and air-conditioning system

5.15.1Recirculated and ambient air filter

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

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

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

Cleaning or replacing the recirculated and ambient air filters:

To remove the recirculated air filter 1, tilt the backrest of the operator seat forward.

Open the quick fasteners 2 by turning them by 90 degrees.

Remove the recirculated air filter 1.

Remove the deflector 4

Remove the ambient air filter 3

Note!

Incorrect cleaning of the filters might damage them.

Never clean the filters with hot water or steam!

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

To clean the filter elements 1 / 3, blow them out with compressed air or wash them in cold or lukewarm water.

5.15.2Heating system

Every year at the start of the heating period, have the following maintenance routine completed by a qualified specialist. Check the entire coolant circuit for leakage.

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

If necessary, bleed the heating system. Clean the solenoid valve.

Check the heat exchanger and clean it, if necessary.

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

5.15.3air-conditioning system

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

Inspection of the condenser:

During the operating period, check the condenser every 500 operating hours: Inspect the condenser 1 for dirt.

If necessary, clean the condenser: 1: loosen the securing screws and tilt the upper part slightly out. Clean it with compressed air, blowing it from the inside (blower side) out.

Ensure that the condenser fins are clean.

Dirt on the condenser might lead to excessive pressure in the coolant circuit, so that the air-conditioning system is automatically switched off.

Compressed-air

Maintenance of a/c system:

During the operating period, the following maintenance tasks must be carried out by a technician specialising in a/c systems: every 500 operating hours: e dryer-collector unit. every 1000 operating hours: of excess pressure switch

Annually:

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

5.16Compressed-air system

Checking pressure:

During operation, the pressure gauge 2 must show the following pressure value: 6.2 to 7.2 bar (90 - 105 PSI).

If the indicated pressure is outside this range or if the pressure gauge is faulty, contact the LIEBHERR service department.

Draining off water:

Condensate tends to collect in the compressed air system. The pressure accumulator 1 is automatically drained each time the system pressure drops. We recommend however regularly draining the pressure accumulator manually (weekly during summer months; daily during winter months).

Press in the pin of the water drain valve 3 and allow the water to drain off. Release the pin when the escaping air is dry.

Adding antifreeze agent to the pump:

At temperatures below freezing point, the condensate in the accumulator might freeze. To prevent this, antifreeze agent is injected into the accumulator to ensure operational safety of the compressed air system also during the cold season. Regularly check the fill level of the antifreeze pump (contains approx. 0.25 l of spirit).

Remove the cap of the antifreeze pump 4 and add antifreeze agent, if required.

5.16.2Compressed air unit of central lubrication system

Draining off water:

Remove the screw at the bottom of the oil mist lubricator 1 and turn the air filter 2 a few times. Let the condensate drain off into a suitable container.

Adding oil:

Remove the filler neck at the oil mist lubricator 1 and add oil, if necessary.

Max. fill level: 1 cm below upper edge of glass container

5.17Automatic lubrication of the machine

5.17.1Semi-automatic lubrication system of slewing gear

The machine is equipped with a semi-automatic lubrication system for the slewing gear. A housing encasing the pinion of the slewing gear mechanism provides a virtually sealed grease-filled box for the lubrication of the pinion and the slewing ring. This housing is connected to a lubrication pump.

Starting lubrication cycle:

To start a cycle, press the button S84. As long as the button is pressed, the electric pump continues to deliver grease to the connected lube and bearing points.

Carry out at least one lubricating cycle during every shift.

Press the button S84 and hold it down for approx. 1 minute.

During the lubricating cycle, move the uppercarriage slowly to complete a full revolution (360°) to lubricate the entire toothed area.

Release the button.

Rotate the uppercarriage again by a full revolution to further distribute the grease.

Adding grease to the grease tank:

Fig.

Grease tank of slewing gear lubrication system

Check the grease tank once a week. It is located at the front of the hydraulic tank. Remove the plug, check the fill level and add grease, if necessary.

5.17.2Automatic central lubrication system

The machine is equipped with an automatic central lubrication system.

The uppercarriage and the attachment do not need to be lubricated manually. During operation, the machine is automatically lubricated at set intervals. After the preset interval has lapsed, the lubricating pump is automatically actuated and feeds a specific amount of grease to the connected grease nipples.

The lubrication system is installed behind the operator's cab in the lubrication box (see Fig. 5-67). It consists of a grease tank, a pneumatically operated lubricating pump and a control unit that initiates and controls the lubricating cycles. The control console is integrated into the operator's cab.

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The lubrication system can be refilled with grease in two different ways: rnal filling pump (optional equipment)

5.17.2.1Operation

1 Display

2 Timer key

3 Double function button "additional lubrication / reset"

Setting lubricating interval:

Adjustment range: 1 min to 2 h 59 min; factory setting: 2 h

The interval between two lubricating cycles can be adjusted by simultaneously press the buttons 2 and 3

Press and hold the button 2

Simultaneously press and hold the button 3 The interval is shown on the display 1, and the interval time is incremented. If the buttons are pressed for a longer period of time, the values increment at a faster rate.

Release the buttons when the desired interval time is displayed. The new interval time is saved.

Displaying interval: Press the button 2 briefly twice. The set interval time (PP) and the time remaining to the next lubricating cycle (rP) are displayed.

Releasing additional lubricating cycle: Press the button 3 to release a lubricating cycle before the set interval has lapsed.

Press and hold the button 3 for at least two seconds. The machine is being lubricated.

Monitoring central lubrication system:

The display shows the filling level of the grease tank, the operating status of the system and any faults:

[ ] (lubrication) - A progress bar indicts that a lubricating cycle is in progress

LL (low level) - the grease tank is empty and must be refilled. The text disappears when the grease tank is filled.

HL (high level) - the grease tank is full

Er (error) - fault or malfunction The central lubrication system must be examined and repaired, if necessary. Faults and malfunctions are signalled with a warning sound. Press the button 3 to acknowledge the warning signal. The displayed error codes provide additional information for the elimination of the problem.

For more information, see operating manual of the manufacturer of the central lubrication system (Lincoln).

5.17.2.2Filling grease tank

Adding grease to the grease tank: copyright by

To refill the grease tank, replace the empty bucket with a full one.

Open and lock the cover of the lubrication box 1

Open the wing nuts 3

Remove the pump unit 2 and the pressure plate 4

Remove the empty grease bucket.

Open the new grease bucket 6 and place it in the box.

Insert the pressure plate 4 and place the pump unit 2 in its place.

Tighten the wing nuts 3

Filling the grease tank with the filling pump (optional equipment):

The grease tank is filled by means of the external filling pump. The filling hose coupling is located beside the lubrication box at the access ladder to the operator's cab.

Open and lock the cover of the lubrication box 1

Remove the dust protection cap from the hose coupling 2

Connect the filling hose and switch on the filling pump.

Observe the red check pin 4 in the lubrication box.

The grease tank is full when the check pin 4 begins to move upwards or when grease exits through the overflow 3.

Note!

Overfilling can damage the grease tank.

When the red check pin 4 begins to move upwards, immediately switch off the filling pump.

Do not block the overflow 3

Disconnect the filling hose and replace the dust protection cap.

5.18Manual lubrication of the machine

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

Note!

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

5.18.1Attachments (optional equipment)

The attachments (e.g. grapple, quick-change adapter systems) must be lubricated manually. In grapples, the respective lubricating points are labelled.

For normal operation, the grapple must be lubricated daily or once per shift. Other working tools must be lubricated at weekly intervals.

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

Examine the attachment to detect all lubricating nipples.

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

If the attachment is equipped with a rotator, the moving parts must also be lubricated.

Lubricate the rotator (bearing, crown gear, pinion) using a grease gun, until clean grease escapes at the respective bearing point (approx. 2 lubricating strokes).

If the rotator is not equipped with a separate lubricating nipple, apply grease to the crown gear and the pinion.

5.18.2Industrial stick with hydraulic quick-change adapter

Lubricate the quick-change adapter through the lubrication nipples with a grease gun (approx. 2 lubricating strokes).

Note!

If the quick-change adapter is lubricated while the bolts are extended, the cavity between the locking bolts is filled with grease, so that they cannot be retracted. Therefore lubricate the system only, if the locking bolts are retracted.

5.18.3LIKUFIX MH 110 quick-coupling system

1

Lubricate the locking bolts via the lubricating nipple 1, using a grease gun.* Lubricate the rotator via the lubricating nipple 2, using a grease gun.* * apply approx. 2 lubricating strokes

Note!

If the quick-change adapter is lubricated while the bolts are extended, the cavity between the locking bolts is filled with grease, so that they cannot be retracted. Therefore lubricate the system only, if the locking bolts are retracted.

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

5.19Couplings of the quick-change adapter systems (optional equipment)

5.19.1Hydraulic coupling

The LIKUFIX hydraulic coupling system and the multi-coupling system are equipped with hydraulic coupling plugs (see arrows).

The coupling plugs are maintenance-free. We recommend cleaning the system regularly. This prevents caking of dirt and icing up in winter. With regular cleaning, the seals of the system have a long service life.

Cleaning:

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

Changing seal ring: copyright by

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

Caution!

The hydraulic lines are under pressure.

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

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

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

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

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

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

5.19.2LIKUFIX electric coupling

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

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

Switch off the diesel engine.

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

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

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

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

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

5.20Travel and swing brakes

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

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

5.21General maintenance tasks

5.21.1Replacing wear parts

Apart from maintenance and care tasks that must be carried out at prescribed intervals, the following minor repairs can be made by the machine operator or a maintenance technician: and hose lines and at connections of the hydraulic units (with the exception of the pressure-relief valves, which are factorysealed). draulic lines and screw connections of the hydraulic unit.

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

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

5.21.2Replacing teeth on digging tool

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

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

U system:

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

Remove the old tooth.

Place the new tooth on the adapter (B).

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

Z system:

1

3

5

2

4

6

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

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

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

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

Note!

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

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

Insert the new tooth into the tooth adapter.

Insert the locking bolt to the stop (E).

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

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

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

5.21.3Welded parts on the machine

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

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

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

Caution!

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

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

5.22Inspection and maintenance schedule

Note!

Careful maintenance is only possible, if the machine is clean. Important visual inspections, e.g. for cracks can only be performed properly on a clean machine. Before carrying out any maintenance work, clean the machine (see also chapter "Cleaning").

Note!

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

Maintenance/inspection at operating hours

TASKS TO BE CARRIED OUT - DIESEL ENGINE

by maintenance personnel (machine owner)

Initial and single interval

Repeat interval

Annually, at the start of the cold season

When required

Check oil level together with authorised specialist technicians

Initial and single interval

Repeat interval

Visual inspection (leakage, dirt, damage)

Drain water and deposit from fuel tank

Check oil level in pump distributor gear

1) Change diesel engine oil: Standard: every 250 operating hours with Centriguard engine oil auxiliary filter: every 500 operating hours

Change oil filter (at each oil change)

Change water filter

Check crankcase bleeding valve; clean if necessary

Change fuel filter

Check cable connections

Check V-belt tension and state

Replace gear oil in pump distributor gear

Check throttle control; adjust, if necessary

Inspection and maintenance schedule

Maintenance/inspection at operating hours

TASKS TO BE CARRIED OUT - DIESEL ENGINE by maintenance personnel (machine owner)

Initial and single interval

Repeat interval

Annually, at the start of the cold season

When required together with authorised specialist technicians

Initial and single interval

Repeat interval

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

Check mounting bolts of engine brackets, oil pan and distributor gear

1500 Complete 1500-hour service according to Cummins operating manual

6000 Complete 6000-hour service according to Cummins operating manual (every two years)

Maintenance/inspection at operating hours

TASKS TO BE CARRIED OUT - MACHINE by maintenance personnel (machine owner)

Initial and single interval

Repeat interval

Annually, at the start of the cold season

When required together with authorised specialist technicians

Initial and single interval

Repeat interval

Radiator

Check coolant level

Check cooling and heating system for damage and leakage

Check corrosion inhibitor and antifreeze agent concentration in coolant

3000 Change coolant (at least every 2 years) Liebherr Antifreeze

6000 Change coolant (at least every 4 years) Liebherr Antifreeze OS

Air Filter

Check underpressure indicator of the air filter

Clean pre-filter

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

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

Maintenance/inspection at operating hours

TASKS TO BE CARRIED OUT - MACHINE

by maintenance personnel (machine owner)

Initial and single interval

Repeat interval

Annually, at the start of the cold season

When required

COMPRESSED-AIR SYSTEM

Check fill level of antifreeze pump together with authorised specialist technicians

Initial and single interval

Repeat interval

Dewater pressure accumulator (daily during winter months, weekly during summer months)

Compressed air unit of central lubrication system: Dewater, check oil mist lubricator; add oil, if necessary

Check compressor

Hydraulic System

Check oil level in hydraulic tank

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

2) Replace filter element in bypass filter (special equipment) (in machines used for dust intensive applications: every 250 operating hours)

2) Replace filter cartridge in return filter

Replace filter cartridge in control oil unit

Replace feed oil filter on slewing gear pump

Check components for proper fixture

Check hydraulic oil cooler for dirt; clean, if necessary

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

Check hydraulic system for leakage; completing functional test

Check / readjust servo, primary and secondary pressures

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

2) Change breather filter on hydraulic tank

Electrical System

Check indicator lights and indicating devices upon start-up

Check lighting system

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

Inspection and maintenance schedule

Maintenance/inspection at operating hours

TASKS TO BE CARRIED OUT - MACHINE

by maintenance personnel (machine owner)

Initial and single interval

Repeat interval

Annually, at the start of the cold season

When required together with authorised specialist technicians

Initial and single interval

Repeat interval

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

Carry out functional tests of entire unit and all components

Slewing Gear Mechanism

Check oil level; check system for leakage

Perform functional test of slewing gear brake

Check gearbox and oil motor for proper mounting

Change gear oil

Slewing Gear

Start lubrication system of slewing gear

Check fill level in grease tank of lubrication system; add grease, if required

Clean collecting channels at the bottom of the slewing gear; remove excess grease

Check mounting bolts for press fit; check slewing gear pinion meshing

Travel Gear

Check oil level; check system for leakage

Functional test of travel brake

Check gearbox and oil motor for proper mounting

Change gear oil

Travel Gear

Visually check tension of chain; regulate, if necessary

Clean chain (after work)

Check fixture of base plates and drive wheels

Clean and lubricate slide faces of tensioning mechanism

Check idlers, support and running rollers for tightness copyright by

Maintenance/inspection at operating hours

TASKS TO BE CARRIED OUT - MACHINE

by maintenance personnel (machine owner)

Initial and single interval

Repeat interval

Annually, at the start of the cold season

When required together with authorised specialist technicians

Initial and single interval

Repeat interval

Central Lubrication System

Perform functional test

Change or refill grease tank

Service entire system; check pumps and control system (at least once annually)

OPERATOR'S CAB + HEATING

Check / add detergent solution in windscreen washer system tank

Perform functional test of heating

Check heating system for leakage

Check door hinges, window hinges and locks

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

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

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

AIR-CONDITIONING SYSTEM

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

Check condenser for dirt; blow clean, if necessary

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

Check compressor mounting bolts and drive belts

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

Check evaporator unit; clean, if necessary

Check electrical lines for chafe marks; check plug connections

Perform functional test of excess pressure switch

Check cooling performance

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

Inspection and maintenance schedule

Maintenance/inspection at operating hours

TASKS TO BE CARRIED OUT - MACHINE by

maintenance personnel (machine owner)

Initial and single interval

Repeat interval

Annually, at the start of the cold season

When required together with authorised specialist technicians

Initial and single interval

Repeat interval

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

UNDERCARRIAGE + UPPERCARRIAGE + WORKING ATTACHMENTS

Lubricate bearings, using the semi-automatic central lubrication system

Exception: machines with fully automatic central lubrication system (special equipment)

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

Lubricate bearings (undercarriage and attachments); depending on the use and for multi-shift operation, lubricate daily

Inspect teeth for wear

Check railings, climbing aids and catwalks for proper fixture and damage

250

Check parts for cracks

Check counterweight and tank for proper fixture

Check lines and screwed connections for proper fixture

Attachment points for fall-arrest equipment: Check bolts for press fit; carry out visual inspection; replace deformed or corroded parts

Check panelling hinges, quick fasteners and gas pressure springs of hoods

Instruct operators in the proper use of the machine

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

HYDRAULIC QUICK-CHANGE ADAPTERS

Perform functional check of the visual and acoustic warning systems

Carry out visual inspection of extended lock bolts

Check hydraulic hoses and the wire harness for damage

Lubricate lock bolts