Service Manual

Chapter 4 - Operating / Maintenance

Operating maintenance .................................................................................................................................... 4-3
1 The lubrication chart ......................................................................................................................... 4-5
1.1 The service trap...................................................................................................................... 4-5
2 Control and maintenance chart......................................................................................................... 4-7
3 Oil sampling procedure..................................................................................................................... 4-13
3.1 Oil sample extraction valve..................................................................................................... 4-13
3.2 Splitterbox............................................................................................................................... 4-14
3.3 Engine .................................................................................................................................... 4-15
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4 Operating maintenance
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The lubrication chart

4.1 The lubrication chart

Symbol Display Quantity*

Diesel engine 245 l

Engine coolant 280 l

Hydraulic system 3650 l

Swing gear 2 x 37 l

Travel gear 2 x 52 l

Splitterbox 70 l

Fuel 5220 l

Grease / Swing ring teeth 15 l

Grease 80 l

Windshield washer 75 l

Check oil level

Oil change

First oil change

Oil analysis

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

4.1.1 The service trap

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To simplify the oil change and the refilling procedure, the drain of major components are centrally connected
to a service trap.
X The Diesel engine system.
X The splitterbox.
X The fuel tank.
X The hydraulic oil tank.
X The windshield washer fluid tank.

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The lubrication chart

X The grease tank for general lubrication.

X The grease tank for swing ring teeth lubrication

Component Adapter Flow max.

WIGGINS
Splitterbox C-1807 50 l/mn
Engine oil OSP 2 50 l/mn
Hydraulic oil 6600 B12 100-200 l/mn
Fuel ZZ 9A1 400 l/mn
Winshield washer EC 280 B8 25 l/mn
Principal grease OSP 2
15-30 l/mn
Pmini 100 bar
Teeth ring grease 6000 B12

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Control and maintenance chart

4.2 Control and maintenance chart

Caution!
Careful maintenance can only be carried out when the machine is clean. In particular, visual
checks such as crack testing are only possible on a clean machine.
X Clean the machine before you start maintenance work (see also the chapter “Safe main-
tenance of the machine”, subheading “Cleaning and crack testing”).

Note
The daily maintenance work that the device operator has to carry out comprises a function
check of the brakes (slewing gear, service and parking brake), steering and the electrical and
hydraulic systems.
Additionally, a visual check must be made for leaks on the engine, hydraulic system, trans-
mission and axles.

WORK TO BE PERFORMED
R 9250

First and only interval Note

Weekly
Daily

Repeat interval

DIESEL ENGINE & SPLITTERBOX

Check oil level

Check coolant level

Check speed on RPM gauge

Check running noises

Check exhaust gas colour

Check engine and external pipework for leaks

Check exhaust connections for leaks. Check oil supply / return pipework for leaks

Check for air filters clogging at the restriction indicators

Check oil pressure and coolant temperature during operation

Check oil level in splitterbox

Check condition of the cyclone tubes of the precleaner, clean if necessary

Check air intake hose for condition and leaks

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Check and clean radiator core and fan

Check radiator cap for leaks, replace if necessary

Drain fuel tank

Daily : perform the complete "Daily" Maintenance Echelon, as started in CUMMINS Ope-
rating and Maintenance Manual

Check fastening of thermic protection on exhaust manifold

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Control and maintenance chart

WORK TO BE PERFORMED
R 9250

First and only interval Note

Weekly
Daily

Repeat interval

HYDRAULIC SYSTEM

Check oil level in hydraulic tank

Check hydraulic system for leaks

Inspect the fastening and the good condition of pipes and hoses for damage and leakage

Clean magnetic rods in one of the return filters (each week another one) (daily during the
first 300 hrs.)

Clean magnetic rods in leak oil filter (daily during the first 300 hrs.)

Check hydraulic cylinder rods for leaks and good condition

Inspect, and if necessary clean oil coolers

Check hydraulic tank air filter, clean if necessary

ELECTRICAL SYSTEM

Clean and check LCD screen of the display for proper function when starting

Check indicator lights and gauges on control panel when starting

Press to open dust discharge valve on air cleaner for cab and electrical boxes

Check head and floodlights, clean if necessary

Visual inspection of wiring system damage

AIR PRESSURE SYSTEM

Check cut in and cut out pressure of air pressure regulator 6,2 - 7,25
bar

Drain air tanks

SWING RING

Check function of swing ring bearing lubrication system during operation

Check function of swing ring teeth lubrication system during operation

Check visually the grease delivery (outlet of new grease around the swing ring)

SWING GEAR
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Check function and operation of swing brake

Visually check mounting bolts of gear and oil motor

Check for leaks on swing gears, check oil level in expansion tanks

TRAVEL GEARS

Check for leaks, if gear is leaking, check oil level

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Control and maintenance chart

WORK TO BE PERFORMED
R 9250

First and only interval Note

Weekly
Daily

Repeat interval

Check function and operation of travel brakes

TRACKS

Clean track chain (after working)

Visually check and tighten if necessary mounting screws of side frames

Check tensioning cylinders, idler, carrier and track rollers for leaks

Visually check and if necessary tighten screws of sprocket, rollers, idlers, chain guides
and track pad bolts.

Check track chain tension visually

CAB, HEATER AIR CONDITIONER

Operate air conditioner every week for 10 minutes (during winter)

Visual check condenser unit and evaporator filter

Check refrigerant level, if necessary refill circuit

Check tension of V-belt for air conditioner (on the engine)

UNDER / UPPERCARRIAGE & ATTACHMENTS

Check function of working attachment lubrication system during operation

Check visually the grease delivery at each lube point

Check bucket teeth visually for wear

The daily maintenance work must include the check of the proper function of hydraulic,
electric, pneumatic and brakes systems before starting operation

Visually check and if necessary tighten mounting screws of counterweight, tanks, power-
pack, control valve console, cab, catwalks, grease box, ladder

Check fastening of pin covers

Check fastening of hoses and pipe clips

Check level in reservoir for winshield washer, refill if necessary

CENTRALIZED LUBRICATION SYSTEM

Daily : perform a complete daily maintenance as stated on page 9250_1001a.4a

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Weekly : perform a complete weekly maintenance as stated on page 9250_1001a.4a

Tab. 0-1 Daily / weekly maintenance schedule R 9250

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Control and maintenance chart

WORK TO BE PERFORMED
R 9250

First and only interval Note

At 7500, 15000, ....hrs
At 1000, 3000, ....hrs

At 2000, 4000, ....hrs

At 500, 1500, ....hrs

Repeat interval
At 250, 750, ....hrs
At delivery

Perform all checks and works in the daily / weekly maintenance schedule

DIESEL ENGINE & SPLITTERBOX

Check the tightness of all screws and bolts on splitterbox

Check the oil quality in splitterbox, change if necessary

Check mounting screws of engine and splitterbox for tightness

Check the engine rubber buffers (replace if necessary and at least every
10000 hours)

Replace primary element of air cleaner (if necessary or once a year)

Replace safety element of air cleaner (if necessary or once a year)

Every 250 hours or 6 months, perform a complete "250 hrs" Maintenance

Echelon, as stated in CUMMINS Operation and Maintenance Manual to ex-
tend the oil change interval, it is advised to use the chart method (see CUM-
MINS Manual page 19 (QSK 45 with 75 US Gallon sump)). This method
allows to extend the oil change interval.

Every 10000 hours or 2 years, perform a complete "10000 hrs" Mainte-

nance Echelon, as stated in CUMMINS Operation and Maintenance Ma-
nual

See CUMMINS Operation and Maintenance Manual for other mainte-

nance (Eliminator, Centinel, Fleetguard, valves and injectors adjustment)

HYDRAULIC SYSTEM

Change servo filter elements (first after 500 hrs)

Change swing pumps replenishing oil filter elements (first after 500 hrs)

Change filter element of leakage oil filters (first after 500 hrs)

Change filter element of return filters (first after 500 hrs)

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Check mounting of components (pumps, motors, clamps, ...)

Check and adjust primary and secondary pressure relief valves

Replace hydraulic oil

Bleed servo system and hydraulic pumps (as necessary)

Clean high pressure filters (as necessary)

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Control and maintenance chart

WORK TO BE PERFORMED
R 9250

First and only interval Note

At 7500, 15000, ....hrs

At 1000, 3000, ....hrs

At 2000, 4000, ....hrs

At 500, 1500, ....hrs

Repeat interval
At 250, 750, ....hrs
At delivery

CENTRALIZED LUBRICATION SYSTEM

Every 1000 hours, perform a complete 1000 hrs Maintenance Echelon as

stated on page 9250_1001a.4a

Every 7500 hours, perform a complete 7500 hrs Maintenance Echelon as

stated on page 9250_1001a.4a

ELECTRICAL SYSTEM

Check level and specific gravity of the electrolyte in the batteries

Check and clean battery terminals

ENGINE AIR SYSTEM

Replace filter cartridge of air dryers

SWING RING

Check and if necessary tighten mounting screws

Check pinion gear mesh

Check axial play of swing ring

SWING GEAR

Replace gear oil (first at 500 hrs) 2x37 l (9,8

US Gal.)

Check mounting screws of gear and oil motor

TRAVEL GEAR

Check mounting screws of gear, sprocket wheels and oil motors

Replace gear oil (first at 1000 hrs) 2x52 l (13,8

US Gal.)

TRACKS
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Check tightening torque of screws of the locking keys of the idler axis

Check tightening torque of screws of rollers, pin locking screws and chain
guides

Check tightening torque of side frames screws

CAB, HEATER AND AIR CONDITIONER

Check locks and hinges on doors and windows (lubricate if necessary)

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Control and maintenance chart

WORK TO BE PERFORMED
R 9250

At 7500, 15000, ....hrs First and only interval Note

At 1000, 3000, ....hrs

At 2000, 4000, ....hrs

At 500, 1500, ....hrs

Repeat interval
At 250, 750, ....hrs
At delivery

Check heater for leaks, heat exchanger and heater filter

Replace the filter / drier (at least every two years)

Yearly check condition of the refrigerant receiver, if necessary replace it

Replace main element on air cleaners (at least once a year)

Replace safety element on air cleaners after 3 services of main element

Lubricate all doors seals with silicone or talc (before cold season)

UNDER / UPPERCARRIAGE & ATTACHMENTS

Check all parts for cracks

Check and lubricate cover hinges and locks

Check tightening of mounting screws for counterweight, tank, powerpack,

control valve console, cab, catwalks, grease box, ladder

Explain proper use and maintenance to the operator

Tab. 0-2 Hours maintenance schedule R 9250

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Oil sampling procedure

4.3 Oil sampling procedure

To make the oil sampling easier, the following components of the excavator have been fitted either with an oil
sample extraction valve (Diesel engine, splitterbox and hydraulic circuit), or with a special drain valve allowing
good accessibility and sampling conditions (both travel gears).

4.3.1 Oil sample extraction valve

Remove the cap 5 and attach a sampling hose as a high-pressure hose for pressure gauge. Turn the valve 6
to adjust and close off the airflow.
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Oil sampling procedure

4.3.2 Splitterbox

The oil sample valve is mounted at the top of the splitterbox.

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Oil sampling procedure

4.3.3 Engine

The valve for taking engine oil sample is mounted on the engine at the side of the splitterbox.
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Oil sampling procedure

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