Lindner URRACO 75 D Operating and maintenance instructions

S h r e d d i n g S y s t e m s
1
1. .7 7
M
MA AI IN NT TE EN NA AN NC CE E I IN NS ST TR RU UC CT TI IO ON NS S
LINDNER Shredder Type URRACO 75 D
Date 2013.11.29
© Copyright LINDNER Mobile Shredder GmbH 2012-2013

URRACO 75 D 

 S ERVICE GUIDELINES
Managing director
LINDNER
Mobile Shredder GmbH
Industriestrasse 1A
D-99820 Hörselberg / Eisenach
Service hotline:
[phone] - 7269 - 600
[email protected]
Manuel Lindner
Gerhard Buhl
Walter Geiger
Page - 2 - of - 38 -
1.7.-1 General.............................................................................................................. - 3 -
1.7.-2 Important Advice for Welding Work.................................................................... - 5 -
1.7.-3 Filling Liquids ..................................................................................................... - 7 -
1.7.-4 Initial Maintenance Work.................................................................................. - 10 -
1.7.-5 Maintenance Intervals...................................................................................... - 13 -
1.7.-6 Inspecting / Changing the Hydraulic Oil Filters................................................. - 18 -
1.7.-7 Replacing the Tank Aeration Filter ................................................................... - 19 -
1.7.-8 Checking the Hydraulic Oil Level / Changing the Hydraulic Oil......................... - 20 -
1.7.-9 Checking the Gearbox Oil Level / Changing the Gearbox Oil........................... - 23 -
1.7.-10 Checking / Changing Engine Oil and Filter....................................................... - 24 -
1.7.-11 Checking the Coolant Level / Changing the Coolant ........................................ - 25 -
1.7.-12 Changing the Air Filter ..................................................................................... - 26 -
1.7.-13 Maintaining the Water Sprinkler Filter (Option)................................................. - 28 -
1.7.-14 Adjusting the Belt Tensioning and Alignment ................................................... - 30 -
1.7.-15 Assembly and Disassembly of the Discharge Conveyor Belt Rollers................ - 33 -
1.7.-16 Tilting Hopper 1 up........................................................................................... - 35 -
1.7.-17 Dismounting the Overbelt Magnet (Option) ...................................................... - 36 -
1.7.-18 Welding in new Knives, Breakers and Blocks................................................... - 37 -

URRACO 75 D 

 S ERVICE GUIDELINES
Managing director
LINDNER
Mobile Shredder GmbH
Industriestrasse 1A
D-99820 Hörselberg / Eisenach
Service hotline:
[phone] - 7269 - 600
[email protected]
Manuel Lindner
Gerhard Buhl
Walter Geiger
Page - 3 - of - 38 -
1.7.-1 General
General maintenance schedules must be observed, otherwise, our warranty for
your shredder will cease to apply.
The first maintenance and any necessary repairs may only be executed by our
service staff. Please refrain from executing any maintenance repair work
yourself or assigning any third parties with such works, since otherwise our
warranty will cease to apply.
All maintenance work may only be executed by trained and instructed
personnel. Before carrying out any maintenance work, carefully read the
instructions contained in the "Safety instructions" section.
The following must be done before entering the machine and before taking up
and maintenance or repair work:
set the key switch (Start) to the centre position and remove the ignition key,
set the key switch (Manual-0-Automatic) to "0 " and remove the key,
turn battery disconnecting switch out,
keep keys and the battery disconnecting switch in a safe place.
The shredder must always be secured against accidental or unauthorised
restarting.
It is strictly forbidden to climb into or onto the machine during operation,
particularly onto the shredding tools and the tilting hopper!
For servicing the drive engine, it is essential to follow the manufacturer’s
operating and maintenance manual!
Dispose of replaced filling liquids according to the manufacturer's instructions in
order to avoid endangering people or the environment.

URRACO 75 D 

 S ERVICE GUIDELINES
Managing director
LINDNER
Mobile Shredder GmbH
Industriestrasse 1A
D-99820 Hörselberg / Eisenach
Service hotline:
[phone] - 7269 - 600
[email protected]
Manuel Lindner
Gerhard Buhl
Walter Geiger
Page - 4 - of - 38 -
The maintenance schedule contains recommended maintenance intervals for the main
components. However, please note that this maintenance schedule may have to be adapted
to the actual conditions in your plant.
If you are working under particularly difficult conditions, it may be necessary to shorten the
recommended intervals. The following maintenance schedule should therefore be used as a
basis for preparing your own schedule, which should take into account your individual
operating conditions.
Thanks to their special training, the staff of LINDNER GmbH are able to provide first class
technical assistance as well as all maintenance services and spare parts which you require.
If you require spare parts or are encountering any problems, please do not hesitate to
contact us.
Phone: + 49 (0) 36920 - 7269 - 600
The contact details of our
Service Department are: Fax: + 49 (0) 36920 - 7269 - 99

URRACO 75 D 

 S ERVICE GUIDELINES
Managing director
LINDNER
Mobile Shredder GmbH
Industriestrasse 1A
D-99820 Hörselberg / Eisenach
Service hotline:
[phone] - 7269 - 600
[email protected]
Manuel Lindner
Gerhard Buhl
Walter Geiger
Page - 5 - of - 38 -
1.7.-2 Important Advice for Welding Work
Before any welding work is carried out, the earth switch must be set to "off" and
all electronic parts and components (remote control system, engine electronics)
must be disconnected from the power supply). Turning out the battery
disconnecting switch does not provide sufficient safety. Considerable damage
to the electronics is possible in the case of nonobservance.
All material residues must be removed from the shredder before each welding
procedure. Risk of fire!
For performing welding work, prepare the shredder as follows:
1. Switch off the drive engine.
2. Turn out battery disconnecting switch and secure it against being switched (lock it).
3. Disconnect the two plugs from the electronic engine control (ECM; Put the cable away
such that the contact pins of the plugs cannot make any contact.
4. Connect the earth cable of the welding apparatus directly to the part to be welded
(connect the earth cable of the welding apparatus as closely as possible to the welding
point).
Before you start welding, the cable and other combustible parts must be covered so that they
cannot be damaged by weld spatters.

URRACO 75 D 

 S ERVICE GUIDELINES
Managing director
LINDNER
Mobile Shredder GmbH
Industriestrasse 1A
D-99820 Hörselberg / Eisenach
Service hotline:
[phone] - 7269 - 600
[email protected]
Manuel Lindner
Gerhard Buhl
Walter Geiger
Page - 6 - of - 38 -
Battery disconnecting switch
Plug of the electronic
engine control (ECM)

URRACO 75 D 

 S ERVICE GUIDELINES
Managing director
LINDNER
Mobile Shredder GmbH
Industriestrasse 1A
D-99820 Hörselberg / Eisenach
Service hotline:
[phone] - 7269 - 600
[email protected]
Manuel Lindner
Gerhard Buhl
Walter Geiger
Page - 7 - of - 38 -
1.7.-3 Filling Liquids
R
Re ec co om mm me en nd de ed d f fi il ll li in ng g l li iq qu ui id ds s f fo or r y yo ou ur r L LI IN ND DN NE ER R s sh hr re ed dd de er r
Total filling capacity including filters as required Changing interval
Fuel
1
approx. 450 litres Diesel oil according to DIN 51601 as required
Coolant1
1
approx. 55 litres coolant mix of distilled water and
antifreeze according to
ASTM D4985-89
(ethylene glycol basis)
every 3000 hours
or annually
1
1
Refer to the drive engine operating and maintenance manual

URRACO 75 D 

 S ERVICE GUIDELINES
Managing director
LINDNER
Mobile Shredder GmbH
Industriestrasse 1A
D-99820 Hörselberg / Eisenach
Service hotline:
[phone] - 7269 - 600
[email protected]
Manuel Lindner
Gerhard Buhl
Walter Geiger
Page - 8 - of - 38 -
Engine oil
2
32 litres Select the lubricant viscosity according to the
ambient temperature:
Required oil viscosity
Ambient temperatureDiesel engine
multigrade oil
EMA LRG-1 API
CH-4 APICG-4
and APICF-4
Degree of
viscosity
min. maximum
SAE 0W / 20 -40 °C (-40 °F) 10 °C (50 °F)
SAE 0W / 30 -40 °C (-40 °F) 30 °C (86 °F)
SAE 0W / 40 -40 °C (-40 °F) 40 °C (104 °F)
SAE 5W / 30 -30 °C (-22 °F) 30 °C (86 °F)
SAE 5W / 40 -30 °C (-22 °F) 40 °C (104 °F)
SAE 10W / 30 -20 °C (-4 °F) 40 °C (104 °F)
SAE 15W / 40 -15 °C (5 °F) 50 °C (122 °F)
Factory-filled: SAE 10W / 40
every 250 hours or
every 6 months
ATTENTION:
Mandatory!
After 100 – 200
operating hours, the
customer must order
an inspection to be
performed by
LINDNER.
After 100-200
operating hours, the
engine inspection has
to be performed by the
responsible, authorised
dealer or OEM dealer
to ensure the warranty
for the engine. The
customer must order
this inspection
independently.
Gearbox
oil
60 litres (depending on sight glass level)
Types of oil: Oils with characteristics as per API GL-5
Ambient temperature: -10°C to +30°C SAE 80W/90
+20°C to +45°C SAE 85W/140
Factory-filled: CLP 220
after first
100 hours,
then every 500
hours
or twic
e yearly
Greases Standard multipurpose grease for antifriction and plain
bearings (e.g. MARSON L2),
Operating temperature range from -30 to + 120 °C
see lubrication
chart in the manual
2
Refer to the drive engine operating and maintenance manual

URRACO 75 D 

 S ERVICE GUIDELINES
Managing director
LINDNER
Mobile Shredder GmbH
Industriestrasse 1A
D-99820 Hörselberg / Eisenach
Service hotline:
[phone] - 7269 - 600
[email protected]
Manuel Lindner
Gerhard Buhl
Walter Geiger
Page - 9 - of - 38 -
Hydraulic
oil
approx. 120 litres Hydraulic oil according to DIN 51524
part 2, select the viscosity class from the
diagram according to the climatic
conditions
Purity class 18/13 according to ISO 4406 or better.
Factory-filled: HLP 46
every 500 to 1000
hours
or twice yearly
(depending on
contamination level)
Auswahldiagramm Selection diagram
A = arktische Verhältnisse oder für extrem lange Leitungen A = arctic conditions or for extremely long lines
W = winterliche Verhältnisse in Mitteleuropa W = winterly conditions in Middle Europe
S = sommerliche Verhältnisse in Mitteleuropa oder geschlossene
Räume
S = summerly conditions in Middle Europe
T =tropische Verhältnisse oder Räume mit starkem Wärmeanfall T =tropical conditions or rooms with high heat exposure
U = übermäßig starker Wärmeanfall (z.B. durch
Verbrennungsmaschinen)
U =excessively high heat exposure (e.g., by combustion engines)
Max. zul. Viskosität (kurzzeitig) max. permissible viscosity (short-term)
Optimaler Betriebsviskositätsbereich optimaler Wirkungsgrad Optimal operating viscosity range, optimal efficiency
min. zul.. Viskosität (kurzzeitig) min. permissible viscosity (short-term)
min. zul. Viskosität (kurzzeitig) min. permissible viscosity (short-term)
Temperatur t in °C Temperature t in °C
1) Druckflüssigkeitstemperaturbereich 1) Pressure liquid temperature range
Produkt- bzw. nenngrößenabhängig gelten folgende
Viskositätsbereiche:
The following viscosity ranges apply, depending on product or
nominal size:
(Der max. zul. Viskositätsbereich ist den Katalogblättern der
einzelnen Produkte zu entnehmen)
(For the maximum admissible viscosity range, refer to the
catalogue sheets of every product.)

URRACO 75 D 

 S ERVICE GUIDELINES
Managing director
LINDNER
Mobile Shredder GmbH
Industriestrasse 1A
D-99820 Hörselberg / Eisenach
Service hotline:
[phone] - 7269 - 600
[email protected]
Manuel Lindner
Gerhard Buhl
Walter Geiger
Page - 10 - of - 38 -
The oil change intervals for the gear and hydraulic oil can be extended subject to written
approval of our Service Department if the results of an oil analysis (laboratory report) have
been submitted.
You can have the oil analysis
conducted yourself in a certified laboratory and then send us the laboratory report, or
further advice and information concerning the oil analysis can be found at
www.wearcheck.de.
The maximum oil change intervals are 1000 h and must on no account be exceeded.
1.7.-4 Initial Maintenance Work
When servicing the drive engine, observe the separately enclosed operating
and maintenance manual of the engine manufacturer!
ATTENTION: Mandatory!
After 100 operating hours, the customer must order an inspection to be
performed by LINDNER.
After 100 -200 operating hours, the engine inspection has to be performed by
the responsible, authorised CAT dealer or OEM dealer to ensure the warranty
for the engine. The customer must order this inspection independently.
All maintenance work may only be executed by trained and instructed
personnel. Before carrying out servicing work, you must always read the safety
instructions.
The initial maintenance tasks are performed 16 hours (2 working days) and 100 - 200 hours
(1 month) after installation and commissioning of the machine.
The daily and the regular maintenance tasks are carried out according to section 1.7-5.

URRACO 75 D 

 S ERVICE GUIDELINES
Managing director
LINDNER
Mobile Shredder GmbH
Industriestrasse 1A
D-99820 Hörselberg / Eisenach
Service hotline:
[phone] - 7269 - 600
[email protected]
Manuel Lindner
Gerhard Buhl
Walter Geiger
Page - 11 - of - 38 -
M
Ma ai in nt te en na an nc ce e a af ft te er r 1 16 6 h ho ou ur rs s o or r 2 2 w wo or rk ki in ng g d da ay ys s ( (t to o b be e e ex xe ec cu ut te ed d b by y t th he e c cu us st to om me er r) )
Filter
elements
Hydraulic
system
Conveyor
belt
Cooler Gearbox Others
Daily
maintenance
tasks to be
executed
Daily
maintenance
tasks to be
executed
Daily
maintenance
tasks to be
executed
Daily
maintenance
tasks to be
executed
Daily
maintenance
tasks to be
executed
Daily
maintenance
tasks to be
executed
Retighten
all
fastening
bolts
Retighten
all bolts,
especially
on the
rakes,
shaft
bearings,
hoppers
and engine
fastening
bolts.
Inspect the
V-belts of
the fans

URRACO 75 D 

 S ERVICE GUIDELINES
Managing director
LINDNER
Mobile Shredder GmbH
Industriestrasse 1A
D-99820 Hörselberg / Eisenach
Service hotline:
[phone] - 7269 - 600
[email protected]
Manuel Lindner
Gerhard Buhl
Walter Geiger
Page - 12 - of - 38 -
M
Ma ai in nt te en na an nc ce e a af ft te er r 1 10 00 0 h ho ou ur rs s o or r o on ne e m mo on nt th h ( (b by y a an n L LI IN ND DN NE ER R G Gm mb bH H e en ng gi in ne ee er r) )
Filter
elements
Hydraulic
system
Conveyor
belt
Cooler Gearbox Others
Daily
maintenance
tasks to be
executed
Daily
maintenance
tasks to be
executed
Daily
maintenance
tasks to be
executed
Daily
maintenance
tasks to be
executed
Daily
maintenance
tasks to be
executed
Daily
maintenance
tasks to be
executed
Replace
suction filter.
Replace
suction/return
filter
Replacing the
tank aeration
filter
Check main
air filter
element
Change
gearbox oil.
Commission-
ing inspection
of the drive
engine

URRACO 75 D 

 S ERVICE GUIDELINES
Managing director
LINDNER
Mobile Shredder GmbH
Industriestrasse 1A
D-99820 Hörselberg / Eisenach
Service hotline:
[phone] - 7269 - 600
[email protected]
Manuel Lindner
Gerhard Buhl
Walter Geiger
Page - 13 - of - 38 -
1.7.-5 Maintenance Intervals
When servicing the drive engine, observe the separately enclosed operating
and maintenance manual of the engine manufacturer!
All maintenance work may only be executed by trained and instructed
personnel. Before carrying out servicing work, you must always read the safety
instructions.
The long-term maintenance tasks always include the performance of all more frequent
maintenance tasks.

URRACO 75 D 

 S ERVICE GUIDELINES
Managing director
LINDNER
Mobile Shredder GmbH
Industriestrasse 1A
D-99820 Hörselberg / Eisenach
Service hotline:
[phone] - 7269 - 600
[email protected]
Manuel Lindner
Gerhard Buhl
Walter Geiger
Page - 14 - of - 38 -
D
Da ai il ly y m ma ai in nt te en na an nc ce e t ta as sk ks s
Filter
elements
Hydraulic
system
Conveyor
belt
Cooler Gearbox Others
 Check and
clean the
main air
filter
element
 Check oil
level and
refill if
necessary
 Visual
check for
damage
 Check
alignment
and
functioning
of the
rollers
 Check the
belt
support
and clean if
necessary.
 Remove
any
jammed
material
from the
conveyor
belt
 Check belt
tensioning
and
alignment
 Check
coolant
level and
refill if
necessary.
 Check if
clean.
 Visual
check for
damage
and leaks.
 Check oil
level and
refill if
necessary.
 Visual
check for
damage
and leaks
 Check
engine oil
level and
refill if
necessary.
 Functional
test of all
(Emergency
Stop)
buttons and
safety
devices
 Overall
visual check
of the entire
machine for
damage,
leaks, loose
connections,
loose or
worn belts
and take any
remedial
action
necessary
 Check tire
pressure

URRACO 75 D 

 S ERVICE GUIDELINES
Managing director
LINDNER
Mobile Shredder GmbH
Industriestrasse 1A
D-99820 Hörselberg / Eisenach
Service hotline:
[phone] - 7269 - 600
[email protected]
Manuel Lindner
Gerhard Buhl
Walter Geiger
Page - 15 - of - 38 -
M
Ma ai in nt te en na an nc ce e e ev ve er ry y 2 25 50 0 h ho ou ur rs s o or r q qu ua ar rt te er rl ly y
Filter
elements
Hydraulic
system
Conveyor
belt
Cooler Gearbox Others
 Check the
main air
filter
element
and clean if
necessary
(max. six
times) or
replace.
Replace
the safety
elements
after every
third
cleaning of
the main
element
 Check oil
and filters
 Change oil
of the main
gearbox
 Engine
mainten-
ance (in
accordanc
e with the
engine
manual)

URRACO 75 D 

 S ERVICE GUIDELINES
Managing director
LINDNER
Mobile Shredder GmbH
Industriestrasse 1A
D-99820 Hörselberg / Eisenach
Service hotline:
[phone] - 7269 - 600
[email protected]
Manuel Lindner
Gerhard Buhl
Walter Geiger
Page - 16 - of - 38 -
M
Ma ai in nt te en na an nc ce e e ev ve er ry y 5 50 00 0 h ho ou ur rs s o or r e ev ve er ry y s si ix x m mo on nt th hs s
Filter
elements
Hydraulic
system
Conveyor
belt Cooler Gearbox Others
 Replace
suction
filter.
 Replace
suction/ret
urn filter
 Replace
the tank
aeration
filter
 Check
preset
pressure
settings.
 Change
the
hydraulic
oil + filters
 Check belt
tension
and adjust
if
necessary.
 Change oil
of the main
gearbox
 Functional
test of all
safety
devices
 Check
shredding
tools and
scrapers
for wear.
 Check all
bolted
connection
s.
 Engine
mainten-
ance (in
accordanc
e with the
engine
manual)
M
Ma ai in nt te en na an nc ce e e ev ve er ry y 1 10 00 00 0 h ho ou ur rs s o or r a an nn nu ua al ll ly y
Filter
elements
Hydraulic
system
Conveyor
belt Cooler Gearbox Others
 Change oil
of the main
gearbox

URRACO 75 D 

 S ERVICE GUIDELINES
Managing director
LINDNER
Mobile Shredder GmbH
Industriestrasse 1A
D-99820 Hörselberg / Eisenach
Service hotline:
[phone] - 7269 - 600
[email protected]
Manuel Lindner
Gerhard Buhl
Walter Geiger
Page - 17 - of - 38 -
A
An nn nu ua al l m ma ai in nt te en na an nc ce e
Filter
elements
Hydraulic
system
Conveyor
belt Cooler Gearbox Others
 Replace
the main
air filter
element
M
Ma ai in nt te en na an nc ce e e ev ve er ry y 3 30 00 00 0 h ho ou ur rs s o or r a an nn nu ua al ll ly y
Filter
elements
Hydraulic
system
Conveyor
belt
Cooler Gearbox Others
 Check and
clean the
cooling
system and
change the
coolant
M
Ma ai in nt te en na an nc ce e e ev ve er ry y 6 6 y ye ea ar rs s
Filter
elements
Hydraulic
system
Conveyor
belt
Cooler Gearbox Others
Replace
all
hydraulic
hoses

URRACO 75 D 

 S ERVICE GUIDELINES
Managing director
LINDNER
Mobile Shredder GmbH
Industriestrasse 1A
D-99820 Hörselberg / Eisenach
Service hotline:
[phone] - 7269 - 600
[email protected]
Manuel Lindner
Gerhard Buhl
Walter Geiger
Page - 18 - of - 38 -
1.7.-6 Inspecting / Changing the Hydraulic Oil Filters
A suction/return filter and a suction filter are installed in the shredder. The filter cartridges
have to be replaced when the <Oil filter> indicator light lights up or at least every 500
operating hours.
Although hydraulic oil filters are electronically monitored, maintenance still must
be carried out at regular intervals. Therefore, replace the filters after 500
operating hours at the latest.
When changing the filter, pay attention to the hydraulic oil temperature. Danger
of scalding.
All installed filter elements are also listed in the enclosed machine data sheet.
 Suction/return filter of the hydraulic oil tank
The integrated suction/return filter is equipped with a return and a suction connector. It is
equipped with an integrated oil temperature control device. Furthermore, it is equipped with
intelligent valve technology to control the oil temperature exceeding 50°C. To prevent air
from being drawn into the suction pipe, an oil guiding system has been installed.
To replace the suction/return filters, proceed as follows:
1. Have the new filter cartridge to hand. To find out which type of filter cartridge you have to
choose, please refer to appendix "Modules and Spare Parts".
2. Remove the complete cap using an appropriate tool by turning it counter clockwise.
3. Pull the cap with the filter element out of the hydraulic tank.
4. Replace the old filter cartridge by a new one.

URRACO 75 D 

 S ERVICE GUIDELINES
Managing director
LINDNER
Mobile Shredder GmbH
Industriestrasse 1A
D-99820 Hörselberg / Eisenach
Service hotline:
[phone] - 7269 - 600
[email protected]
Manuel Lindner
Gerhard Buhl
Walter Geiger
Page - 19 - of - 38 -
Suction filter
To replace the suction filter, proceed as follows:
1. Have the new filter(s) to hand. Filter cartridge type: see Appendix "Modules and spare
parts".
2. Unscrew the old filters from the filter head.
3. Clean the filter head sealing surface. The old sealing ring may still be sticking to the filter
head. If this is the case, remove it carefully.
4. Fill the oil filter with clean hydraulic oil.
5. Apply a thin hydraulic oil film on the filter seal.
6. Screw the filter onto the filter head. Tighten the filters until the seal touches the surface of
the filter head.
7. Tighten the filter by about another half to three-quarters of a turn.
1.7.-7 Replacing the Tank Aeration Filter
The tank aeration filter on the hydraulic tank must be replaced every 500 operating hours.
The type of filter to be used is listed in the Appendix "Modules and Spare Parts”.
Tank aeration filter

URRACO 75 D 

 S ERVICE GUIDELINES
Managing director
LINDNER
Mobile Shredder GmbH
Industriestrasse 1A
D-99820 Hörselberg / Eisenach
Service hotline:
[phone] - 7269 - 600
[email protected]
Manuel Lindner
Gerhard Buhl
Walter Geiger
Page - 20 - of - 38 -
1.7.-8 Checking the Hydraulic Oil Level / Changing the Hydraulic Oil
Maximum oil filling is only permissible with retracted hydraulic cylinders.
Checking the oil level
If the oil drops below the minimum level, the <Hydraulic oil level> indicator light lights up on
the control panel. In this case, the machine switches off immediately.
The hydraulic oil level must be checked daily via the sight glass; the oil should be
approximately in the upper third of the sight glass. Ensure that the shedder is standing
horizontally.
Oil drain plug
Sight glass
Hydraulic oil tank