Service Manual General

Conservation guidelines

1.5.00 Conservation guidelines

1 General
All parts of a construction machine are exposed to corrosion, especially when the machine is
taken out of service. Corrosion can be compared to wear. However, the effects of corrosion can
greatly exceed that of mechanical wear and shorten the service life of the affected parts
significantly. For that reason, for longer shut down, the machines and its components must be
preserved according to certain guidelines.
In general, these guidelines are tiered according to the following times:
Taking the machine out of service – for an unknown duration
Shut down of the machine
Shut down for up to 2 months
Shut down for up to 12 months
Shut down for longer than 12 months
Return to operation
The required measures are graduated depending on the different time frames. The
conservation measures cannot be strictly standardized and they must be shorted or lengthened
depending on the assessment of necessity (such as environmental influences).
Such influences are, for example:
Placement location of machine (for example in unprotected surrounding, in
closed areas, protected by a roof, temperate surrounding)
Type of climate (for example extreme temperatures, location in water / near the
coast, etc.)
Note!
For conservation for sea transport, special guidelines must be observed, which are not
included in these instructions. Refer to the special operating instructions.

2 Taking the machine out of service – for an unknown duration

If a machine is taken out of service for a longer period of time without conservation, then it must
be operated in intervals not to exceed 14 days, to prevent abnormal corrosion and its effects.
Before putting the machine back into service, check all oil levels and correct them, if
necessary.
Always carry out the specified daily maintenance work before putting the machine back into
service. In addition, carry out the time limited maintenance work according to the inspection
schedule and additional Diesel engine Operating instructions no later than the specified
intervals.
LWT / Ausgabe / Edition / Edition / 02.2010

Put the machine into operation according to the Operating instructions and operate it until the
Diesel engine and the hydraulic system has reached the specified operating temperature in
the hydraulic tank and in the coolant circuit.
Actuate all functions of the travel, working hydraulic as well as functions of additionally
installed hydraulic components and alternately operate them over a period of approx. 20
minutes. The hydraulic cylinders must be extended and retracted over their full stroke length.
When turning the machine off, retract all hydraulic cylinders fully, if possible, and fill the fuel
tank. If the machine is parked on soft ground, park the machine on wooden planks or similar
and secure it to prevent it from rolling off.
Check the batteries and remove them and recharge them, if necessary. Check the electrical
contact points and grease them, if necessary.

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PR Litronic Serie 4
LR Litronic Serie 4 1.5.00 - 1 / 6
RL Litronic Serie 4
General Service Manual
Conservation guidelines

3 Shut down of the machine

Preparations for shut down

Park the machine on horizontal, dry and solid ground and secure it to prevent it from rolling
off. Lower the working attachment to the ground level so that there is no longer any residual
pressure of the hydraulic.
Clean the machine diligently according to the procedure outlined in the Operating
instructions.
The machine must be completely dry before starting the conservation measures. Dry
electronic components and damp areas on the machine with pressurized air.
If freezing temperatures are expected for the intended duration of shut down, then the fuel
tank must be filled with winter fuel. Then start the Diesel engine and let it run for some time to
bring the winter fuel into the fuel circuit. Then add enough fuel to the fuel tank until it is full.
Note!
When a conserved machine is moved for loading or transport, then the conservation
protection on the piston rods of the cylinders will most often be removed by the scraper ring.
For that reason, if the machine is transported, the conservation of the piston rods must be
rechecked after loading and carried out again, if necessary.

Note!
Despite completed conservations measures, the machine must still be inspected in certain
intervals and touched up, if necessary. This is within left to the discretion of the operator, but
these inspections should be carried out regularly (monthly), especially in aggravated
conditions (cold, heat, near the coast, etc.).

3.1 Shut down for up to 2 months

Required tools / Service items

Description Id. No. Description Display

Optical charge See section To check the battery
tester 2.1 condition and the
antifreeze in the
coolant

WAXOYL 120-4 8504472 Spray can 500ml

Anti corrosion wax Long term protection
for up to 2 years
Ballistol Spray 10025514 Application area:
Corrosion protection Door locks
Dehumidification 10013313 Prevents infiltration
capsule of moisture over an
LWT / Ausgabe / Edition / Edition / 02.2010

extended period of
time

Check the entire machine for damage and remedy, if necessary.

Check the machine for paint damage and remedy, if necessary.
Take care of any maintenance work which would fall within the timeframe of the planned shut
down.
Due to the UV exposure of the components, synthetic materials, such as plastic parts, hoses,
rubber etc. must be covered with suitable aids.
Electrical components, contact points and plug connections which are not sealed must be
sealed with conservation wax „Waxoyl 120-4“.

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PR Litronic Serie 4
1.5.00 - 2 / 6 LR Litronic Serie 4
RL Litronic Serie 4
 Service Manual General
Conservation guidelines

Apply a thick layer of conservation wax „Waxoyl 120-4“ to cover ball joints, hinges, blank
parts and exposed piston rods. (Do not protect ball bearings with Waxoyl!)
Place a dehumidification capsule into the central electric box.
Protect all door and container locks with „Ballistol Spray“.
Set the battery master switch (if present) to position „0“ and then remove the batteries.
Check the battery acid level and add distilled water, if necessary. Always store the batteries
in a cool and dry area. Check the load current regularly every 6 weeks and recharge, if
necessary.
Close the exhaust outlet with an air and watertight cover.
Pay attention to any additional guidelines for special components or special local conditions.

3.2 Shut down for up to 12 months

Carry out all measures according to paragraph 3.1. In addition, the following is required:
Clean the Diesel engine externally.
Drain water from the fuel tank or condensation of the Diesel engine prefilter (see Operating
instructions).
Add commercially available Diesel fuel to the fuel tank until it is completely full. If the shut
down is during the cold time of the year, fill the fuel dank with winter Diesel fuel (Winter
Diesel fuel is suitable up to a temperature of -22°C / -7.6°F). Then start the Diesel engine and
let it run for some time to bring the winter fuel into the fuel circuit. Then add enough fuel to
the fuel tank until it is full.
Check the coolant to ensure it has sufficient corrosion and antifreeze protection - at least
50% corrosion inhibitor antifreeze fluid (for guidelines refer to the Operating instructions).
Seal the entire machine (Diesel engine, hydraulic aggregates, main frame, tank, track / axles,
equalizer bar, working attachments, etc.) with preservation wax „Waxoyl 120-4“. (Amount of
preservative agent: An area of approx. 5m² can be treated with one liter Waxoyl)
Note!
The following points must be observed when applying the corrosion inhibitor wax:
Observe a drying time of 3 hours.
Ambient temperature at least +15°C / 59°F.
Use protective equipment (breathing protection, safety glasses, respirator, etc.).
The solvents of the anti corrosion wax are flammable! (Do not smoke and avoid open
flames!)
Cold resistant to a temperature of -40°C / -40°F.
Release the chain tension by relieving the tension cylinder (see Operating instructions).
Check the machine monthly and reapply conservation protective measures if necessary.
LWT / Ausgabe / Edition / Edition / 02.2010

copyright by
PR Litronic Serie 4
LR Litronic Serie 4 1.5.00 - 3 / 6
RL Litronic Serie 4
General Service Manual
Conservation guidelines

3.3 Shut down for longer than 12 months

Carry out all measures according to paragraph 3.1 and 3.2. In addition, the following is required:
Note!
If a shut down for longer than 12 months is scheduled, then contact the Service Dept. of the
Diesel engine manufacturer.
Close off all openings, such as air filter, exhaust pipe, vent openings on components, etc.
airtight.
The vent for the fuel tank (if present) must remain open for safety reasons!
Rub the rubber seal of the cab and containers with talcum powder, close the doors. If the cab
is not installed, cover the operator’s platform properly. If necessary, remove the operator’s
seat. Cover the instrument panel and protect it.

4 Return to operation

4.1 After a shut down of 2 months

Remove the dehumidification capsule from the electronic box.
Check the fill levels and lubricate the machine according to the Operating instructions.
Install the batteries and clean / grease the battery terminals.
Open the exhaust outlet.
Drain water from the fuel tank or drain any condensation of the Diesel engine prefilter (see
Operating instructions).
Clean anti corrosion wax from ball joints, hinges, blank parts and exposed piston rods.
Put the machine back into service as outlined in the Operating instructions.
Before working with the machine, check all functions of the machine and remedy and defects
immediately. Carry out a thorough visual inspection on the machine.
Actuate all functions of the travel, working hydraulic as well as functions of additionally
installed hydraulic components and alternately operate them over a period of approx. 20
minutes. The hydraulic cylinders must be extended and retracted over their full stroke length.
Observe any additional guidelines for special components or special local conditions.

4.2 After a shut down of 12 months

Carry out the items according to paragraph 4.1.
Take an oil sample of the hydraulic oil and send it in for analysis.
Carry out the scheduled maintenance and inspection work on the machine before putting it
back into service.
On the Diesel engine, mechanically actuate the AGR flap (exhaust return) and the engine
brake flap and check for easy movement.
Grease the V-belts!
LWT / Ausgabe / Edition / Edition / 02.2010

Use a high pressure cleaner with steam (at least 120°C) as well as 5% additive of solvent
(such as petroleum) to clean the anti corrosion wax from the machine and aggregates.
(Caution when walking on surfaces, there is a danger of slipping due to the wax residue.)
Check the V-belt of the Diesel engine and replace it if necessary.
Carry out a Diesel engine test run: Increase the Diesel engine rpm only slowly to ¾ of the
high idle rpm until the operating temperature is reached.
Check the oil pressure display immediately after starting the Diesel engine.
Check the vacuum display of the air filter.
Adjust the chain tension to suit the application (see Operating instructions).

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PR Litronic Serie 4
1.5.00 - 4 / 6 LR Litronic Serie 4
RL Litronic Serie 4
 Service Manual General
Conservation guidelines

4.3 After shut down of longer than 12 months

Complete all items outlined in paragraph 4.2 and 4.1.
Note!
After a scheduled shut down of longer than 12 months contact the Service Dept. of the Diesel
engine manufacturer.
Remove all covers and closures, which were installed for conservation measures.
Turn the Diesel engine manually a few turns (use the turning device - flywheel – see Special
tools).
Start the machine and bring it to operating temperature.
After the machine was brought to operating temperature, change all lube and service fluids
as well as filters according to the Operating instructions
Check the entire machine for function and for leaks.
If necessary, carry out any time limited maintenance work at this time.
LWT / Ausgabe / Edition / Edition / 02.2010

copyright by
PR Litronic Serie 4
LR Litronic Serie 4 1.5.00 - 5 / 6
RL Litronic Serie 4
General Service Manual
Conservation guidelines

LWT / Ausgabe / Edition / Edition / 02.2010

copyright by
PR Litronic Serie 4
1.5.00 - 6 / 6 LR Litronic Serie 4
RL Litronic Serie 4