating manual

5.6Lubricants and fuels

5.6.1Diesel fuels

Minimum quality requirement

Approved diesel fuels in line with DIN EN 590, ASTM D 975 1-D/2-D

Maximum sulphur content5000 ppm1)

Viscosity at 60 °C460 µm

Minimum cetane number45

Tab. 5-2

Minimum quality requirement

Do not mix diesel fuel with fuel additives.

5.6.2Engine oils

Liebherr recommendation

Description

Liebherr Motoroil 5W- 30

Liebherr Motoroil 10W-40

Liebherr Motoroil 10W-40 low ash2)

Tab. 5-3 Liebherr recommendation

1) The sulphur content of the fuel determines the change interval in dependence on the quality of the engine oil.

2) For machines with diesel particulate filters, use low ash engine oil (LH-00-ENG3A LA).

Minimum quality requirement

Specification

LH-00-ENG3A

LH-00-ENG3A LA

Tab. 5-4 Minimum quality requirement

If engine oils from other manufacturers are used, information on the change intervals must be obtained from the respective manufacturer or supplier.

5.6.2.1Adverse factor

Adverse factors affect the change interval of the engine oil.

Adapt change interval of the engine oil.

Adverse factors are:

The sulphur content of the fuel determines the change interval in dependence on the quality of the engine oil.

Sulphur content of fuel LH-00ENG3A Liebherr Motoroil 5W-30

Up to 15 ppm 1000h2000h

15 ppm to 300 ppm500h1000h

300 ppm to 2000 ppm500h500h

2000 ppm to 5000 ppm250h250h

5.6.3Coolant

5.6.3.1Requirement

For Water Used

Make sure that water used meets following requirements: (WHO) from 2006.

5.6.3.2Corrosion

Liebherr recommendation

Description

Manufacturer

DCA 4 (Diesel Coolant Additives 4)Fleetguard, Cummins Filtration

Caltex XL Corrosion Inhibitor ConcentrateChevron Texaco

Chevron Heavy Duty Extended Life Corrosion Inhibitor Nitrite Free (ECLC)

Chevron Texaco

Havoline Extended LIFE Corrosion InhibitorChevron Texaco

Total WT SupraTotal, Paris

Tab. 5-6 Liebherr recommendation with 50:50 mixing ratio

5.6.3.3Anti-freeze

Liebherr recommendation

Type

Description

ConcentrateLiebherr Antifreeze OS Concentrate PremixA) Liebherr Antifreeze OS Mix

Tab.

Liebherr recommendation

Up to -50°C40% water 60% anti-freeze and corrosion protection agent

Up to -37°C50% water 50% anti-freeze and corrosion protection agent

Tab.

A) Premix= premix (50% water and 50% anti-freeze and corrosion protection agent)

Minimum quality requirement

See global Liebherr specificat

If coolant from other manufacturers are used, information on the change intervals must be obtained from the respective manufacturer or supplier.

5.6.4Hydraulic oils

Liebherr recommendation

Liebherr mineral oil

15 to 55°CLiebherr Hydraulic Basic 100

10 to 45°CLiebherr Hydraulic Basic 68

-20 to 40°CLiebherr Hydraulic HVI

Liebherr-PAO3) biodegradable

-25 to 45°CLiebherr Hydraulic Plus

-40 to 30°CLiebherr Hydraulic Plus Arctic

Tab. 5-9 Liebherr recommendation

3) PAO= poly-alpha-olefin

Minimum quality requirement

See global Liebherr specificat

If hydraulic oils or filters from other manufacturers are used, information on the change and replacement intervals must be obtained from the respective manufacturer or supplier.

5.6.4.1Oil analysis

Normal application (Oil analysis optional)

Liebherr mineral oil

Liebherr Hydraulic Basic 68

Liebherr Hydraulic Basic 100

Liebherr Hydraulic HVI

Dust intensive application Normal

Every 250h, at least once a year

Every 1000h, at least once a year

Eco-friendly application (oil analysis mandatory)

Liebherr-PAO biodegradable

Liebherr Hydraulic Plus

Upon handover, then every 250h, at least once a year

5.6.4.2Filter replacement

Upon handover, then every 1000h, at least once a year

Liebherr bypass filter (Option)4)

Liebherr bypass filter (option) integrated in return filter4) application Normal intensive

Liebherr breather filterEvery 500h, additionally at every hydraulic oil change

If necessary, every 2000h

If necessary, every 2000h

Every 1000h, additionally at every hydraulic oil change

Every 2000h, additionally at every hydraulic oil change

5.6.4.3Oil change

Without oil analysis With oil analysis5)

Liebherr mineral oilEvery 3000hEvery 6000h

Liebherr Hydraulik Basic 68

Liebherr Hydraulic Basic 100

Liebherr Hydraulic HVI

Liebherr-PAO biodegradable Every 4000h6) Every 8000h

Liebherr Hydraulik Plus

Liebherr Hydraulik Plus Arctic

Tab. 5-12 Oil change

5)Change oil after negative oil analysis.

6) For eco-friendly applications, oil analysis is mandatory.

5.6.5Axle oil

Note

Machine with Kessler axles LT-D!

Use gear oil Liebherr Gear Basic 90 LS or gear oil in line with specification API GL-5 and MIL-L_2105 D.

Liebherr recommendation

Tab. 5-13 Liebherr recommendation

Minimum quality requirement

Specification

API: GL-5

MIL-L: 2105 D

ZF: TE-ML 05C, 05D

Tab. 5-14 Minimum quality requirement

If axle oils from other manufacturers are used, information on the change intervals must be obtained from the respective manufacturer or supplier.

5.6.6Gear oils

Gear oils specified in the chart are not suitable for following transmissions: Liebherr recommendations

-30 to 50°CLiebherr Gear Badic 90 LS

-35 to 50°CLiebherr Gear Plus 20W-40

-30 to 50°CLiebherr Gear Hypoid 90 EP

-25 to 50°CLiebherr Hypoid 85W-140 EP

-40 to 50°CLiebherr Syntogear Plus 75W-90

Tab. 5-15 Liebherr recommendation

Minimum quality requirement

Specification

API: GL-5

MIL-L: 2105 D or E, PRF-2105 D or E

Tab. 5-16 Minimum quality requirement

Adhere to device specifications on ZF approvals.

If gear oils from other manufacturers are used, information on the change intervals must be obtained from the respective manufacturer or supplier.

5.6.7Transmission oils

Liebherr recommendation

Description

Liebherr Motoroil 10W-40

Tab. 5-17 Liebherr recommendation

Minimum quality requirement

SAE viscosity class Specification

10W-40ACAE E4

Tab. 5-18 Minimum quality requirement

If gear oils from other manufacturers are used, information on the change intervals must be obtained from the respective manufacturer or supplier.

5.6.8Pump distributor gear oils

5.6.8.1Machine without pump distributor gear oil cooler

Liebherr recommendation

-25 to 50°CLiebherr Hypoid 85W-140 EP

-30 to 50°CLiebherr Gear Basic 90 LS

-30 to 50°CLiebherr Gear Hypoid 90 EP

-40 to 50°CLiebherr Syntogear Plus 75W-90

Tab. 5-19 Liebherr recommendation

Minimum quality requirement

Specification

API: GL-5

MIL-L: 2105 D or E, PRF-2105 D or E

Tab. 5-20 Minimum quality requirement

If gear oils from other manufacturers are used, information on the change intervals must be obtained from the respective manufacturer or supplier.

5.6.8.2Machine with pump distributor gear oil cooler

Liebherr recommendation

Ambient temperature Description

5 to 50°CLiebherr Hypoid 85W-140 EP

-5 to 50°CLiebherr Gear Basic 90 LS

-5 to 50°CLiebherr Gear Hypoid 90 EP

-20 to 50°CLiebherr Syntogear Plus 75W-90

Tab. 5-21 Liebherr recommendation

Minimum quality requirement

Specification

API: GL-5

MIL-L: 2105 D or E, PRF-2105 D or E

Tab. 5-22 Minimum quality requirement

Make sure the following conditions are met:

If gear oils from other manufacturers are used, information on the change intervals must be obtained from the respective manufacturer or supplier.

5.6.9Energy recuperation cylinder oils

Liebherr recommendation

Description

Tab. 5-23 Liebherr recommendation

Minimum quality requirement

See Liebherr specification for energy recuperation cylinder oils.

If energy recuperation cylinder oils from other manufacturers are used, information on the change intervals must be obtained from the respective manufacturer or supplier.

5.6.10Greases

Liebherr recommendation

Ambient temperature Description

From -20°CLiebherr Universalfett 9900

From -55°CLiebherr Universalfett Arctic

Tab. 5-24 Liebherr recommendation

Minimum quality requirement

Thickener Shelf life Specification

Soap-based (lithium complex At least every 3 years

Pumpable in line with KP 2 K (DIN 51502)

VKA welding force: 2300N (DIN 51350/4, ASTM D 2596)

For R984: VKA welding force: 5500N (DIN 51350/4, ASTM D 2596)

Tab. 5-25 Minimum quality requirement

5.6.11Windscreen washer fluid

Liebherr recommendation

Liebherr recommends commercially available windscreen washer fluid with antifreeze.

Minimum quality requirement

Use mixture of water and denatured alcohol.

5.6.12Lubricants and care products for electrical and mechanical systems

Liebherr recommendation

Application

Product

Contact spray for slip ringsCramolin

Lubricant for pistons, piston nuts and for mounting piston rod bearings on hydraulic cylinders

Special corrosion inhibitor for mounting recesses of sealing elements on hydraulic cylinders

5.7Diesel engine

Danger!

Gleitmo 800

Rostilo Trap CFX

Risk of burns from hot engine oil! Avoid skin contact with hot oil or parts containing oil. When changing the engine oil or the oil filter cartridges, proceed with great caution.

The maintenance tasks for the diesel engine are described in detail in the enclosed operating manual of the engine manufacturer (Cummins). The information in this document complements this operating manual, referring specifically to the operating conditions of the diesel engine in Liebherr machines.

5.7.1Checking the oil level

copyright by

Ensure that the machine is in a horizontal position. Switch off the diesel engine. Wait a few minutes until the engine oil has collected in the oil pan. Pull out the dip stick and clean with a clean cloth. Insert the dip stick to the stop. Pull out the dip stick again and check the oil level. The oil level must be between the min and max marks. If necessary, add engine oil until the level reaches the max mark.

5.7.2Changing engine oil

Preparation:

Ensure that the machine is in a horizontal position. The engine oil must be warm (increased fluidity). The diesel engine can be accessed from the engine compartment. The oil pan and the oil filter cartridges can be accessed through an opening at the bottom of the upper carriage.

Remove the cover plate of the diesel engine and replace it after completion of the maintenance tasks.

Draining off engine oil:

3

2

4 valve protect the V-ribbed belt against escaping engine oil. Open the filler neck 3

Remove the cover cap from the drain valve 1 on the oil pan. Screw the drain hose 2 to the drain valve of the oil pan.

Collect the engine oil in a suitable container. Disconnect the drain hose and replace the cover cap of the drain valve.

Replacing oil filter cartridges:

5-15 Oil filter cartridges

The oil filter cartridges are located behind the fuel filters and can be accessed from the bottom.

Loosen and remove the oil filter cartridges 4 using a strap spanner. Clean the sealing surfaces of the filter bracket. Apply oil to rubber seal rings of the new oil filter cartridges. Screw in the new oil filter cartridges until the seal rings touch the filter head.

Tighten the oil filter cartridges by hand by 1/2 to 3/4 revolutions, using the oil filter strap spanner.

Adding engine oil:

Add engine oil through the filler neck 3 until the oil level reaches the upper mark (max) on the dipstick. Seal the filler neck.

Start the diesel engine and check the oil pressure. Switch off the diesel engine after 2 to 3 minutes. Check the oil level again and add engine oil, if necessary.

5.8Cooling system

Danger!

Risk of scalding from hot coolant.

During machine operation, the engine cooling system is hot and pressurised. Do not touch any parts containing coolant. Avoid contact with the coolant. Check the coolant level only after the lid of the filler neck has cooled down. The coolant must be changed when the engine is cold.

The maintenance tasks for the cooling system are described in detail in the enclosed operating manual of the engine manufacturer (Cummins). The information in this document complements this operating manual, referring specifically to the operating conditions of the diesel engine in Liebherr machines.

5.8.1Checking and cleaning the cooling system

The machine is equipped with a combined cooling system for coolant, oil and intercooling air.

A clean cooling system is a prerequisite for optimum cooling.

It is also necessary to regularly check the engine, fan and radiator for damage and to clean these parts.

If there is leakage at the pressure-relief valve (lid of expansion vessel), replace it. Check the state and tightness of the coolant hoses, and the connecting hoses between the coolant radiator and the engine.

5.8.2Checking coolant level

Checking expansion tank and coolant level

The expansion tank can be accessed through an opening in the bonnet.

To open the screw lid, turn it by 180°.

In this position, release any excess pressure, if necessary. When the tank is depressurised, carefully turn the lid further to remove it.

When cold, the coolant level must reach the lower end of the dip tube below the filler neck.

If necessary, add coolant.

Close the screw lid.

After coolant has been added, switch on the engine and let it run for a short time, while the heating is on. Then check the coolant level again.

5.8.3Changing coolant

When changing the coolant, observe the following instructions: the cooling circuit. contact position.

The drain valves A and B at the bottom of the radiator can be accessed when the cover plates are removed. Drain the coolant by connecting drain hoses to the valves. For detailed information, see operating manual of the engine manufacturer (Cummins).

5.8.4Coolant

The system must be filled with corrosion inhibitor and antifreeze agent at all times. Upon delivery, the coolant contains antifreeze agents for temperatures down to37°C (corresponds to approx. 50% antifreeze agent).

The mixing ratio of the antifreeze agent must be regularly checked in the course of routine maintenance.

5.8.5Changing water filter

The water filter contains a corrosion inhibitor in the form of a paste additive. This additive improves the corrosion protection properties of the coolant. Close the stop valves (see arrows) at the filter housing. Screw out the filter cartridge. Apply a little oil to the seal ring of the new filter cartridge. Screw in the new filter cartridge until the seal ring touches the filter head.

Note!

The filter cartridge is easily damaged.

Do not use any tools when tightening the filter cartridge.

Tighten the filter cartridge by hand completing 1/2 - 3/4 revolution. Open the stop valves.

5.9Fuel system

Danger!

Danger of explosion!

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

5.9.1Refuelling

Note!

If the fuel tank is emptied while the diesel engine is running, the fuel system must be bled, which is a complicated and time-consuming procedure. Therefore avoid running the tank empty and refuel the machine on time.

Note!

To minimise condensation in the tank, keep the fuel level as high as possible.

The indicator P3 indicates the fuel level in the tank. When the red bars are on, there is very little fuel left in the tank. If the fuel level is low, refuel before starting work.

5.9.1.1Direct refuelling

Remove the tank lid 1 Refill fuel through the strainer.

5.9.1.2Refuelling unit (optional equipment)

By installing auxiliary fuel tanks in the undercarriage, the machine can carry more fuel reserves so that refuelling can be postponed longer. This increases the operating time until the next refuelling stop.

The auxiliary tanks must be filled first. When the fuel in the standard tank of the uppercarriage is used up, this tank can be refilled by pumping fuel from the auxiliary tanks.

TankCapacity

Fuel tank in uppercarriage1585 l

Additional tank in undercarriage6000 (2 x 3000) l

Pumping fuel from auxiliary tank to standard tank: copyright by

The indicator P3 indicates the fuel level in the standard tank. If the red bars are lit, there is very little fuel left in the tank of the uppercarriage. Pump fuel from the auxiliary tanks to the standard fuel tank.

1 Fuel hose/uppercarriage

2 Plug A

B

The fuel line coupling, control unit and electrical connection of the refuelling unit are located on the platform service unit.

Swivel the uppercarriage so that it faces away from the travel direction. Remove the dust protection cap.

Remove the fuel hose 1 from the holder and connect it to the fuel coupling. Connect the plug 2 to the power socket. The tank and the refuelling unit are not connected. The slewing gear is automatically switched off so that the uppercarriage cannot be swivelled.

Actuate the switch A

The refuelling pump is started. The standard fuel tank in the uppercarriage is filled. When the fuel tank in the uppercarriage is full, or when the auxiliary tanks are empty, the refuelling pump is automatically switched off.

Alternatively, actuate the switch B

The refuelling pump is switched off.

Disconnect the plug 2 and the fuel hose 1 and place the fuel hose 1 in the holder. The tank and the refuelling unit are now disconnected. The slewing gear is automatically released so that the uppercarriage can be swivelled.

Replace the dust protection cap.

Refilling auxiliary tank through the hose coupling:

5-21 Hose coupling at the undercarriage

The hose coupling for the connection of the fuel hose (type: Wiggins) is located near the access ladder on the undercarriage.

The tank may only be refuelled through this hose coupling, if the refuelling unit is equipped with an automatic shut-off function. This function must stop the refuelling process as soon as the auxiliary tank is full. If this is not possible, use the tank lid, (see Fig. 5-22).

Remove the dust protection cap.

Connect the fuel hose to the hose coupling. Switch on the fuel pump of the unit.

Wait until the auxiliary tank is full and the refuelling pump is automatically switched off.

Disconnect the fuel hose and replace the dust protection cap.

Refilling auxiliary tank through the tank lid:

5-22 Tank lid at the undercarriage

The tank lid of the auxiliary tank is located at the undercarriage. Remove the tank lid 1

Refill fuel through the strainer.

5.9.2Fuel tank maintenance

The fuel tanks must be dewatered daily. Depending on the fuel quality and the conditions under which the machine is operated, the interval may be prolonged to one week.

Dewatering fuel tank:

1 nsists of two elements with one water drain valve 1 each located in the tank base.

Place a suitable container under the valve.

Open the water drain valve 1

Drain off the water until fuel begins to escape.

Close the drain valve 1

Emptying and cleaning fuel tank:

Dewater the fuel tank.

Place a suitable container under the valve.

Remove the tank lid 3 and the water drain valve 1 and drain off the fuel. Regularly check the fuel tank and the strainer 2 for dirt.

If required, replace the strainer 2 and/or rinse out the fuel tank.

5.9.3Fuel filter

The fuel filters 1 and 2 must be changed regularly.

The water in the electronic fuel filter must be drained off every day. Depending on the fuel quality and the conditions under which the machine is operated, the interval may be prolonged to one week.

For detailed information, see operating manual of the engine manufacturer (Cummins).

5.10Dry air filter

The engine can only be protected from abrasion caused by dust and thus excessive wear, if the air filter is regularly cleaned or replaced.

The dry air filter is designed in such a way that it provides excellent protection with relatively long maintenance intervals.

Note!

By blowing out the housing, dirt can be blown into the suction area, resulting in increased wear to the diesel engine.

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

5.10.1Checking suction vacuum

Indicator

The underpressure indicator stores the maximum reached underpressure at the filter output during operation. The component can be accessed from the engine compartment.

If the red indicator strip is visible in the alarm window 1, the maximum permissible underpressure of 50mbar has been reached.

When the red indicator strip is visible, replace the main element.

To delete the stored underpressure value, press the reset button 2

5.10.2Cleaning pre-filter

1 Pre-filter

3 Clamp

2 Clamp

The pre-filter is located at the bottom of the dry air filter. The pre-filter must be removed and inspected every month and cleaned, if necessary.

Release the clamps 2 and 3

Remove and clean the pre-filter 1

Replace the pre-filter and tighten the clamps.

5.10.3Replacing filter cartridges

Note!

Frequent removal and remounting of the main element might result in damage to the seals between the filter element and the filter housing. Replace the main element only if the maximum permissible underpressure is reached, or at least once every year.

The filter cartridges should not be cleaned (e.g. by washing with water) as this would impair the filter's effectiveness. Always replace dirty filter cartridges.

Change the safety element every third time the main element is replaced, or at least once every year.

Before installing a new cartridge, carefully clean the seal and the seal padding in the housing.

1

3

Changing the main element:

2

4

Switch off the engine, screw off the wing screw 2 and remove the main element 1

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

Insert the new main element 1, and ensure that it is positioned tightly and firmly in its seat.

Tighten the wing screw 2 by hand.

Changing the safety element: Remove the main element 1

Unscrew the mounting screw 4 and remove the safety element 3

Carefully clean the inside of the air filter housing with a damp cloth. Clean the sealing surfaces in the housing and examine them for damage. Carefully insert the new safety element 3

Tighten the mounting screw 4 by hand.

Insert the new main element 1 and ensure that it is positioned tightly and firmly in its seat.

Tighten the wing screw 2 by hand.

5.10.4Checking the clean air lines

Fig. 5-30 Checking the clean air line

The clean air lines can be accessed from the engine compartment. Then connect the components of the suction system:

1 Connection of dry air filter and turbocharger

2 Connection of turbocharger and intercooling air cooler

3 Connection of intercooling air cooler and engine suction pipe

Each time you replace the filter cartridge, check the clean air lines for damage and leakage.

If necessary, retighten clamps of the lines.

Fig.

Please note that certain clamps may not be retightened.

Note!

Clamps with spring packs (2, see arrow) can compensate changes in diameter. Retightening might interfere with this function.

Do not retighten clamps with spring packs.

If necessary, retighten the clamps 1

5.11Hydraulic system

Maintenance work on the hydraulic system is mainly limited to the hydraulic filter. All other components of the unit do not require any special maintenance or servicing. The network of pipes and hoses must however be inspected regularly for leaks.

Danger!

High-pressure liquid might penetrate the skin and cause damage. At operating temperature, the hydraulic oil is hot and can even be under pressure. Escaping oil can cause serious injury.

Before carrying out any work on the hydraulic system, you must fully depressurise it.

Do not use your bare hands to check the equipment for leaks.

Do not allow your skin to come into contact with hot oil or components containing hot oil.

Note!

Cleanliness is of particular importance for the proper working of the hydraulic system.

For this reason, the following intervals must be strictly adhered to:

5.11.1Test position

To check the oil level or to add oil to the system, place the machine in a horizontal position. The working attachment must be positioned as follows: Fully open the grapple shells and position the stick vertically. Place the attachment on the ground.

5.11.2Checking the oil level in the hydraulic tank

The oil level can be checked through the sight glass located at the rear of the hydraulic tank. When the machine is in test position, the level must be close to the centre mark in the sight glass.

The upper mark MAXI indicates the maximum oil level when all cylinders are fully retracted.

The lower mark MINI indicates the minimum oil level when all cylinders are fully extended.

If the oil level drops below the lower mark MINI, the minimum level is reached and the respective warning symbol is shown at the display.

If required, add oil through the return filter until the level reaches the centre mark.

5.11.3Releasing the pressure from the hydraulic system

Fig. 5-34 Releasing pressure in the hydraulic system, breather filter

The breather filter 1 can be rotated by hand when the safety pin 2 is inserted. If necessary, use an open end spanner to open the filter. Lower the working attachment to the ground. Switch off the diesel engine.

Operate the pilot control devices (joystick and pedals) in all directions (while the ignition key is in contact position).

Rotate the breather filter 1 by maximum one full revolution. The hydraulic system is now gradually depressurised.

After completion of the maintenance task, retighten the breather filter 1.

5.11.4Replacing the breather filter

Depressurise the hydraulic system. Replace the breather filter (see Fig. 5-34) each time you change the hydraulic oil.

Note!

In areas with excessive production of dust, observe the special instructions for the filter change.

5.11.5Emptying and refilling the hydraulic tank

A Top view

C Front view

2 Return filter lid

B Rear view

1 Breather filter

3/4 Drain valve

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

Draining oil:

Depressurise the hydraulic system. Remove the lid 2 from the return filter. Screw the drain hose onto the drain valves 4 and 5 at the bottom of the tank and let the oil drain into a suitable container.

Adding hydraulic oil:

Depressurise the hydraulic system. Remove the lid 2 from the return filter.

Add oil through the filter cartridge until it reaches the centre mark in the sight glass.

Tighten the breather filter 1

Replace the lid 2 of the return filter.

Caution!

Hydraulic components might be damaged, if the system is not bled! Bleed the hydraulic pumps after each hydraulic oil change.

Draining off the condensate (only for mineral oil):

Regularly drain the condensate from the system. Place a suitable container under the machine. Connect the drain hose to the drain valves 4 and 5 (see Fig. 5-35) until the oil flowing into the container does not contain any water.

5.11.6Return filter

1 Lid

3 Hex head screw

5 Filter cartridge

2 Magnetic rod

4 Seal ring

The magnetic rod must be cleaned and the filter cartridge must be replaced at prescribed intervals (see inspection and maintenance schedule).

Note!

In areas with excessive production of dust, observe the special instructions for the filter change.

Cleaning magnetic rod, replacing filter cartridge: Depressurise the hydraulic system.

Loosen the screws 3 on the lid 1 and remove the lid 1 together with the magnetic rod 2.

Carefully clean the magnetic rod 2 removing any persistent dirt. Remove the spent filter cartridge 5 holding it by the bracket.

Insert the new filter cartridge into the tank, holding it by the bracket, and push it slightly down. Place the bracket along the side of the tank ring. Ensure that the filter cartridge is positioned vertically in the tank.

Insert the new seal ring 4

Carefully replace and centre the lid 1 in the filter cartridge. Ensure that the seal ring 4 is not damaged.

Note!

The filling opening of the hydraulic tank is equipped with a protective cylinder. It prevents foreign particles entering the hydraulic tank. If required, the protective cylinder can be removed from the filling opening.

After a filter change, you must also change the pressure filter of the control oil unit.

5.11.7Control oil filter, control circuit

1 Control oil unit

3 Mounting stud

5 Filter cartridge seal ring

7 Seal of filter pot

2 Control oil filter

4 Filter cartridge

6 Filter pot

8 Accumulator

The control oil unit can be accessed from the engine compartment.

Note!

The filter cartridge cannot be cleaned. Replace the cartridge each time you open the filter pot.

Replacing filter cartridge:

The control oil filter 2 is an integral part of the control oil unit 1

Depressurise the hydraulic system.

Place a suitable container to collect the hydraulic oil under the bleed point.

Remove the filter pot 6 of the pressure filter 2 and pull out the filter cartridge 4

Clean the filter pot 6.

Apply a little hydraulic oil to the threads and sealing faces at the filter pot 6 and at the control oil unit 1 as well as to the sealing rings 5 and 7

Carefully place the new filter cartridge 4 onto the mounting stud 2.

Screw in the filter pot 6 to the stop and tighten it by hand.

Checking the control circuit:

Regularly inspect the pipelines and the connections of all units (pumps, pressure accumulators, pressure-relief valve, pressure filter, etc.) for leakage.

5.11.8Bleeding hydraulic pumps

Prior to commissioning the pumps, after repairs and after a replacement of the pump, fill the pump housing through the leak oil connection with hydraulic oil.

After the system has been filled, and after an oil change in the hydraulic system, bleed the hydraulic pumps.

Caution!

Hydraulic pumps that were not bled might be damaged during operation, or might result in a limited functioning of the hydraulic unit.

Bleed the hydraulic pumps also if air has been trapped in the system as a result of work carried out on the hydraulic system.

Depressurise the hydraulic system.

The hydraulic pumps must be bled in the prescribed sequence. Start with the pump installed at the lowest point (no. 1), and finish with the pump located at the highest point (no. 5).

Open the leak oil hose at the hydraulic pumps 1, 2, 3 and 5. At the hydraulic pump, open one screw plug (see arrows).

copyright by

Place a suitable container to collect the hydraulic oil under the bleed point. Open the leak oil hose or the screw plug a little to allow the air to escape. The hydraulic pump is being bled.

As soon as the hydraulic oil escapes without bubbles, tighten the screw plug or leak oil hose connection.

5.11.9Removing the suction hose

Fig. 5-39 Suction hose, shut-off valve

The shut-off valve of the suction hose has two positions: A open B closed

Depressurise the hydraulic system.

If the suction hose is to be disconnected at the pump or at the hydraulic tank, close the shut-off valve B

Place a suitable container to collect the hydraulic oil under the bleed point. Drain the hydraulic oil from the pump and suction hose.

After completion of the repair, turn the shut-off valve to its initial position A and engage it.

5.11.10Replacing the feed line filter

The cartridges of the feed line filters attached to the slewing gear pump must be replaced at prescribed intervals. Depressurise the hydraulic system. Place a suitable container to collect the hydraulic oil under the bleed point. Remove the filter pot. Take out the filter cartridge and insert a new one. Reinstall the filter pot.

5.11.11High-pressure filter

The high-pressure filter of the hydraulic circuit is accessible from the engine compartment. The filter cartridge must be inspected at prescribed intervals and each time a hydraulic unit is replaced. If necessary, the cartridge must be cleaned.

1 Head section

3 Seal ring

5 Seal ring

2 Filter pot

4 Filter cartridge

Cleaning or replacing filter cartridge: Depressurise the hydraulic system. Place a suitable container to collect the hydraulic oil under the bleed point. Remove the filter pot 2

Remove the filter cartridge 4

Wash the filter cartridge 4 with petrol or replace it. Clean the filter pot 2 and the head section 1 Mount the filter pot 2 with the filter cartridge 4

Leakage check:

Start the diesel engine and move the working attachment for a short period of time (approx. 1 minute).

Switch off the diesel engine and check the connections at the filter pot and filter head for leaks.

5.11.12Bypass oil filter (optional equipment)

The bypass oil filter is designed to remove small particles and water from the hydraulic system.

The filter cartridge must be replaced each time the return filter is changed, or at least every 6 months.

Note!

Where environmentally friendly hydraulic oils are used, LIEBHERR prescribes the use of bypass oil filters.

The machine can be equipped with two bypass oil filters. They are installed behind a cover to the side of the engine compartment (see Fig. 5-43).

3

Changing filter cartridge: Switch off the engine.

4

6

Release the pressure from the hydraulic system. Remove the screw 1 and the lid 3.

Remove the spent filter cartridge 5 by turning it at the carrying straps in clockwise direction while lifting it slightly.

Wait until the oil has been drained off, then remove the filter cartridge 5 and collect dripping oil in a suitable container.

Check the inlet and outlet of the filter housing 6 for dirt deposits and clean it, if necessary.

Remove the new filter cartridge 5 from the packaging while leaving the cardboard mantle attached to the cartridge.

Note!

If the packaging is damaged, there is a risk that moisture has entered the filter cartridge, shortening its service life.

Ensure that the packaging of the new filter cartridge is not damaged.

Insert the new filter cartridge 5.

Fill the filter housing 6 with the same hydraulic oil as is used in the machine. Clean the lid 3 and insert a new O-ring 4

Replace the lid 3 and secure it with the screw 1. Tighten the screw with a torque of 50Nm.

Start the machine and check the bypass oil filter for leakage.

5.11.13Maintenance of hydraulic cylinders

5.11.13.1Checking piston rod bearing

Note

If there is a leak at the piston rod bearing of a hydraulic cylinder (arrow), we recommend having the seal kit replaced by a LIEBHERR technician.

5.11.13.2Preservation of piston rods

Prior to standstills of more than 4 weeks, and in particular prior to any sea transport of the machine, carry out the following tasks:

If possible, position and transport the machine in such a way that the piston rods are fully retracted into the cylinders.

Exposed piston rods must be protected with a thick layer of acid-free corrosion protection grease.

Before loading the machine, check the piston rods again for proper preservation. Also apply corrosion protection grease to the piston rods, if the respective cylinder is rarely operated during work. Piston rods that are not frequently retracted and extended are not properly lubricated with hydraulic oil.

Regularly check the preservation of rarely operated hydraulic cylinders.

5.11.14Replacing hydraulic hoses

Danger!

Defective hydraulic hoses can cause serious accidents and injury to persons. Always replace defective hydraulic hoses (bubbles, moisture, damaged surface, etc.) without delay.

Install the new hydraulic hose in such a way that it is not exposed to torsion loads during operation.

:

The mounting bolts of the SAE fittings must be tightened with the prescribed tightening torques (see below).

Ensure that the hydraulic hose is not twisted during installation. Tightening torque [Nm]

Split flangeScrew8.810.9 M82231 M104462 M1276108 M14122172

Full flange Screw (10.9)Tightening torque [Nm]

Full flange, cone-shapedScrew (10.9)Tightening torque [Nm] M1065 M12110 M14180 M16250 M20450 copyright by

5.12Oil change in components

5.12.1General instructions

Ensure that the machine is in a horizontal position. Switch off the diesel engine. Before draining the oil, wait some time so that the oil can collect in the unit. The oil should be drained while it is at operating temperature.

5.12.2Slewing gear mechanism – oil change

1 Oil tank

3 Drain valve

2 Lid

Draining oil:

Remove the lid 2

Lift the cover in front of the drain valve 3

Connect the drain hose to the drain valve 3 and let the oil drain into a suitable container.

Disconnect the drain hose.

Adding oil:

Add oil directly into the oil tank 1 until the level reaches the MAX mark. Replace the lid 2

5.12.3Pump distributor gear

1 Oil filler neck

3 Drain valve

2 Dip stick

Checking the oil level: Switch off the diesel engine. Wait a few minutes until the engine oil has collected in the pump.

Pull out the dip stick 2 and clean with a clean cloth.

Insert the dip stick 2 to the stop.

Pull out the dip stick 2 again and check the oil level. The oil level must be between the min and max marks. If necessary, add gear oil until the level reaches the max mark.

Draining oil:

Remove the screw cap at the drain valve 3

Connect the drain hose to the drain valve 3 and let the oil drain into a suitable container.

Disconnect the drain hose.

Replace the screw cap at the drain valve 3

Adding oil:

Add oil through the filler neck 1 until it reaches the max mark on the dipstick.

Refilling oil:

Upon the first start-up of the diesel engine, the oil cooler of the pump distribution gear is filled with oil. The equivalent oil volume is thus missing in the pump distribution gear.

Start the diesel engine and let it run for 30 seconds. Switch off the diesel engine and add the required oil volume.

5.12.4Travel gear

Before the oil change, ensure that the machine is at operating temperature:

Draining oil:

To drain off oil or to add oil, position the chassis in such a way that the screw plugs 1, 2 and 3 are in the positions indicated in the drawing.

Place a suitable collecting vessel under the screw plug 3

Remove the screw plug 3

Remove the screw plug 1 or 2 Collect the escaping oil in the vessel.

Adding oil: Close the screw plug 3

Add oil through the opening 1 until the oil level reaches the opening. Insert and tighten the screw plugs 1 and 2

5.13Travel gear

The drive is maintenance-free, unless the running face or the flange requires regeneration or until all travel gear parts are completely worn.

The lifetime design of the support rollers, running rollers and idlers prolongs the service life of the drive gear, while the metal seals protect it against dirt.

5.13.1Cleaning drive gear

Do not use the engine force to remove dried sludge, mud, stones or other foreign objects from the travel gear, as this can result in serious damage to the machine. Do not start the machine, if large objects (e.g. stones, pieces of timber, metal parts, wire, etc.) are jammed in the travel gear.

After operation (i.e. after each shift), clean the dirty travel gear parts. Clean and lubricate the sliding surfaces of the chain tensioners.

If the ambient temperature is below zero, place the machine on planks to prevent the chains from becoming frozen to the ground.

Note!

To prevent serious damage to the equipment , never attempt to move the machine when it is frozen to the ground. Frozen chains can be freed by carefully heating the base plates.

5.13.2Checking fixtures of components

Carry out regular visual inspections of the securing screws of the base plates and the drives in order to find any loose bolts.

Remove the cover A

Check the tightening torques (see table).

No.MountingTightening torque [Nm]

3Tumbler wheel2100

4Hydraulic motor960

5.13.3Checking chain tension

Checking chain tension

Under normal operating conditions, the dip between the two support rollers should be between 25 to 30mm

Release the chain by moving the machine forward and back. Place the measuring rod onto the section between two support rollers. Measure the distance A between the measuring rod lower edge and the base plate.

If necessary, tension the chain.

5.13.4Tensioning chain

As the travel gear is exposed to normal wear, the chain tension must be regularly checked and retightened, if necessary.

Remove the lid 3 from the longitudinal member of the undercarriage. Screw the high pressure hose 1 to the hand grease gun.

Add grease until the chain is sufficiently

Check chain tension.

5.13.5Releasing chain

Danger!

Risk of injury from slackening chain or expelled grease. When releasing the chain, always wear protective goggles and gloves. The lubrication nipple 1 may not be loosened.

When releasing the chain, keep your head away from the running roller frame. When loosening the lubrication nipple extension 2 keep your hands away from the lubricating nipple. To loosen the lubrication nipple extension, always use suitable tools.

Clean the chain and remove any jammed objects. Park the machine on level ground.

Turn lubrication nipple extension 2 by a few revolutions until grease escapes from the longitudinal groove 3 of the lubrication nipple extension.

As soon as the desired chain tension is reached, tighten the lubrication nipple extension 2

After adjustment, move the machine forward and back and then check the chain tension again.

5.13.6Changing lubrication nipple

Release the chain as described in section "Releasing chain".

As soon as no grease escapes from the longitudinal groove 3 of the lubrication nipple extension 2,(see Fig. 5-53): Fully unscrew the lubrication nipple extension. Fully screw in and tighten the preassembled unit (lubrication nipple extension 2 and lubrication nipple 1).

Tension the chain as described in section "Tensioning chain".

5.14Electrical system

5.14.1Notes regarding the electrical system

Regularly inspect the electrical system of the machine for defects. Defects such as loose connections, chaffed cables or poorly fixed clamps must be replaced without delay.

Identify the cause for blown fuses and broken incandescent lamps, eliminate it and replace the fuse or the lamp.

Before carrying out any work on the electrical equipment, or carrying out electric arc welding work disconnect the batteries.

5.14.2Battery main switch

Caution!

The auxiliary heater (optional equipment) remains on for a little while after the ignition has been switched off. It might be damaged, if it is suddenly switched off with the battery main switch during this afterrun time.

Only switch off the battery main switch after the afterrun time of the auxiliary heater has lapsed.

Before carrying out any work on the electrical system or performing welding work on the machine, set the battery main switch to position 0 (off).

Note!

The battery might discharge itself during prolonged standstills.

Prior to prolonged standstills, switch the battery main switch to position 0 (off).

5.14.3Battery care

Danger!

Battery acid is highly corrosive.

When working on the battery, always wear protective goggles and gloves.

Danger!

Risk of explosion from hydrogen gas and sparks.

Check the vent hoses for damage, especially after installation of the battery. The negative pole (-) must be disconnected first and reconnected last. Avoid sparks and naked flames when charging batteries or working on them. Charge the batteries only in well ventilated rooms.

For proper functioning, the battery must always bee kept clean. The liquid level in the cells should be about 10 to 15 mm above the upper edge of the plate. To refill the battery, only use demineralised water.

The hydrogen gas produced in the batteries must be fed through rubber hoses B to the outside of the building. Ensure that the rubber hoses are not kinked or damaged, as this could lead to hydrogen gas collecting in the battery box.

Lay the vent hoses B in such a way that there are not kinks or blocked sections in the hoses.

Always replace damaged vent hoses.

Regularly clean the pole heads and cable terminals A and apply a thick layer of acid-proof grease.

From time to time, check the acid density using a battery tester C

If the battery is fully charged, the density is 1.28 kg/l (31.5°Bé).

If the battery tester shows a lower value, the battery is discharged to some degree and might need to be recharged.

5.14.4Slip ring body

Fig. 5-56 Slip ring body

The slip ring body is installed at the centre of the slewing gear. It connects the electrical components in the uppercarriage to the electrical consumers in the undercarriage. The slip ring body can be accessed from the uppercarriage.

Slip ring bodies are easily damaged by humidity, and insufficient care can lead to the formation of an oxide layer on the conductive surfaces. This can impair the electric conductivity and result in malfunctions.

In order to prevent this, we recommend carrying out the following tasks every 500 operating hours:

Loosen the lock nuts 2

Remove the housing 1.

Remove any oxidation from the slip ring body (use a cleaning spray, if necessary). Replace damaged (corroded) fork terminals. Apply Cramolin contact spray to all slip ring elements.

Mount the housing 1

Tighten the lock nuts 2 with a uniform torque.