Manual safety regulation_EN

BP09_017_0905EN 5.5.3 Hydraulic fluids

Category 32 Mineral oil 68
Type Ć15_C to +80_C HLP 0_C to +9

Classification 490984 51524 Part 2 279845.0
DIN 6743 Part 4
ISO
24318
Requirement Ċ
DIN
ISO 46
Ć10_C to +90_C
VDMA
Others Ċ
Viscosities
000171.007
DIN Ċ
ISO
mm2/s ISO VG Ċ

Use

Particular
characteristics
Initial filling

Material no.

Manufacturer

Changeover guidelines
VDMA

5 — 19

Synthetic ester Aqueous solutions
HEES HFC

51502
6743/0

Ċ Ċ
Ċ Ċ
24568 24317Ă/Ă24320
Ċ 7th Luxembourg Report

51519 46 46
3448 Ć10_C to +80_C Ć20_C to +60_C

95_C biodegrades quickly non−readily flammable

009 484527 239879.002

BECHEM HYDROSTAR FUCHS HYDROTHERM Maintenance

HEESĂ46 46ĂM

24569 24314



Maintenance cards

In this section you will find the maintenance cards necessary for this
machine. The table of contents includes a summary of the maintenĆ
ance cards in numerical order, you will find an alphabetical summary
in the Index of key words under the entry for Maintenance cards".

BP09_013_1205EN 5ĂĊĂ21

5ĂĊĂ22

00–001 Visual checks Maintenance card
00−001

Page 1 of 2

This maintenance card describes visual checks that you must
carry out before commencing any maintenance work. You will find
the maintenance intervals in the maintenance summary at the start
of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safety regulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

See also the maintenance cards:
Filter change
Hoses

No special tools required.

Danger
Inspect the electrical cables particularly closely and carefully.
There is a danger of flash overs from defective cables, particularly
when there is high air or ambient humidity. There is a danger of fire
and explosion through the formation of sparks when the machine is
used in a potentially explosive atmosphere.

WK00_001_1109EN 5ĂĊĂ23

Maintenance card
00−001

Page 2 of 2

General The general visual inspections listed below should always be carried
Electrical system out before any maintenance work, and also each time before starting
Hydraulic system work with the machine.

" Check the fill levels of the functional fluids.
" Check that all safety equipment is available and in a fully

functioning condition.

Should you locate any damage to the electrical system, you must
have the damage rectified immediately by a qualified electrician.

" Check that all electrical connections are secure and free from
corrosion.

" Check that the electrical cables have no breaks.
" Check the insulation on the electrical cables.

Timely detection and rectification of damage to the hydraulic system
can prevent lengthy downtimes and high repair costs.

" Check that the displays on the vacuum meter of the suction
filters are still in the green range. The suction filters must be
replaced if the displays are in the red range.
Maintenance card: Filter change

" Check the contamination indicators on the boom filters.
The filters are in order if the red button remains depressed.
The filter must be replaced if the red button pops out.
Maintenance card: Filter change

" Check the fluid cooler for contamination and deposits.
" Check all hydraulic hose lines for leaks.

Maintenance card: Hoses

" Check all screwed hydraulic screwĆcouplings for tightness
and leaks.
Maintenance card: Hoses

5ĂĊĂ24 WK00_001_1109EN

Maintenance card
01−021

Page 1 of 6

01–021 Transfer gearboxes G64SB This maintenance card describes a full oil change and checking the
and G64SC oil level in the transfer gearbox.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter Safety
regulations" and the description of the Residual risks during mainĆ
tenance, inspection and repair work" at the start of the chapter enĆ
titled Maintenance" (i.e. this chapter).

No further maintenance cards required.

No special tools required.

MA The tightening torques can be found in the corresponding
Spare parts list.

WK01_021_1110EN 5ĂĊĂ25

Maintenance card
01−021

Page 2 of 6

Caution
The transfer gearbox must never be shifted when under load. Only
shift the transfer gearbox when the Cardan shaft is stationary.

Check that the expirator screws are clean and operating correctly
each time that the oil in the transfer gearbox is changed. If necessĆ
ary, clean or replace the expirator screws.

The transfer gearbox must never be operated if an expirator screw is
missing or defective. Otherwise, leaks may occur due to an increase
in pressure.
This may then cause damage to the transfer gearbox.

Environmental protection
All operating equipment and functional fluids, e.g. oils (including bioĆ
logically degradable oils), filters and auxiliary materials must be
carefully collected and disposed of separately, both from each other
and from other waste. Different categories of oil must also be kept
separately from each other. Nationally and regionally applicable disĆ
posal regulations must be observed for these materials.

Note
The lubrication circuit on the transfer gearbox lubricates the gearbox
and the connection of the hydraulic pumps.

Check the oil level in the transfer gearbox each time the oil is
changed and top up with gearbox oil, as required.

5ĂĊĂ26 WK01_021_1110EN

Full fluid change Maintenance card
01−021

Page 3 of 6

This section describes how to change the transfer gearbox oil.

Note
The full oil change intervals can be found in the maintenance sumĆ
mary at the start of this chapter.

Data concerning oil specification and filling capacity is contained in
the spare parts sheet. It is not permissible to use oils other than
those specified without first consulting with Putzmeister After Sales
department (APS department).

Data concerning parts required and tightening torques can be found
in the spare parts sheet.

Note
Before changing the oil, carry out the following procedures:
ć Engage the power takeĆoff and allow the transfer gearbox to warm

up.
ć Disengage the power takeĆoff.
ć Allow the oil to settle for a while, then start the full oil change.

WK01_021_1110EN 5ĂĊĂ27

Maintenance card
01−021

Page 4 of 6

The gearbox oil can be added via the bore hole of expirator
screw (1). The oil level in the gearbox must reach as far as oil level
check screw (2).

OIL OIL

1 1

22

3 3

No. 0 Designation WK01_021_1110EN 1
1 Expirator screw
2 Oil level check screw
3 Oil drain plug

" Unscrew expirator screw (1) and oil level check screw (2). In
the process, make sure that no foreign bodies enter the gearĆ
box through the open bore holes.

" Drain the gearbox oil via the bore hole of the oil drain plug (3).

" Clean all screws/plugs that were removed.

" After the oil has drained, replace the sealing ring of the oil
drain plug (3) and screw the plug back into place.

5ĂĊĂ28 WK01_021_1110EN

Maintenance card
01−021

Page 5 of 6

" Add the gearbox oil via the bore hole of expirator screw (1).
The oil level must reach as far as the bore hole of oil level
check screw (2).

" After approx. 10 minutes, check the oil level and correct, if
necessary.

" Replace the sealing rings of the expirator screw (1) and oil
level check screw (2) and screw the screws back in.

WK01_021_1110EN 5ĂĊĂ29

Maintenance card
01−021

Page 6 of 6

5ĂĊĂ30 WK01_021_1110EN

Maintenance card
01−024

Page 1 of 4

01–024 Slewing gear transmission This maintenance card describes the oil level check, full oil change
and lubrication with grease on the slewing gear transmission. You
will find the maintenance intervals in the maintenance summary at
the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter Safety
regulations" and the description of the Residual risks during mainĆ
tenance, inspection and repair work" at the start of the chapter
entitled Maintenance" (i.e. this chapter).

No further maintenance cards required.

No special tools required.

WK01_024_1208EN 5ĂĊĂ31

Maintenance card
01−024

Page 2 of 4

Danger
Shut the machine down and dump the accumulator pressure
completely before you start working on the slewing gear
transmission.

Note
The roller bearing on the transmission drive shaft has permanent
grease lubrication and does not usually need to be lubricated.
However, if it becomes necessary to replenish the grease packing
as a result of repairs to the transmission drive shaft, use roller
bearing grease 80, DIN 51 825, worked penetration 220 = 250
(NLGI Class 3).

Carry out the full oil change with the machine at operating tempeĆ
rature. This allows the transmission oil to flow out more easily. It is
recommended that the transmission be flushed out with a small
quantity of warm new oil to ensure that wear particles and contaĆ
mination are washed out in low ambient temperature conditions.

5ĂĊĂ32 WK01_024_1208EN

Slewing gear trans- Maintenance card
mission 01−024

Page 3 of 4

1
2
3

Checking oil level 4
Full fluid change
WK01_024_1208EN 1

No. 0 Designation
1 Sealing plug
2 Oil filler
3 Inspection glass
4 Oil drain plug

Check the oil level once a week when the gearbox is idle and the
machine is standing on a level surface. The oil level in the oil filler
must not be below the MIN" mark on the oil dipstick.

The first full oil change must be carried out after 100 operating
hours, every further full oil change after 1000 operating hours,
but at least once a year.

WK01_024_1208EN 5ĂĊĂ33

Maintenance card
01−024

Page 4 of 4

Filling the gearbox with transmission oil

" Remove the sealing plug (1) from the oil filler (2).
" Place a suitable container underneath to collect the transĆ

mission oil which flows out.
" Unscrew the lowest gearbox oil drain plug (4) and allow the

transmission oil to drain off.
" Reseal the oil drain opening with the oil drain plug (4).
" Fill the gearbox with transmission oil up to the upper edge of

the inspection glass (3) via the oil fillerĂ(2).
" Reseal the oil filler (2) with the sealing plug (1).

5ĂĊĂ34 WK01_024_1208EN

Maintenance card
01−020

Page 1 of 6

01–020 Inspecting, cleaning and, if This maintenance card describes how to inspect and clean cardan
required, lubricating the shafts. The section Lubricating the cardan shaft" applies only to carĆ
cardan shaft dan shafts that are equipped with lubrication nipples. You will find
the maintenance intervals in the maintenance summary at the start of
this chapter.

Note
There are specific risks of accident associated with maintenance,
inspection and repair work. For this reason, read the chapter
Safety regulations" and the description of the Residual risks during
maintenance, inspection and repair work" at the start of the chapter
entitled Maintenance" (i.e. this chapter).

No further maintenance cards required.

No special tools required.

MA The tightening torques can be found in the corresponding
Spare parts list.

Danger
Moving machine components can cause injury and serious material
damage.
The drive must be inoperative when work is carried out on the carĆ
dan shafts. Turn off the engine and make sure that the drive cannot
be put into operation again without permission.

WK01_020_1504EN 5ĂĊĂ35

Maintenance card
01−020

Page 2 of 6

Inspecting the cardan shaft This section describes the inspection of the cardan shaft.
Caution
Repair or replacement of the cardan shaft must only be carried out
by an authorized specialist workshop.

1 2 34

56

6 66 7 WK01_020_1504EN 1
Example illustration

No. 0 Designation

1 Linear compensation
2 Cardan shaft without lubrication nipples (maintenance−

free)
3 Joint
4 Flange
5 Cardan shaft equipped with lubrication nipples
6 Lubrication nipples (optional)
7 Cross pin bearings

5ĂĊĂ36 WK01_020_1504EN

Maintenance card
01−020

Page 3 of 6

" Inspect the cardan shaft for changed operating noises, vibraĆ
tions and unusual behaviour. Determine the cause, if necessĆ
ary, and arrange repairs.

" Check whether any noticeable play is present by lifting the
joints (2) and the linear compensation (1). If there is noticeable
play, arrange a repair.

" Check the bolts on the flange (3) for firm seating.

" Inspect the adjacent components for damage.

" At the cross pin bearing (7), check to see whether grease has
emerged. If visible traces of grease are found at the cross pin
bearing, proceed as follows:
å For maintenance−free cardan shafts: Arrange to have the
cardan shaft repaired by a specialist workshop.
å For cardan shafts that are equipped with lubrication
nipples: Lubricate the cross pin bearings as described in the
next section.

WK01_020_1504EN 5ĂĊĂ37

Maintenance card
01−020

Page 4 of 6

Cleaning the cardan shaft The cardan shaft should only be cleaned if coarse dirt causes imbalĆ
ances. Cleaning must only be carried out by a specialist workshop.

Caution
Do not use a steam jet or corrosive cleaning agents to clean the carĆ
dan shaft. Otherwise the seals could be damaged by water ingress
and dirt.

Note
After cleaning, the cardan shaft must be lubricated if lubrication
nipples are present.

Lubricating the cardan shaft For those cardan shafts that are equipped with lubrication nipples,
lubricating the cross pin bearings is described in this section.

Caution
The maintenance intervals must be adhered to, otherwise
ć the cross pin bearings and teeth will become worn and
ć the power take−offs can be damaged by the impact of the cardan

shaft.

Also after cleaning or downtime of 6 months or more, the cross pin
bearings of the cardan shaft must be lubricated.

Note
Lubricate the cross pin bearings of the cardan shaft directly at the
lubrication nipples and not at the cross pin bearings.

5ĂĊĂ38 WK01_020_1504EN

Maintenance card
01−020

Page 5 of 6

1
23

22 33

No. 0 Designation WK01_020_1504EN 2
1 Grease gun
2 Lubrication nipples (optional)
3 Cross pin bearings

" Clean the lubrication nipples (2).

WK01_020_1504EN 5ĂĊĂ39

Maintenance card
01−020

Page 6 of 6

Caution
The grease must not be forced in at too high a pressure or with hard
impacts. The maximum permitted lubrication pressure is 15 bar.

" Force just enough grease in at one of the lubrication nipples
(2) at each joint, until the grease escapes visibly from all four
seals on the cross pin bearings (3).

Caution
If grease cannot emerge from all four seals on the cross pin bearings
(3), the cardan shaft must be repaired.

5ĂĊĂ40 WK01_020_1504EN

03–001 Changing the Maintenance card
hydraulic fluid 03−001

Page 1 of 6

This maintenance card describes how to carry out a full oil change
on the hydraulic system. You will find the service intervals in the
maintenance summary at the start of this section.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safety regulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

Refer also to the maintenance cards:
Function checks
Filter change
Hoses

No special tools required.

Note
Cleanliness is of the greatest possible importance in the maintenĆ
ance of hydraulic systems. You must make it impossible for dirt or
other impurities to enter the system. Even small particles may cause
valves to be scored, pumps to seize and choke and control bores to
become blocked.

Hydraulic fluid drums must stand for some time before the fluid is
taken from them. Never roll the barrels to where you will be drawing
off the fluid. Clean bungs, filler caps and their surroundings before
opening them.

If possible, you should use a filler unit to fill up the hydraulic system.
Never leave the tank lid open longer than necessary.

WK03_001_1109EN 5ĂĊĂ41

Maintenance card
03−001

Page 2 of 6

Preparation The following tasks must be carried out before starting the full fluid
change:

" Switch off the remote control.

" Switch the hydraulic pumps off.ā

" Reduce fluid pressure completely.

" Check the contamination indicator on the vent filter of the fluid
reservoir. You must replace the filter element for the vent filter
when the red check ring is visible in the inspection glass.
Maintenance card: Filter change

1

10401903

1 Red check ring in the inspection glass

5ĂĊĂ42 WK03_001_1109EN

Maintenance card
03−001

Page 3 of 6

Danger
The accumulator pressure in pressurized systems must be released.

" Switch the drive engine off.

" Secure the system against unauthorized starting ć if you have
any keyed switches, remove the key and disconnect the supĆ
ply voltage.

" Secure your working area and fix notices to the blocked conĆ
trols and setting devices.

Changing the fluid

10300400

Draining off the fluid

Environmental protection
You must make sure you collect the old hydraulic fluid and dispose
of it in accordance with the regulations. Biologically degradable hyĆ
draulic fluids must also be disposed of separately from other waste,
just like mineral hydraulic fluidsā!

" Remove a hose from the hydraulic system tank and drain off
the fluid.

WK03_001_1109EN 5ĂĊĂ43

Maintenance card
03−001

Page 4 of 6

" Then disconnect all hoses from the tank.

Note
Mark the hoses and their connection points for re−assembly.

10400300

Marking the hoses

" Wipe out all the openings with a lint−free cloth. Wipe as far into
the tank as possible when doing this. You should also reĆ
member that there may also be separate apertures intended
for tank cleaning.

" Remove all filter inserts.
Maintenance card: Filter change

" Change all filters and refit the filter elements.

" Replace any defective hoses.
Maintenance card: Hoses

Environmental protection
Dispose of the old filter inserts in accordance with the regulations in
force.

5ĂĊĂ44 WK03_001_1109EN

Maintenance card
03−001

Page 5 of 6

10300500

Filling the tank

" Fill the tank with new fluid.

Note
Only fill the tank through the mesh in the filler inlet. Fill up the tank up
to the Maximum" marking after bleeding and a test run. Use only the
hydraulic fluids specified in the lubrication recommendations.

" Remove the dirt deposits from the oil cooler.

" Check all screwed joints and tighten where necessary. Check
all flared screwed joints.
Maintenance card: Hoses

" Check the electrical connections.
" Carry out all function checks.

Maintenance card: Function checks

" Bleed hydraulic system.

" Carry out several test runs.

" Refit all the safety equipment, markings and notices you have
removed.

WK03_001_1109EN 5ĂĊĂ45

Maintenance card
03−001

Page 6 of 6

5ĂĊĂ46 WK03_001_1109EN

03–002 Function checks Maintenance card
03−002

Page 1 of 2

This maintenance card describes the inspection of machine funcĆ
tions. The inspections are carried out with the machine running. You
will find the service intervals in the maintenance summary at the start
of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safety regulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

No further maintenance cards required.

The following special tools are required:
Pressure gauge and connections for the tapping points shown in the
hydraulic circuit diagram

Note
Only qualified personnel authorized by us may carry out work on the
hydraulic system. Notify the Putzmeister After Sales department or
the dealer/agent who looks after you immediately should you find
any irregularities.

" Measure the pressures generated by the pumps, using the
measuring equipment specified directly on the pumps, and
compare your results with the values specified in the test
reading.

" Check the proper functioning of the pressure−relief valves in
the high pressure circuit and the pressure accumulator.

WK03_002_1109EN 5ĂĊĂ47

Maintenance card
03−002

Page 2 of 2

5ĂĊĂ48 WK03_002_1109EN

Maintenance card
03−026

Page 1 of 8

03–026 Checking the accumulator This maintenance card describes how to check the accumulator
preĆcharge pressure. In Germany, the maintenance intervals are preĆ
scribed by the Industrial Health & Safety Ordinance [BetriebsicherĆ
heitsverordnung (BetrSichV)]. Please note any applicable regulations
in your country of use.

Note
There are specific risks of accident associated with maintenance,
inspection and repair work. For this reason, read the chapter
Safety regulations" and the description of the Residual risks during
maintenance, inspection and repair work" at the start of the chapter
entitled Maintenance" (i.e. this chapter).

No further maintenance cards required.

No special tools required.

WK03_026_1402EN 5ĂĊĂ49

Maintenance card
03−026

Page 2 of 8

Danger of explosion
Use only nitrogen to fill the accumulator. There is a danger of
explosion if compressed air, oxygen or similar are used.

Note
Check the accumulator preĆcharge pressure once the hydraulic fluid
has warmed up to its operating temperature (of 50 _C to 70 _C).

The setpoint value for the accumulator preĆcharge pressure can be
found on the hydraulic circuit diagram as item 120 and in the test
reading for the concrete pump under the entry Accumulator preĆ
charge pressure". The hydraulic circuit diagram and the test reading
can be found in the documentation binder in the Technical data"
file.

The actual value you measure must not be more than 15 % less than
the setpoint value specified.

5ĂĊĂ50 WK03_026_1402EN

Maintenance card
03−026

Page 3 of 8

1

2
3

4

5 WK03_026_1402EN 1

Pos.0 Designation
1 Accumulator
2 Transfer tube changeĆover valve
3 Delivery cylinder emergency control lever
4 Transfer tube damping cock
5 Accumulator dump valve

Note
You can observe the pointer on the pressure gauge slowly going
down as you slowly release the accumulator pressure. Once the
accumulator preĆcharge pressure actually present is applied,
the pressure gauge drops suddenly. The value found immediately
beforehand is the present accumulator preĆcharge pressure.

WK03_026_1402EN 5ĂĊĂ51

Maintenance card
03−026

Page 4 of 8

" Start the machine up.
" Load the accumulator with hydraulic fluid until the maximum

pressure is shown on the pressure gauge.

" Switch off the engine.
å The accumulator pump halts.
å The accumulator dump valve remains under stress, i.e. the
accumulator pressure is not dumped.

" Operate the Transfer tube changeĆover valve" and dump the
accumulator pressure slowly.

Note
Depending on the direction in which you operate the emergency
control lever, it is possible for the transfer tube to switch over again.
This depends on the transfer tube position.

" Observe the pressure gauge and read off the accumulator preĆ
charge pressure.

You must have the accumulator topped up if the actual value is 15 %
or more below the setpoint value.

5ĂĊĂ52 WK03_026_1402EN

Topping up the Maintenance card
accumulator 03−026

Page 5 of 8

In Germany, the persons permitted to top up the accumulator, and
the inspection periods, are dependent on the category classified
according to the Industrial Health & Safety Ordinance [BetriebsicherĆ
heitsverordnung (BetrSichV)] and on the maximum permissible
pressure.
− In accordance with Directive 97/23/EC, hydraulic fluids and

nitrogen belong to the fluids in group 2. Directive 97/23/EC,
appendix II, diagram 2 applies.
− The maximum permissible pressure (PS), the volume (V in litres)
and the classified category of the accumulator can be found in
the declaration of conformity for the accumulator (see Technical
appendix" binder).

" For additional information, please see the following table.

Note
Please note the provisions for inspection periods for recurring
inspections" that apply in your country.

WK03_026_1402EN 5ĂĊĂ53

Maintenance card
03−026

Page 6 of 8

Recurring inspection
in accordance with BetrSichV

Classification of the pressure equipment External inspection
in accordance with part 9 in connection Internal inspection
with appendix II of Directive 97/23/EC, Stability inspection

in accordance with diagram 2 Inspector

Category I, category II −f
Category III (PS v 1 bar)

Category III (PS u 1 bar) 2 years 10 years * 10 years F
Category IV

f = to be carried out by subject expert
F = to be carried out by authorized supervision institution
− = no prescribed inspection period
* = in accordance with BetrSichV, appendix 5, number 2:
For pressure equipment with gas cushions in hydraulic fluid systems,
recurring internal inspections must be carried out at the latest after
10 years, provided the liquids and gases used do not exert any
corrosive impact on the walls of the device.

Note
A subject expert for the inspection and filling of accumulators is
someone who has demonstrably been instructed in this activity by
an authorized inspector. The tools and equipment necessary for
inspecting and filling pressure vessels must be available to him.

The accumulator must only be filled with nitrogen (see Gas preĆfill
pressure = xx bar").

5ĂĊĂ54 WK03_026_1402EN

Maintenance card
03−026

Page 7 of 8

WK03_026_1402EN 2

The hydraulic system contains an accumulator. Before maintenance
work on the hydraulic system, the system must be depressurized.

Danger
Risk of slipping/falling or suffering impact, and even severe injury,
caused by hydraulic fluid escaping under high pressure. The risk
exists if the hydraulic system is not depressurized before maintenĆ
ance work.
Always depressurize all lines before working on the hydraulic
system.
Be aware that if threaded connections are unusually difficult to open,
it may indicate that pressure is present in the system.
Before maintenance work on the accumulator, the hydraulic system
must be depressurized and the accumulator preĆcharge pressure
must be dumped.

WK03_026_1402EN 5ĂĊĂ55

Maintenance card
03−026

Page 8 of 8

5ĂĊĂ56 WK03_026_1402EN

Maintenance card
03−025

Page 1 of 4

03–025 Drain off condensate water This maintenance card describes how to drain the condensate water
from the hydraulic system. You will find the maintenance intervals in
the maintenance summary at the start of this chapter.

Note
There are specific risks of accidents associated with maintenance,
inspection and repair work. For this reason, read the chapter
Safety regulations" and the description of the Residual risks during
maintenance, inspection and repair work" at the start of the chapter
entitled Maintenance" (i.e. this chapter).

No further maintenance cards required.

No special tools required.

After relatively long periods of machine downtime (e.g. overnight),
condensate water collects in the hydraulic fluid reservoir and is
caught in the water drain tank, from where it must be drained.

Danger
A high water content may lead to corrosion damage in the hydraulic
system, which can cause excessive wear and even machine damĆ
age. The condensate water must therefore be drained every time
before starting work.

WK03_025_1307EN 5ĂĊĂ57

Maintenance card 3
03−025 4

Page 2 of 4 WK03_025_1307EN 1

1

2

No. 0 Designation

1 Water drain tank
2 Water drain cock
3 Holder for hose
4 Plug on the drain outlet

5ĂĊĂ58 WK03_025_1307EN

Maintenance card
03−025

Page 3 of 4

Environmental protection
The liquid which is drained off is not just water but an environĆ
mentally harmful mixture of water and hydraulic fluid. Dispose of
this mixture of water and hydraulic fluid correctly in order to avoid
environmental pollution.

Empty the collection container every time the condensate water is
drained to prevent the container from overflowing and polluting the
environment.

Draining the hydraulic
fluid reservoir

WK03_025_1307EN 2

Drain off condensate To drain the condensate water, proceed as follows:
water
" Place a suitable container underneath to catch the escaping
condensate.

" Unscrew the plug (4) from the drain outlet.
" Fit the hose to the drain outlet (see illustration).

WK03_025_1307EN 5ĂĊĂ59

Maintenance card
03−025

Page 4 of 4

" Open the water drain cock (2).
å The water will flow into the collection container.

" When only hydraulic fluid emerges, close the water drain
cock (2).

" Remove the hose and fit it back on the holder.
" Screw the plug back on the drain outlet.

5ĂĊĂ60 WK03_025_1307EN

04–002 Hydraulic hoses Maintenance card
04−002

Page 1 of 4

This maintenance card describes how to check and replace the
hydraulic hoses. You will find the maintenance intervals in the mainĆ
tenance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safety regulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

No further maintenance cards required.

No special tools required.

MA The tightening torques can be found in the corresponding
Spare parts list.

Note
Check all hydraulic hoses (including hose fittings) with the machine
running.
You must replace the hydraulic hoses at the slightest sign of damage
or even mere indications of threatened damage.

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04−002

Page 2 of 4

Environmental protection
All functional fluids and operating materials, e.g. oils (including bioĆ
logically degradable oils), filters and auxiliary materials must be
carefully collected and disposed of separately, both from each other
and from other waste. Different categories of oil must also be kept
separately from each other. Nationally and regionally applicable disĆ
posal regulations must be observed for these materials.

Leaking
hydraulic hoses

10400800

Check hydraulic hoses

Dark and moist patches on the fitting are external signs of incipient
damage. Check:
− the hydraulic hoses for kinks, cracks or a porous surface and
− whether the hydraulic hoses have been laid without restrictions.

Note
Beware of strong sunlight, the action of heat and the effects of
chemicals.

5ĂĊĂ62 WK04_002_1110EN

Replacing Maintenance card
hydraulic hoses 04−002

Page 3 of 4

The procedure for replacing hydraulic hoses is as follows:

" Shut down the machine and secure against unauthorized
starting.

" Fully dump any (residual) pressure in the hydraulic system.

Danger
Hydraulic hoses may be mechanically pre−stressed. There is a risk
of injury from whipping hoses.

" Take care when undoing the joints.
" Close the connection points with a plug immediately you have

removed the old hydraulic hoses. No dirt may enter the hyĆ
draulic circuit and the hydraulic circuit must not run empty.

Danger
Hydraulic hoses should not be more than six years old, including a
storage time of two years. Take note of the date of manufacture on
the hydraulic hoses.

" Keep the hydraulic hoses free from dirt.
" Fit the hydraulic hoses to be free from bends or points of abĆ

rasion.
" Bleed the hydraulic system.
" Carry out a test run and inspect all hydraulic hoses again after

fitting new hydraulic hoses.

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Page 4 of 4

Flared screwed joints

10400100

Tightening flared screwed joint

" Check whether the flared screwed joints are tight.
Note
You may only tighten leaking flared screwed joints with the permitted
tightening torque. Tighten the flared screwed joints until you clearly
feel an increase in the force required if you do not have a torque
wrench available. You must replace these flared screwed joints if
leaking continues.
The tightening torques can be found in the table Flared screwed
joints" at the start of this chapter.

5ĂĊĂ64 WK04_002_1110EN

04–014 Changing the ventilation Maintenance card
filter element 04−014

Page 1 of 4

This maintenance card describes how to change the ventilation filter
element.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safety regulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

No further maintenance cards required.

No special tools required.

Ventilation filter for ... Filter element Maintenance
indicator
water tank no
fuel tank yes no
hydraulic fluid reservoir yes no
yes

Note
When a maintenance indicator is integrated into the screw cap on
the filter housing, you can use it to detect the latest time that the filter
element should be changed. Without a maintenance indicator,
change the filter elements when they appear very dirty.

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8
1

7
6

23 4 5

WK04_014_1109EN 1

No. 0 Designation
1 Filter element
2 3−stage maintenance indicator
3 Rotary knob, resets the maintenance indicator
4 Screw cap with maintenance indicator
5 Hydraulic fluid reservoir filter housing
6 Fuel/water tank filter housing
7 Screw cap without maintenance indicator
8 Filter element (optional)

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04−014

Page 3 of 4

" Undo the screw cap from the filter housing.
" Remove the filter element from the filter housing.

Environmental protection
Dispose of used filter elements in accordance with the relevant
regulations.

Caution
The filtering process causes dirt particles to accumulate in the filter
housing. You must therefore clean the filter housing thoroughly
before refitting the new filter element, as otherwise the new filter
element will rapidly become clogged again.

" Clean the filter housing and the inside of the screw cap with a
clean cloth.

" When fitted, reset the 3−stage maintenance indicator by turnĆ
ing the rotary knob anti−clockwise in the direction of the arrow.
å The 3−stage maintenance indicator jumps back to its origĆ
inal position.

" Insert a new filter element into the screw cap.
" Screw the screw cap with filter element inserted back onto the

filter housing.

WK04_014_1109EN 5ĂĊĂ67