New Holland Ec130 Excavator Repair Service Workshop Manual PDF

FOREWORD
Using the Technical Handbook .............................................................................................................. 1

Servicing and repair ................................................................................................................................ 1
Warnings and symbols ............................................................................................................................ 2
Danger in the event of non-obser-vance of the safety instructions .................................................... 2
Organizational measures ........................................................................................................................ 3
Selection and qualification of personnel - basic responsibilities ........................................................ 4
Safety instructions governing specific operational phases

Standard operation .................................................................................................................................. 4
Special work in conjunction with utilization of the machine - maintenance and repairs during
operation - disposal of parts and consumables .................................................................................... 5
Warning of special dangers

Electric energy ........................................................................................................................................ 6
Gas, dust, steam and smoke .................................................................................................................. 6
Hydraulic and pneumatic equipment ...................................................................................................... 7
Noise ...................................................................................................................................................... 7
Oil, grease and other chemical substances ............................................................................................ 7
Transporting and towing - recommissioning ........................................................................................ 7
California, Proposition 65 Warning ........................................................................................................ 7
Repair work - safety instructions ............................................................................................................ 8
Accumulators, safety instructions .......................................................................................................... 9
ENGINE .................................................................................................................................................... 10
Engine, repair instructions .................................................................................................................... 10
Assisted starting (with jump-leads) - safety instructions .................................................................. 10
WELDING OPERATIONS ........................................................................................................................ 11
Welding operations - safety instructions.............................................................................................. 11

TECHNICAL HANDBOOK EC 130
FOREWORD 2796842
This Technical Handbook (THB) has been writ- Servicing and repair
ten with the servicing mechanic in mind and
contains important information required to carry Servicing and repair work should be carried out
out repair and servicing procedures. as soon as possible. This keeps overall servicing
& repair costs to a minimum and increases the
Read through the Technical Handbook, but also availabilily of the excavator
the Operating Instructions for the hydraulic ex-
cavator before commencing any servicing or re- During servicing and repair work, always follow
pair work. The Technical Handbook, as well as the instructions contained in the Technical Hand-
the Operating Instructions and Spare Parts book and Operating instructions.
List should be used as a source of reference and
assistance - even when the user is well acquaint- Major work that is not described in the Technical
ed with the range of excavators. Handbook will be gladly undertaken by the After
Sales Service.
Using the Technical Handbook allows the exper-
ienced mechanic to carry out repair work in a The After Sales Service is always available for
correct manner. assistance and advice.
Using the Technical Handbook When making any enquiries, please always state
the Machine Model and the machines Serial No.
The Technical Handbook is divided into main and
sub-groups that deal with the machine as actually
delivered. Any auxiliary attachments or optional
upgrading introduced later are not described.
The main table of contents allows to find the

required information quickly.
For the sake of clarity, the illustrations have been

simplified and can therefore differ slightly from the
actual appearance of the machine.
73179380 01 1
Warnings and symbols 2732729 Danger in the event of non-obser-

The following signs are used in the manual to
vance of the safety instructions
designate instructions of particular importance:
This hydraulic excavator has been built in

Imminent danger involving the risk of accordance with state-of-the-art standards
death or of severe injuries. and the recognized safety rules.
However, operating the machine if a fault
is suspected or has occurred, or carrying
out repair work inexpertly may
- endanger the lives of persons in con-
Precautionary rules and measures de-
tact with it
signed to protect the machine operator
and other persons from life-threatening - damage the machine and other prop-
danger or injuries and to prevent exten- erty.
sive damage. The hydraulic excavator must be stopped
immediately on any damage being sus-
pected or occurring to ensure that the
safety of the operator, of other persons at
the place of use or of other material prop-
Information and precautionary measures erty is not compromised.
designed to prevent damage to the ma-
chine or other property. All components are carefully co-ordinated.
Trouble-free operation and a long service
life can only be achieved with original
spare parts.
2 01 73179380
Organizational measures 2261965
The operating instructions must always be at Observe all safety instructions and warnings at-
hand at the place of use of the machine, e.g. by tached to the machine.
stowing them in the tool compartment or tool-box
provided for such purpose. See to it that safety instructions and warnings
attached to the machine are always complete and
In addition to the operating instructions, observe perfectly legible.
and instruct the user in all other generally ap-
plicable legal and other mandatory regulations In the event of safety-relevant modifications or
relevant to accident prevention and environmental changes in the behaviour of the machine during
protection. operation, stop the machine immediately and re-
port the malfunction to the competent author-
These compulsory regulations may also deal with ity/person.
the handling of hazardous substances, issuing
and/or wearing of personal protective equipment Never make any modifications, additions or con-
or traffic regulations. versions which might affect safety without the
suppliers approval. This also applies to the in-
The operating instructions must be supplemented stallation and adjustment of safety devices and
by instructions covering the duties involved in valves as well as to welding work on load-bearing
supervising and notifying special organizational elements.
features, such as job organization, working se-
quences or the personnel entrusted with the Spare parts must comply with the technical re-
work. quirements specified by the manufacturer. Spare
parts from original equipment manufacturers can
Personnel entrusted with work on the machine be relied to do so.
must have read the operating instructions and in
particular the chapter on safety before beginning Replace hydraulic hoses within stipulated and ap-
work. Reading the instructions after work has be- propriate intervals, even if no safety-relevant de-
gun is too late. This applies especially to persons fects have been detected.
working only occasionally on the machine, e.g.
during setting up or maintenance. Adhere to prescribed intervals or those specified
in the operating instructions for routine checks
Check - at least from time to time - whether the and inspections.
personnel is carrying out the work in compliance
with the operating instructions and paying atten- For the execution of maintenance work, tools and
tion to risks and safety factors. workshop equipment adapted to the task on hand
are absolutely indispensable.
For reasons of security, long hair must be tied
back or otherwise secured, garments must be The personnel must be familiar with the location
close-fitting and no jewellery, such as rings, may and operation of fire extinguishers.
be worn. Injury may result from being caught up
Observe all fire-warning and fire-fighting proce-
in the machinery or from rings catching on mov-
dures.
ing parts.
Use protective equipment wherever required by

the circumstances or by law.
73179380 01 3
Selection and qualification of per- Safety instructions governing

sonnel - basic responsibilities specific operational phases
Any work on and with the machine must be ex- Standard operation
ecuted by reliable personnel only. Statutory
minimum age limits must be observed. Avoid any operational mode that might be prejudi-
cial to safety.
Employ only trained or instructed staff and set out
clearly the individual responsibilities of the per- Before beginning work, familiarize yourself with
sonnel for operation, set-up, maintenance and re- the surroundings and circumstances of the site,
pair. such as obstacles in the working and travelling
area, the soil bearing capacity and any barriers
Make sure that only authorized personnel works separating the construction site from public roads.
on or with the machine.
Take the necessary precautions to ensure that
Define the machine operators responsibilities - the machine is used only when in a safe and
also with regard to observing traffic regulations - reliable state.
giving the operator the authority to refuse instruc-
tions by third parties that are contrary to safety. Operate the machine only if all protective and
safety-oriented devices, such as removable safety
Do not allow persons to be trained or instructed devices, emergency shut-off equipment, sound-
or persons taking part in a general training proofing elements and exhausters, are in place
course to work on or with the machine without and fully functional.
being permanently supervised by an experienced
person. Check the machine at least once per working
shift for obvious damage and defects. Report any
Work on the electrical system and equipment of changes (incl. changes in the machines working
the machine must be carried out only by a skilled behaviour) to the competent organization/person
electrician or by instructed persons under the su- immediately. If necessary, stop the machine im-
pervision and guidance of a skilled electrician and mediately and lock it.
in accordance with electrical engineering rules
and regulations. In the event of malfunctions, stop the machine
immediately and lock it. Have any defects recti-
Work on chassis, brake and steering systems fied immediately.
must be performed by skilled personnel only,
which has been specially trained for such work. Start the machine from the drivers seat only.
Work on the hydraulic system must be carried out During start-up and shut-down procedures always
only by personnel with special knowledge and watch the indicators in accordance with the op-
experience of hydraulic equipment. erating instructions.
Before setting the machine in motion, make sure

that nobody is at risk.
Before starting work or travelling with the ma-

chine, check that the braking, steering, signalling
and lighting systems are fully functional.
Before setting the machine in motion always

check that the accessories have been safely
stowed away.
When travelling on public roads, ways and places

always observe the valid traffic regulations and, if
necessary, make sure beforehand that the ma-
chine is in a condition compatible with these reg-
ulations.
4 01 73179380
In conditions of poor visibility and after dark al- Special work in conjunction with
ways switch on the lighting system. utilization of the machine - main-
Persons accompanying the driver must be seated tenance and repairs during opera-
on the passenger seats provided for this purpose. tion - disposal of parts and con-
When crossing underpasses, bridges and tunnels sumables
or when passing under overhead lines always
Observe the adjusting, maintenance and
make sure that there is is sufficient clearance.
inspection activities and intervals set out in the
Always keep at a distance from the edges of operating instructions, including information on
building pits and slopes. the replacement of parts and equipment. These
activities may be executed by skilled personnel
Avoid any operation that might be a risk to ma- only.
chine stability.
Brief operating personnel before beginning spe-
Never travel across slopes; always keep the cial operations and maintenance work, and ap-
working equipment and the load close to the point a person to supervise the activities.
ground, especially when travelling downhill.
In any work concerning the operation, conversion
On sloping terrain always adapt your travelling or adjustment of the machine and its safety-ori-
speed to the prevailing ground conditions. Never ented devices or any work related to mainten-
change to a lower gear on a slope but always ance, inspection and repair, always observe the
before reaching it. start-up and shut-down procedures set out in the
operating instructions and the information on
Before leaving the drivers seat always secure the maintenance work.
machine against inadvertent movement and un-
authorized use. Ensure that the maintenance area is adequately
secured.
If the machine is completely shut down for main-

tenance and repair work, it must be secured
against inadvertent starting by:
- removing the ignition key and
- attaching a warning sign.
Carry out maintenance and repair work only if the

machine is positioned on stable and level ground
and has been secured against inadvertent move-
ment and buckling.
To avoid the risk of accidents, individual parts

and large assemblies being moved for replace-
ment purposes should be carefully attached to
lifting tackle and secured. Use only suitable and
technically perfect lifting gear and suspension
systems with adequate lifting capacity. Never
work or stand under suspended loads.
The fastening of loads and the instructing of

crane operators should be entrusted to exper-
ienced persons only. The marshaller giving the
instructions must be within sight or sound of the
operator.
73179380 01 5
For carrying out overhead assembly work always Warning of special dangers
use specially designed or otherwise safety-ori-
ented ladders and working platforms. Never use Electric energy
machine parts as a climbing aid.
Use only original fuses with the specified current
Wear a safety harness when carrying out main- rating. Switch off the machine immediately if trou-
tenance work at greater heights. ble occurs in the electrical system.
Keep all handles, steps, handrails, platforms, When working with the machine, maintain a safe
landings and ladders free from dirt, snow and ice. distance from overhead electric lines. If work is to
be carried out close to overhead lines, the work-
Clean the machine, especially connections and ing equipment must be kept well away from them.
threaded unions, of any traces of oil, fuel or Caution, danger! Check out the prescribed safety
preservatives before carrying out mainten- distances.
ance/repair. Never use aggressive detergents.
Use lint-free cleaning rags. If your machine comes into contact with a live
wire
Before cleaning the machine with water, steam jet
(high-pressure cleaning) or detergents, cover or - do not leave the machine
tape up all openings which - for safety and func- - drive the machine out of the hazard zone
tional reasons - must be protected against water,
steam or detergent penetration. Special care must - warn others against approaching and touching
be taken with electric motors and switchgear the machine
cabinets. - have the live wire de-energized
Ensure during cleaning of the machine that the - do not leave the machine until the damaged
temperature sensors of the fire-warning and fire- line has been safely de-energized.
fighting systems do not come into contact with
hot cleaning agents as this might activate the The electrical equipment of machines is to be
fire-fighting system. inspected and checked at regular intervals. De-
fects such as loose connections or scorched ca-
After cleaning, remove all covers and tapes ap- bles must be rectified immediately.
plied for that purpose.
After cleaning, examine all fuel, lubricant, and

hydraulic fluid lines for leaks, loose connections,
Gas, dust, steam and smoke
chafe marks and damage. Any defects found
must be rectified without delay. Operate internal combustion engines and fuel-
operated heating systems only on adequately
Always tighten any screwed connections that
ventilated premises. Before starting the machine
have been loosened during maintenance and re-
on enclosed premises, make sure that there is
pair.
sufficient ventilation.
Any safety devices removed for set-up, main-
Observe the regulations in force at the respective
tenance or repair purposes must be refitted and
site.
checked immediately upon completion of the
maintenance and repair work. Carry out welding, flame-cutting and grinding
work on the machine only if this has been ex-
Ensure that all consumables and replaced parts
pressly authorized, as there may be a risk of
are disposed of safely and with minimum envi-
explosion and fire.
ronmental impact.
Before carrying out welding, flame-cutting and
grinding operations, clean the machine and its
surroundings from dust and other inflammable
substances and make sure that the premises are
adequately ventilated (risk of explosion).
6 01 73179380
Hydraulic and pneumatic equipment Transporting and towing - recom-

Check all lines, hoses and screwed connections
missioning
regularly for leaks and obvious damage. Repair The machine must be towed, loaded and trans-
damage immediately. Splashed oil may cause in- ported only in accordance with the operating
jury and fire. instructions.
Depressurize all system sections and pressure For towing the machine observe the prescribed
pipes (hydraulic system, compressed-air system) transport position, admissible speed and itinerary.
to be removed in accordance with the specific
instructions for the unit concerned before carrying Use only appropriate means of transport and lift-
out any repair work. ing gear of adequate capacity.
Hydraulic and compressed-air lines must be laid The recommissioning procedure must be strictly
and fitted properly. Ensure that no connections in accordance with the operating instructions.
are interchanged. The fittings, lengths and quality
of the hoses must comply with the technical re-
quirements.
California, Proposition 65 Warn-
ing
Noise 2732686
During operation, all sound baffles of the machine Diesel engine exhaust and some of its constitu-
must be closed. ents are known to the state of California to cause
cancer, birth defects, and other reproductive
Always wear the prescribed ear protectors. harm.
Oil, grease and other chemical sub-

stances
When handling oil, grease and other chemical
substances, observe the product-related safety
regulations.
Be careful when handling hot consumables (risk

of burning or scalding).
73179380 01 7
Repair work - safety instructions 2732233
Operating instructions Pressurized or spring loaded units

Never carry out repair work without hav- Never open defective pressurized or
ing read and understood the operating spring loaded units but replace them as
instructions. an entirety.
Pay special attention to: In exceptional cases, open only when the
system and the operating sequence are
"Fundamental Safety Instructions",
precisely known and any special tools re-
"Inspection and servicing - safety instruc-
quired are available.
tions" and all warnings and safety instruc-
tions attached to the machine. The operating manual contains no infor-
mation on this point.
The descriptions of job sequences pro-
vide only experienced personnel with the
necessary instructions.
The operating manual must be kept with
the machine at all times.
Dismantling components
Never dismantle while the machine is at
operating temperature.
Oils, greases, brake fluid or coolants may
Repair personnel have a high temperature and result in
Repair personnel must have know-how burning or scalding.
and experience relevant to repairing this Leave time for the machine to cool down.
or comparable machines. Before starting work, depressurize piping
and hoses, cylinders, radiator, hydraulic
tank, air-brake reservoir and other sys-
tems or units.
Replace defective components in good
Working at greater heights time to prevent major damage.
Always wear safety harnesses when work- Clean the defective component carefully
ing at greater heights. before dismantling it.
Wear an approved safety harness; it must Mark the dismantled parts in the correct
be equipped with stabilizers and safety sequence to facilitate assembly.
cables. When dismantling the component, close
off exposed hose and piping connections,
exposed drill holes and housing carefully
to prevent any dust from penetrating.
8 01 73179380
Accumulators, safety instructions
2732232
Accumulators are installed in the hydraulic

system. These accumulators contain nitro-
Never remove lead seals gen under high initial pressure.
Never change rated pressure of pressure Wear safety goggles.
relief valves without the explicit authoriza-
Even when the hydraulic pressure in the
tion of the manufacturer.
system is reduced, the nitrogen remains
Never remove lead seals from pressure in the accumulator.
relief valves and accumulators.
The accumulators are completely safe in
operation. If incorrectly handled, however,
there is a risk of explosion!
The accumulators installed in this ma-
chine should not be repaired. Defective
After the repair work accumulators have to be changed.
To prevent corrosion, coat all bright metal Never handle accumulator mechanically,
machine parts with a grease film. never weld or solder it.
On completing the work, reassemble all Prior to change the accumulator, always
protective devices, covers, and sound- wear goggles and working gloves, depres-
and vibration-insulation material. surize the hydraulic part of the system.
Never start up the driving motor while Use only genuine spare parts. In case of
work is being done on the machine. questions ask your dealer.
Check the repaired components and all Never remove or paint over warning and
machine functions with a trial run. information plates, rating plates or type
identification markings. Replace illegible
Never release the machine for recommis-
or damaged plates immediately.
sioning until it is fully functioning.
73179380 01 9
ENGINE 2732231
Engine, repair instructions Assisted starting

(with jump-leads) - safety
instructions 2472291
Read and observe: "Repair, safety instruc-

tions" and operating instructions for en-
gine before working on engine. Keep any potential ignition sources such
Risk of injury from rotating or hot engine as unshielded lights or burning cigarettes
parts! away from the batteries. The battery vap-
ours are highly flammable. Explosion ha-
Switch off engine and leave to cool down. zard.
Do repair work only if machine is secured Wear safety goggles.
as described in section "Securing the ma-
chine" of these operating instructions. Do not lean over the batteries when start-
ing the machine from another vehicle.
Check and change V-belts only when en-
gine is stationary. Risk of injury from acid splashes and
battery gases.
Repair work on the engine demands ex-
tensive know-how and special tools. Never use assisted starting when the bat-
teries are defective or frozen.
Never connect batteries (battery assem-
blies) unless they have the same voltage.
Use only tested jump-leads with insulated
terminal clips and an adequate lead diam-
eter.
Ensure that the bodies of the supplying
and receiving machines are not in con-
tact. Otherwise a current flow could result
from connecting the positive poles. Risk
of short-circuiting.
Never use welding generators or welding
transformers as a source of current.
Position the jump-leads in such a way
that they cannot be caught by rotating
engine components.
Read and observe: "Inspection and ser-
vicing, safety instructions", paying par-
ticular attention to the section "Handling
batteries".
10 01 73179380
WELDING OPERATIONS
Welding operations - safety instructions 2732228
Never perform welding operations unless Prior to any welding operations on the
you are qualified to do so. machine:
Observe the accident prevention regula- - Disconnect the battery, first at the neg-
tions. ative pole and then at the positive pole.
Any work on receptacles that contain or - Disconnect the positive pole at the al-
have contained substances which are ternator.
- combustible or which encourage com- Protect the disconnected terminals and
bustion, which plugs from short-circuiting and soiling
- are susceptible to explosion, or which by covering them with foil or adhesive
tape.
- may develop health-hazardous gases,
vapours, mist or dust during welding Apply the welding current terminals very
operations close to the welding point.
must be carried out only under expert su- The welding current must not flow via the
pervision and only by experienced per- ball bearing slewing ring, via pin coupl-
sons authorized to do such work. ings or link joints of hydraulic cylinders.
Detailed information on the correct execu- On completion of the welding operation,
tion of welding operations is given in the restore all electrical connections.
technical manual "Welding for mainten- When connecting the battery, first con-
ance and repair". nect the positive pole and then the nega-
Should you have any problems or que- tive pole.
ries, apply to the after-sales service de-
partment.
If parts of the machine have to be
dismantled, read and take note of the fol-
lowing sections:
"Assembling attachments, safety instruc-
tions",
"Inspection and servicing, safety instruc-
tions",
"Repair, safety instructions".
73179380 01 11
Notes 2800145
12 01 73179380
S
A Safety instructions governing specific oper-
ational phases ...................................................... 4
Accumulators, safety instructions ........................ 9
Selection and qualification of personnel - basic
Assisted starting (with jump-leads) - safety responsibilities ...................................................... 4
instructions ........................................................ 10
Servicing and repair.............................................. 1
C Special work in conjunction with utilization of

the machine - maintenance and repairs during
California, Proposition 65 Warning ...................... 7 operation - disposal of parts and consumables .... 5
Standard operation .............................................. 4

D
Danger in the event of non-obser-vance of the T
safety instructions ................................................ 2
Transporting and towing - recommissioning ........ 7
E
U
Electric energy ...................................................... 6
Using the Technical Handbook ............................ 1
ENGINE .............................................................. 10
Engine, repair instructions .................................. 10 W

Warning of special dangers .................................. 6
F
Warnings and symbols ........................................ 2
FOREWORD ........................................................ 1
WELDING OPERATIONS .................................. 11
G Welding operations - safety instructions ............ 11
Gas, dust, steam and smoke ................................ 6
H
Hydraulic and pneumatic equipment .................... 7
N
Noise .................................................................... 7
O
Oil, grease and other chemical substances .......... 7
Organizational measures...................................... 3
R
Repair work - safety instructions .......................... 8
Service Data General

Service Data EC 130
73179380 02 1
BLANK PAGE
2 02 73179380
Allgemein
General
2 801 850.00 de/us

VORWORT ................................................................................................................................................ 1
FOREWORD .............................................................................................................................................. 1

SI - UND WEITERE GROSSEN ................................................................................................................ 3
SI - AND ADDITIONAL UNITS

Raum - und Massegroen
...................................................................................................................... 3
Quantities of space and mass ................................................................................................................ 3
Zeitgroen
.............................................................................................................................................. 4
Time-related quantities ............................................................................................................................ 4
Kraft-, Energie- und Leistungsgroen
.................................................................................................... 5
Quantities of force, energy and power .................................................................................................... 5
UMRECHNUNGSTABELLEN .................................................................................................................... 6
CONVERSIONS TABLES
Umrechnung von Langen-Maen
............................................................................................................ 6
Conversion for units of length .................................................................................................................. 6
Umrechnung von Flachenmaen
............................................................................................................ 7
Conversion for units of area .................................................................................................................... 7
Umrechnung von foot (Fuss) und inch (Zoll) in Meter ............................................................................ 8
Conversion from foot (Fuss) and inch (Zoll) to metric measures ............................................................ 8
Umrechnung von Newtonmeter "Nm" in Foot Pounds "ft.lb." .................................................................. 9
Conversion from newtonmeter "Nm" into foot pounds "ft.lb." .................................................................. 9
Umrechnungstabelle fur
Druckeinheiten von Gasen, Dampfen
und Flussigkeiten
................................ 17
Conversion table for units of pressure in gases, steam and fluids ........................................................ 17
Einheiten von Energie, Arbeit und Warmemenge
.......................................... 18
Conversion table for units of power, ernergy and heat quantity ............................................................ 18
Einheiten der mechanischen Spannung (Festigkeit) ...................................... 19
Conversion table for units of mechanical stress (strength) .................................................................... 19
Praktisch gleichwertige Einheiten fur
Druck und mechanische Spannung (Festigkeit) ........................ 20
Practically equivalent units for pressure and mechanical stress (strength) .......................................... 20
Temperatur - Einheiten und Umrechungsformeln ................................................................................ 21
Units of temperature and conversion formulas ...................................................................................... 21
Leistung, Energiestrom, Warmestrom
.................................................................................................. 22
Power, energy and heat flow ................................................................................................................ 22
Geschwindigkeiten ................................................................................................................................ 23
Speed .................................................................................................................................................... 23
Masseeinheiten (Gewichte) .................................................................................................................. 24
Units of mass (weight) .......................................................................................................................... 24
Volumeneinheiten, Durchflumenge .................................................................................................... 25
Units of volume, flow rates .................................................................................................................... 25
Kraftstoffverbrauch ................................................................................................................................ 26
Fuel consumption .................................................................................................................................. 26
BERECHNUNGSBEISPIELE .................................................................................................................. 27
CALCULATION EXAMPLES
Steigungswinkel .................................................................................................................................... 27
Angles of slope ...................................................................................................................................... 27
Fahrgeschwindigkeiten.......................................................................................................................... 27
Travel speeds ........................................................................................................................................ 27
Hydraulische Leistungen (Pumpen/Motoren) ........................................................................................ 28
Hydraulic outputs (pumps/motors) ........................................................................................................ 28
Zylinder-Hubzeiten ................................................................................................................................ 28
Stroking times of cylinders .................................................................................................................... 28
Drehzahlen von Hydraulikmotoren ........................................................................................................ 28
Speeds of hydraulic motors .................................................................................................................. 28
ANZIEHDREHMOMENTE
Allgemeine Hinweise ............................................................................................................................ 29
TIGHTENING TORQUES
General information .............................................................................................................................. 30
Schrauben mit Regelgewinde nach DIN 13 - 13 .................................................................................. 31
Bolts with standard thread DIN 13 - 13.................................................................................................. 31
Schrauben mit metrischem Feingewinde DIN 13 - 13 .......................................................................... 32
Bolts with metric fine thread DIN 13 - 13 .............................................................................................. 32
Anziehdrehmomente fur
SAE Flanschsystem ...................................................................................... 33
Tightening torques for SAE flange-system ............................................................................................ 33
Anzugswinkel ........................................................................................................................................ 33
Tightening angles .................................................................................................................................. 33
SERVICE DATEN / SERVICE DATA
VORWORT 2801092 FOREWORD
Jede Person, die mit der Inbetriebnahme, Be- Anyone involved with commissioning, operat-
dienung, Inspektion und Wartung dieser ing, inspecting and servicing for this con-
Baumaschine befat ist, mu - bevor sie die struction machine must read through and
ersten Handgriffe ausfuhrt
- die "BETRIEB- acquaint himself with the "OPERATING MAN-
SANLEITUNG" und besonders das Kapitel UAL" - and especially the Section "FUNDA-
"GRUNDLEGENDE SICHERHEITSHINWEISE" MENTAL SAFETY INSTRUCTIONS" - before
gelesen und verstanden haben. starting work.
Die "Service Daten" enthalten Angaben, die fur

Kun- The "Service Data" contains details which are impor-
dendienstmitarbeiter wichtig sind. Maschinendaten, tant to the service staff. Data included in other parts
die an anderer Stelle der Dokumentation aufgefuhrt
of the general documentation have been left aside.
sind, werden hier nicht wiederholt. Zur Dokumen- The set of documents for this construction machine
tation dieser Baumaschine gehoren:
includes:
Betriebsanleitung Operating manual
Ersatzteilliste Spare parts list
Zur Dokumentation im weiteren Sinne gehoren

auch "Technical Handbooks" (THB) and "Service Informa-
"Technische Handbucher"
(THB) und "Service Infor- tion" bulletins (si) are, furthermore, to be considered
mationen" (si). as supplements to the general documentation.
Data regarding auxiliary units for operating ancillary

In dieser Broschure
sind die Daten der Hilfsaggregate or special systems, as well as data on machines
zum Betrieb von Zusatz- oder Sonderausrustungen
produced only in small numbers, have not been in-
sowie Daten von Einzelgeraten
nicht aufgefuhrt.
cluded.
Die aufgefuhrten
Fullmengen
der Betriebsmittel sind Filling quantities are only approximate figures intend-
ca.-Angaben, die Dispositionshilfe sein sollen. Jedes ed to help in stockholding the various fluids and
Aggregat besitzt geeignete Kontrolleinrichtungen, z. agents. Each unit has appropriate checking systems,
B. Peilstab oder Kontrollschrauben, mit denen die e.g. dipstick or checking screws, with which the exact
exakte Befullung
gepruft
wird. filling level can be checked.
Die in den Kapiteln aufgefuhrten

Sach-Nrn. The Part Nos. given in the sections are not to
nicht zum Bestellen von Ersatzteilen verwen- be used when ordering spare parts. They are
den. Sie sollen nur dokumentieren, auf wel- only intended to identify the component being
ches Bauteil sich die nachstehenden Daten referred to. When ordering spare parts, use
beziehen. Zur Ersatzteilbestellung die zur only the Part Nos. given in the spare parts
Maschine gehorende
Ersatzteilliste verwen- lists.
den.
2 801 850.00 de/us 1

2 2 801 850.00 de/us


SI - UND WEITERE GROSSEN 2801093
SI - AND ADDITIONAL UNITS

Raum - und Massegroen

Quantities of space and mass
Groe
Formel Einheit Umrechnung Erlauterungen

zeichen Unit Conversion und
Bemerkungen
Quantity Symbol alt old neu new Fur

genaue fur
uber-
Explanations
Rechnungen schlagige
and
Rechnungen Remarks
SI-Einheit Auswahl (2 % Unge-

SI-Units weitere naugikeit)
Einheiten
Selection of for exact for rough
additional calculation calculation
units appr. 2 %
inexact
Lange
I m, mm, cm m m, mm, km
Length dm, m, km
Flache
A mm2, cm2, dm2, m2 mm2, cm2
Area m2
Volumen V, Vn mm3, cm3, dm3, m3 mm3, cm3, dm3,

Volume m3, l l
Masse m g, mg, g, kg, kg g, mg, g

Mass Mg=t, (kp s2/m) Mg, t
Dichte g/cm3, kg/dm3, kg/m3 g/cm3, kg/dm3

Density kg/m3,
(kp s2/m4)
Massentragheitsmoment
J kp m2, kg m2 Mg m2 1 kp m s2 = 1 kp m s2 =
Inertia moment (kp m s2) 9,81 kg m2 10 kg m2
Spezifisches Volumen v m3/kg, m3/t m3/kg m3/Mg

Specific volume
2 801 850.00 de/us 3

Zeitgroen

Time-related quantities
Groe

Bemerkungen

genaue fur
uber-
Explanations
and
Rechnungen Remarks

Einheiten
units appr. 2 %
inexact
Zeitdauer t s, min, h, s ms, min, h, d

Time d = day
Frequenz f Hz Hz 1 Hz 1/s
Frequency
Drehzahl n U/min 1/s 1/min s = min/60

Rate of revolutions
Geschwindigkeit v m/s, km/h m/s km/h

Speed
Beschleunigung a m/s2 m/s2

Acceleration
Volumenstrom V m3/s, m3/min, m3/s m3/min,

Volume flow m3/h l/h
Massenstrom m kg/s, kg/min, kg/s

Mass flow kg/h
Warmestrom
(kcal/h) W kW, MW 1 kcal/h = 1 kcal/h = 1 W = 1 J/s =
Heat flow 1,163 W 1,2 W 1 Nm/s
Spez. Kraftstoff- b, bs kg/PSh kg/J g/(kW h) 1 g/(PS h) = 1 g/(PS h) =

oder spez. Olver- g/PSh 1,359 g/(kW h) 1,36 g/(kW h)
brauch
Specific fuel and
oil consumption
4 2 801 850.00 de/us


Quantities of force, energy and power
Groe

Bemerkungen

genaue fur
uber-
Explanations
and
Rechnungen Remarks

Einheiten
units appr. 2 %
inexact
Kraft F (dyn, p) N (Newton) MN, kN, 1 kp = 1 kg x 1 kp = 10 N 1 N = 1 kg x

Force (njuten) mN 9,81m/s2 = 1 m/s2 =
9,81 N 1 kg m/s2
Druck (von Fluiden) P, Pi, (kp/cm2,at,atm,) N/m2, bar, mbar 1 kp/cm2 = 1 kp/cm2=1 bar 1 N/m2=1 Pa
Pressure (of fluids) 0,981 bar
Pe, (mWS, Torr,) Pa (Pascal) 1 atm = 1 mWS = 1Pa = 10-5 bar
1,013 bar 0,1 bar
Pu , Pu (mmHg) 1 mWS = 1 bar =
0,098 bar 105 N/m2
Mechanische Spannung (kp/cm2, N/m2, pa N/mm2 1 kp/mm2 = 1 kp/mm2 = 1 N/m2 = 1 Pa

Mechanical stress kp/mm2) 9,81 N/mm2 10 N/mm2
1 kp/cm2 = 1 kp/cm2 =
9,81 N/mm2 10 N/cm2
Energie, Arbeit W (kpm) J (Joule) MJ, kJ, 1 kpm = 9,81 J 1 kpm = 10 J 3,6 MJ =
Energy (dschul) kW h 1 kWh
1 J = 1 NM = 1
Ws
Warmemenge
Q (cal, erg) J (Joule) MJ, kJ, 1 kcal = 3,6 MJ =
Heat capacity (dschul) kW h 4,19 kJ 1 kW h
1 J = 1 Nm = 1
Ws
Leistung P (PS), W W kW, MW 1 PS = 1 PS = 1 W =1 J/s =

Power 0,735499 kW 0,74 kW 1 Nm/s
1 kW = 1 kW = 1,36 PS
1,359622 PS
Dreh-Biegemoment M (kp m) Nm N cm 1 kp m = 1 kp m =
Torque, bending moment 9,81 N m 10 N m
2 801 850.00 de/us 5

UMRECHNUNGSTABELLEN
CONVERSIONS TABLES

Conversion for units of length
Lange
in ft yd mile UK cm m
Length n mile
1 inch (Zoll) 1 0,0833 0,0278 2,54 0,0254
1 foot (Fu) 12 1 0,3333 0,00019 0,00016 30,48 0,3048
1 yard 36 3 1 0,00057 0,00049 91,44 0,9144
1 statute mile (Landmeile) 63 360 5 280 1 760 1 0,86842 1609,3
1 UK nautical mile (engl. 72 960 6 080 2 026,7 1,15151 1 1 853,2

Seemeile)
1 cm 0,3937 0,0328 0,0109 1 0,01
1m 39,370 3,2808 1,0936 0,00062 0,00054 100 1
6 2 801 850.00 de/us


Conversion for units of area
Flache
in2 ft2 yd2 sqmile acre cm2 m2
Area
1 square inch (Quadratzoll) 1 0,0069 6,4516
1 square foot (Quadratfu) 144 1 0,111 929,03 0,0929
1 square yard (Quadratyard) 1 296 9 1 0,00021 8361,3 0,8361
1 square mile (Quadratmeile) 1 640
1 acre 43 560 4 840 0,00156 1 4 046,9
1 cm2 0,1550 1 0,0001
1 m2 1 550,0 10,764 1,1960 10 000 1
2 801 850.00 de/us 7

Umrechnung von foot (Fuss) und inch (Zoll) in Meter

Conversion from foot (Fuss) and inch (Zoll) to metric measures
1 in (inch) = 25,4 mm (genau) 1 ft (foot) = 12 in = 304,8 mm Beispiel: 4 ft 2 in = 1,27 m
1 in (inch) = 25,4 mm (exact) Example: 4 ft 2 in = 1,27 m
ft in
+0 +1 +2 +3 +4 +5 +6 +7 +8 +9 +10 +11
m m m m m m m m m m m m
0 0,0254 0,0508 0,0762 0,1016 0,1270 0,1524 0,1778 0, 2032 0,2286 0,2540 0,2794
1 0,3048 0,3302 0,3556 0,3810 0,4064 0,4318 0,4572 0,4826 0,5080 0,5334 0,5588 0,5842
2 0,6096 0,6350 0,6604 0,6858 0,7112 0,7366 0,7620 0,7874 0,8128 0,8382 0,8636 0,8890
3 0,9144 0,9398 0,9652 0,9906 1,0160 1,0414 1,0668 1,0922 1,1176 1,1430 1,1684 1,1938
4 1,2192 1,2446 1,2700 1,2954 1,3208 1,3462 1,3716 1,3970 1,4224 1,4478 1,4732 1,4986
5 1,5240 1,5494 1,5748 1,6002 1,6256 1,6510 1,6764 1,7018 1,7272 1,7526 1,7780 1,8034
6 1,8288 1,8542 1,8796 1,9050 1,9304 1,9558 1,9812 2,0066 2,0320 2,0574 2,0828 2,1082
7 2,1336 2,1590 2,1844 2,2098 2,2352 2,2606 2,2860 2,3114 2,3368 2,3622 2,3876 2,4130
8 2,4384 2,4638 2,4892 2,5146 2,5400 2,5654 2,5908 2,6162 2,6416 2,6670 2,6924 2,7178
9 2,7432 2,7686 2,7940 2,8194 2,8448 2,8702 2,8956 2,9210 2,9464 2,9718 2,9972 3,0226
10 3,0480 3,0734 3,0988 3,1242 3,1496 3,1750 3,2004 3,2258 3,2512 3,2766 3,3020 3,3274
11 3,3528 3,3782 3,4036 3,4290 3,4544 3,4798 3,5052 3,5306 3,5560 3,5814 3,6068 3,6322
12 3,6576 3,6830 3,70 3,7338 3,7592 3,7846 3,8100 3,8354 3,8608 3,8862 3,9116 3,9370
8 2 801 850.00 de/us

Umrechnung von Newtonmeter "Nm" in Foot Pounds "ft.lb."

Conversion from newtonmeter "Nm" into foot pounds "ft.lb."
Nm 0 1 2 3 4 5 6 7 8 9
10 7.376 8.113 8.851 9.588 10.326 11.063 11.801 12.539 13.276 14.014
20 14.751 15.489 16.226 16.964 17.701 18.439 19.177 19.914 20.652 21.389
30 22.127 22.864 23.602 24.339 25.077 25.815 26.552 27.290 28.027 28.765
40 29.502 30.240 30.978 31.715 32.453 33.190 33.928 34.665 35.403 36.140
50 36.878 37.616 38.353 39.091 39.828 40.566 41.303 42.041 42.778 43.516
60 44.254 44.991 45.729 46.466 47.204 47.941 48.679 49.417 50.154 50.892
70 51.629 52.367 53.104 53.842 54.579 55.317 56.055 56.792 57.530 58.267
80 59.005 59.742 60.480 61.217 61.955 62.693 63.430 64.168 64.905 65.643
90 66.380 67.118 67.856 68.593 69.331 70.068 70.806 71.543 72.281 73.018
100 73.756 74.494 75.231 75.969 76.706 77.444 78.181 78.919 79.656 80.394
110 81.132 81.869 82.607 83.344 84.082 84.819 85.557 86.295 87.032 87.770
120 88.507 89.245 89.982 90.720 91.457 92.195 92.933 93.670 94.408 95.145
130 95.883 96.620 97.358 98.095 98.833 99.571 100.308 101.046 101.783 102.521
140 103.258 103.996 104.734 105.471 106.209 106.946 107.684 108.421 109.159 109.896
150 110.634 111.372 112.109 112.847 113.584 114.322 115.059 115.797 116.534 117.272
160 118.010 118.747 119.485 120.222 120.960 121.697 122.435 123.173 123.910 124.648
170 125.385 126.123 126.860 127.598 128.335 129.073 129.811 130.548 131.286 132.023
180 132.761 133.498 134.236 134.973 135.711 136.449 137.186 137.924 138.661 139.399
190 140.136 140.874 141.612 142.349 143.087 143.824 144.562 145.299 146.037 146.774
200 147.512 148.250 148.987 149.725 150.462 151.200 151.937 152.675 153.412 154.150
210 154.888 155.625 156.363 157.100 157.838 158.575 159.313 160.051 160.788 161.526
220 162.263 163.001 163.738 164.476 165.213 165.951 166.689 167.426 168.164 168.901
230 169.639 170.376 171.114 171.851 172.589 173.327 174.064 174.802 175.539 176.277
240 177.014 177.752 178.490 179.227 179.965 180.702 181.440 182.177 182.915 183.652
250 184.390 185.128 185.865 186.603 187.340 188.078 188.815 189.553 190.290 191.028
260 191.766 192.503 193.241 193.978 194.716 195.453 196.191 196.929 197.666 198.404
270 199.141 199.879 200.616 201.354 202.091 202.829 203.567 204.304 205.042 205.779
280 206.517 207.254 207.992 208.729 209.467 210.205 210.942 211.680 212.417 213.155
290 213.892 214.630 215.368 216.105 216.843 217.580 218.318 219.055 219.793 220.530
300 221.268 222.006 222.743 223.481 224.218 224.956 225.693 226.431 227.168 227.906
310 228.644 229.381 230.119 230.856 231.594 232.331 233.069 233.807 234.544 235.282
320 236.019 236.757 237.494 238.232 238.969 239.707 240.445 241.182 241.920 242.657
330 243.395 244.132 244.870 245.607 246.345 247.083 247.820 248.558 249.295 250.033
340 250.770 251.508 252.245 252.983 253.721 254.458 255.196 255.933 256.671 257.408
350 258.146 258.884 259.621 260.359 261.096 261.834 262.571 263.309 264.046 264.784
360 265.521 266.259 266.997 267.734 268.472 269.209 269.947 270.684 271.422 272.159
370 272.897 273.635 274.372 275.110 275.847 276.585 277.323 278.060 278.798 279.535
380 280.273 281.010 281.748 282.485 283.223 283.960 284.698 285.436 286.173 286.911
390 287.648 288.386 289.123 289.861 290.598 291.336 292.074 292.811 293.549 294.286
400 295.024 295.761 296.499 297.237 297.974 298.712 299.449 300.187 300.924 301.662
410 302.399 303.137 303.875 304.612 305.350 306.087 306.825 307.562 308.300 309.038
420 309.775 310.513 311.250 311.988 312.725 313.463 314.200 314.938 315.676 316.413
430 317.151 317.888 318.626 319.363 320.101 320.838 321.576 322.313 323.051 323.789
440 324.526 325.264 326.001 326.739 327.477 328.214 328.952 329.689 330.427 331.164
450 331.902 332.639 333.377 334.115 334.852 335.590 336.327 337.065 337.802 338.540
460 339.278 340.015 340.753 341.490 342.228 342.965 343.703 344.440 345.178 345.916
470 346.653 347.391 348.128 348.866 349.603 350.341 351.078 351.816 352.553 353.291
480 354.029 354.766 355.504 356.241 356.979 357.717 358.454 359.192 359.929 360.667
490 361.404 362.142 362.879 363.617 364.354 365.092 365.830 366.567 367.305 368.042
500 368.780 369.517 370.255 370.992 371.730 372.468 373.205 373.943 374.680 375.418
510 376.156 376.893 377.631 378.368 379.106 379.843 380.581 381.318 382.056 382.793
520 383.531 384.269 385.006 385.744 386.481 387.219 387.957 388.694 389.432 390.169
530 390.907 391.644 392.382 393.119 393.857 394.594 395.332 396.070 396.807 397.545
540 398.282 399.020 399.757 400.495 401.232 401.970 402.708 403.445 404.183 404.920
550 405.658 406.396 407.133 407.871 408.608 409.346 410.083 410.821 411.558 412.296
560 413.033 413.771 414.509 415.246 415.984 416.721 417.459 418.196 418.934 419.671
570 420.409 421.147 421.884 422.622 423.359 424.097 424.834 425.572 426.310 427.047
580 427.785 428.522 429.260 429.997 430.735 431.472 432.210 432.948 433.685 434.423
590 435.160 435.898 436.635 437.373 438.111 438.848 439.586 440.323 441.061 441.798
600 442.536 443.273 444.011 444.749 445.486 446.224 446.961 447.699 448.436 449.174
610 449.911 450.649 451.386 452.124 452.862 453.599 454.337 455.074 455.812 456.550
620 457.287 458.025 458.762 459.500 460.237 460.975 461.712 462.450 463.187 463.925
630 464.663 465.400 466.138 466.875 467.613 468.350 469.088 469.826 470.563 471.301
640 472.038 472.776 473.513 474.251 474.989 475.726 476.464 477.201 477.939 478.676
650 479.414 480.151 480.889 481.626 482.364 483.102 483.839 484.577 485.314 486.052
660 486.790 487.527 488.265 489.002 489.740 490.477 491.215 491.952 492.690 493.427
670 494.165 494.903 495.640 496.378 497.115 497.853 498.590 499.328 500.065 500.803
680 501.541 502.278 503.016 503.753 504.491 505.229 505.966 506.704 507.441 508.179
690 508.916 509.654 510.391 511.129 511.866 512.604 513.342 514.079 514.817 515.554
700 516.292 517.030 517.767 518.505 519.242 519.980 520.717 521.455 522.192 522.930
2 801 850.00 de/us 9

Nm 0 1 2 3 4 5 6 7 8 9
710 523.667 524.405 525.143 525.880 526.618 527.355 528.093 528.830 529.568 530.305
720 531.043 531.781 532.518 533.256 533.993 534.731 535.469 536.206 536.944 537.681
730 538.419 539.156 539.894 540.631 541.369 542.106 542.844 543.582 544.319 545.057
740 545.794 546.532 547.269 548.007 548.744 549.482 550.220 550.957 551.695 552.432
750 553.170 553.907 554.645 555.383 556.120 556.858 557.595 558.333 559.070 559.808
760 560.545 561.283 562.021 562.758 563.496 564.233 564.971 565.708 566.446 567.184
770 567.921 568.659 569.396 570.134 570.871 571.609 572.346 573.084 573.822 574.559
780 575.297 576.034 576.772 577.509 578.247 578.984 579.722 580.459 581.197 581.935
790 582.672 583.410 584.147 584.885 585.623 586.360 587.098 587.835 588.573 589.310
800 590.048 590.785 591.523 592.260 592.998 593.736 594.473 595.211 595.948 596.686
810 597.423 598.161 598.899 599.636 600.374 601.111 601.849 602.586 603.324 604.062
820 604.799 605.537 606.274 607.012 607.749 608.487 609.224 609.962 610.699 611.437
830 612.175 612.912 613.650 614.387 615.125 615.863 616.600 617.338 618.075 618.813
840 619.550 620.288 621.025 621.763 622.500 623.238 623.976 624.713 625.451 626.188
850 626.926 627.663 628.401 629.138 629.876 630.614 631.351 632.089 632.826 633.564
860 634.302 635.039 635.777 636.514 637.252 637.989 638.727 639.464 640.202 640.939
870 641.677 642.415 643.152 643.890 644.627 645.365 646.102 646.840 647.578 648.315
880 649.053 649.790 650.528 651.265 652.003 652.740 653.478 654.216 654.953 655.691
890 656.428 657.166 657.903 658.641 659.378 660.116 660.854 661.591 662.329 663.066
900 663.804 664.542 665.279 666.017 666.754 667.492 668.229 668.967 669.704 670.442
910 671.179 671.917 672.655 673.392 674.130 674.867 675.605 676.342 677.080 677.817
920 678.555 679.293 680.030 680.768 681.505 682.243 682.980 683.718 684.456 685.193
930 685.931 686.668 687.406 688.143 688.881 689.618 690.356 691.094 691.831 692.569
940 693.306 694.044 694.781 695.519 696.257 696.994 697.732 698.469 699.207 699.944
950 700.682 701.419 702.157 702.895 703.632 704.370 705.107 705.845 706.582 707.320
960 708.057 708.795 709.532 710.270 711.008 711.745 712.483 713.220 713.958 714.696
970 715.433 716.171 716.908 717.646 718.383 719.121 719.858 720.596 721.333 722.071
980 722.809 723.546 724.284 725.021 725.759 726.496 727.234 727.972 728.709 729.447
990 730.184 730.922 731.659 732.397 733.135 733.872 734.610 735.347 736.085 736.822
1000 737.560 738.297 739.035 739.772 740.510 741.248 741.985 742.723 743.460 744.198
1010 744.936 745.673 746.411 747.148 747.886 748.623 749.361 750.098 750.836 751.573
1020 752.311 753.049 753.786 754.524 755.261 755.999 756.736 757.474 758.211 758.949
1030 759.687 760.424 761.162 761.899 762.637 763.375 764.112 764.850 765.587 766.325
1040 767.062 767.800 768.537 769.275 770.012 770.750 771.488 772.225 772.963 773.700
1050 774.438 775.175 775.913 776.651 777.388 778.126 778.863 779.601 780.338 781.076
1060 781.813 782.551 783.289 784.026 784.764 785.501 786.239 786.976 787.714 788.451
1070 789.189 789.927 790.664 791.402 792.139 792.877 793.615 794.352 795.090 795.827
1080 796.565 797.302 798.040 798.777 799.515 800.252 800.990 801.728 802.465 803.203
1090 803.940 804.678 805.415 806.153 806.890 807.628 808.366 809.103 809.841 810.578
1100 811.316 812.053 812.791 813.529 814.266 815.004 815.741 816.479 817.216 817.954
1110 818.691 819.429 820.167 820.904 821.642 822.379 823.117 823.854 824.592 825.330
1120 826.067 826.805 827.542 828.280 829.017 829.755 830.492 831.230 831.968 832.705
1130 833.443 834.180 834.918 835.655 836.393 837.130 837.868 838.605 839.343 840.081
1140 840.818 841.556 842.293 843.031 843.769 844.506 845.244 845.981 846.719 847.456
1150 848.194 848.931 849.669 850.406 851.144 851.882 852.619 853.357 854.094 854.832
1160 855.569 856.307 857.045 857.782 858.520 859.257 859.995 860.732 861.470 862.208
1170 862.945 863.683 864.420 865.158 865.895 866.633 867.370 868.108 868.845 869.583
1180 870.321 871.058 871.796 872.533 873.271 874.009 874.746 875.484 876.221 876.959
1190 877.696 878.434 879.171 879.909 880.646 881.384 882.122 882.859 883.597 884.334
1200 885.072 885.809 886.547 887.284 888.022 888.760 889.497 890.235 890.972 891.710
1210 892.448 893.185 893.923 894.660 895.398 896.135 896.873 897.610 898.348 899.085
1220 899.823 900.561 901.298 902.036 902.773 903.511 904.248 904.986 905.724 906.461
1230 907.199 907.936 908.674 909.411 910.149 910.886 911.624 912.362 913.099 913.837
1240 914.574 915.312 916.049 916.787 917.524 918.262 919.000 919.737 920.475 921.212
1250 921.950 922.687 923.425 924.163 924.900 925.638 926.375 927.113 927.850 928.588
1260 929.325 930.063 930.801 931.538 932.276 933.013 933.751 934.488 935.226 935.963
1270 936.701 937.439 938.176 938.914 939.651 940.389 941.126 941.864 942.602 943.339
1280 944.077 944.814 945.552 946.289 947.027 947.764 948.502 949.240 949.977 950.715
1290 951.452 952.190 952.927 953.665 954.403 955.140 955.878 956.615 957.353 958.090
1300 958.828 959.565 960.303 961.041 961.778 962.516 963.253 963.991 964.728 965.466
1310 966.203 966.941 967.678 968.416 969.154 969.891 970.629 971.366 972.104 972.842
1320 973.579 974.317 975.054 975.792 976.529 977.267 978.004 978.742 979.479 980.217
1330 980.955 981.692 982.430 983.167 983.905 984.642 985.380 986.118 986.855 987.593
1340 988.330 989.068 989.805 990.543 991.281 992.018 992.756 993.493 994.231 994.968
1350 995.706 996.443 997.181 997.918 998.656 999.394 1000.131 1000.869 1001.606 1002.344
1360 1003.082 1003.819 1004.557 1005.294 1006.032 1006.769 1007.507 1008.244 1008.982 1009.719
1370 1010.457 1011.195 1011.932 1012.670 1013.407 1014.145 1014.882 1015.620 1016.357 1017.095
1380 1017.833 1018.570 1019.308 1020.045 1020.783 1021.521 1022.258 1022.996 1023.733 1024.471
1390 1025.208 1025.946 1026.683 1027.421 1028.158 1028.896 1029.634 1030.371 1031.109 1031.846
1400 1032.584 1033.321 1034.059 1034.797 1035.534 1036.272 1037.009 1037.747 1038.484 1039.222
10 2 801 850.00 de/us

Nm 0 1 2 3 4 5 6 7 8 9
1410 1039.959 1040.697 1041.435 1042.172 1042.910 1043.647 1044.385 1045.122 1045.860 1046.597
1420 1047.335 1048.073 1048.810 1049.548 1050.285 1051.023 1051.760 1052.498 1053.236 1053.973
1430 1054.711 1055.448 1056.186 1056.923 1057.661 1058.398 1059.136 1059.874 1060.611 1061.349
1440 1062.086 1062.824 1063.561 1064.299 1065.036 1065.774 1066.512 1067.249 1067.987 1068.724
1450 1069.462 1070.199 1070.937 1071.675 1072.412 1073.150 1073.887 1074.625 1075.362 1076.100
1460 1076.837 1077.575 1078.312 1079.050 1079.788 1080.525 1081.263 1082.000 1082.738 1083.476
1470 1084.213 1084.951 1085.688 1086.426 1087.163 1087.901 1088.638 1089.376 1090.114 1090.851
1480 1091.589 1092.326 1093.064 1093.801 1094.539 1095.276 1096.014 1096.751 1097.489 1098.227
1490 1098.964 1099.702 1100.439 1101.177 1101.915 1102.652 1103.390 1104.127 1104.865 1105.602
1500 1106.340 1107.077 1107.815 1108.552 1109.290 1110.028 1110.765 1111.503 1112.240 1112.978
1510 1113.715 1114.453 1115.191 1115.928 1116.666 1117.403 1118.141 1118.878 1119.616 1120.354
1520 1121.091 1121.829 1122.566 1123.304 1124.041 1124.779 1125.516 1126.254 1126.991 1127.729
1530 1128.467 1129.204 1129.942 1130.679 1131.417 1132.155 1132.892 1133.630 1134.367 1135.105
1540 1135.842 1136.580 1137.317 1138.055 1138.792 1139.530 1140.268 1141.005 1141.743 1142.480
1550 1143.218 1143.955 1144.693 1145.430 1146.168 1146.906 1147.643 1148.381 1149.118 1149.856
1560 1150.594 1151.331 1152.069 1152.806 1153.544 1154.281 1155.019 1155.756 1156.494 1157.231
1570 1157.969 1158.707 1159.444 1160.182 1160.919 1161.657 1162.394 1163.132 1163.870 1164.607
1580 1165.345 1166.082 1166.820 1167.557 1168.295 1169.032 1169.770 1170.508 1171.245 1171.983
1590 1172.720 1173.458 1174.195 1174.933 1175.670 1176.408 1177.146 1177.883 1178.621 1179.358
1600 1180.096 1180.833 1181.571 1182.309 1183.046 1183.784 1184.521 1185.259 1185.996 1186.734
1610 1187.471 1188.209 1188.947 1189.684 1190.422 1191.159 1191.897 1192.634 1193.372 1194.109
1620 1194.847 1195.585 1196.322 1197.060 1197.797 1198.535 1199.272 1200.010 1200.748 1201.485
1630 1202.223 1202.960 1203.698 1204.435 1205.173 1205.910 1206.648 1207.385 1208.123 1208.861
1640 1209.598 1210.336 1211.073 1211.811 1212.549 1213.286 1214.024 1214.761 1215.499 1216.236
1650 1216.974 1217.711 1218.449 1219.187 1219.924 1220.662 1221.399 1222.137 1222.874 1223.612
1660 1224.349 1225.087 1225.824 1226.562 1227.300 1228.037 1228.775 1229.512 1230.250 1230.988
1670 1231.725 1232.463 1233.200 1233.938 1234.675 1235.413 1236.150 1236.888 1237.625 1238.363
1680 1239.101 1239.838 1240.576 1241.313 1242.051 1242.788 1243.526 1244.264 1245.001 1245.739
1690 1246.476 1247.214 1247.951 1248.689 1249.427 1250.164 1250.902 1251.639 1252.377 1253.114
1700 1253.852 1254.589 1255.327 1256.064 1256.802 1257.540 1258.277 1259.015 1259.752 1260.490
1710 1261.228 1261.965 1262.703 1263.440 1264.178 1264.915 1265.653 1266.390 1267.128 1267.865
1720 1268.603 1269.341 1270.078 1270.816 1271.553 1272.291 1273.028 1273.766 1274.503 1275.241
1730 1275.979 1276.716 1277.454 1278.191 1278.929 1279.667 1280.404 1281.142 1281.879 1282.617
1740 1283.354 1284.092 1284.829 1285.567 1286.304 1287.042 1287.780 1288.517 1289.255 1289.992
1750 1290.730 1291.467 1292.205 1292.943 1293.680 1294.418 1295.155 1295.893 1296.630 1297.368
1760 1298.105 1298.843 1299.581 1300.318 1301.056 1301.793 1302.531 1303.268 1304.006 1304.743
1770 1305.481 1306.219 1306.956 1307.694 1308.431 1309.169 1309.906 1310.644 1311.382 1312.199
1780 1312.857 1313.594 1314.332 1315.069 1315.807 1316.544 1317.282 1318.020 1318.757 1319.495
1790 1320.232 1320.970 1321.707 1322.445 1323.182 1323.920 1324.657 1325.395 1326.133 1326.870
1800 1327.608 1328.345 1329.083 1329.821 1330.558 1331.296 1332.033 1332.771 1333.508 1334.246
1810 1334.983 1335.721 1336.458 1337.196 1337.934 1338.671 1339.409 1340.146 1340.884 1341.622
1820 1342.359 1343.097 1343.834 1344.572 1345.309 1346.047 1346.784 1347.522 1348.260 1348.997
1830 1349.735 1350.472 1351.210 1351.947 1352.685 1353.422 1354.160 1354.897 1355.635 1356.373
1840 1357.110 1357.848 1358.585 1359.323 1360.061 1360.798 1361.536 1362.273 1363.011 1363.748
1850 1364.486 1365.223 1365.961 1366.698 1367.436 1368.174 1368.911 1369.649 1370.386 1371.124
1860 1371.861 1372.599 1373.337 1374.074 1374.812 1375.549 1376.287 1377.024 1377.762 1378.500
1870 1379.237 1379.975 1380.712 1381.450 1382.187 1382.925 1383.662 1384.400 1385.137 1385.875
1880 1386.613 1387.350 1388.088 1388.825 1389.563 1390.301 1391.038 1391.776 1392.513 1393.251
1890 1393.988 1394.726 1395.463 1396.201 1396.938 1397.676 1398.414 1399.151 1399.889 1400.626
1900 1401.364 1402.101 1402.839 1403.576 1404.314 1405.052 1405.789 1406.527 1407.264 1408.002
1910 1408.740 1409.477 1410.215 1410.952 1411.690 1412.427 1413.165 1413.902 1414.640 1415.377
1920 1416.115 1416.853 1417.590 1418.328 1419.065 1419.803 1420.540 1421.278 1422.016 1422.753
1930 1423.491 1424.228 1424.966 1425.703 1426.441 1427.178 1427.916 1428.654 1429.391 1430.129
1940 1430.866 1431.604 1432.341 1433.079 1433.816 1434.554 1435.292 1436.029 1436.767 1437.504
1950 1438.242 1438.979 1439.717 1440.455 1441.192 1441.930 1442.667 1443.405 1444.142 1444.880
1960 1445.617 1446.355 1447.093 1447.830 1448.568 1449.305 1450.043 1450.780 1451.518 1452.255
1970 1452.993 1453.730 1454.468 1455.206 1455.943 1456.681 1457.418 1458.156 1458.894 1459.631
1980 1460.369 1461.106 1461.844 1462.581 1463.319 1464.056 1464.794 1465.531 1466.269 1467.007
1990 1467.744 1468.482 1469.219 1469.957 1470.695 1471.432 1472.170 1472.907 1473.645 1474.382
2000 1475.120 1475.857 1476.595 1477.333 1478.070 1478.808 1479.545 1480.283 1481.020 1481.758
2010 1482.495 1483.233 1483.970 1484.708 1485.446 1486.183 1486.921 1487.658 1488.396 1489.134
2020 1489.871 1490.609 1491.346 1492.084 1492.821 1493.559 1494.296 1495.034 1495.771 1496.509
2030 1497.247 1497.984 1498.722 1499.459 1500.197 1500.934 1501.672 1502.409 1503.147 1503.885
2040 1504.622 1505.360 1506.097 1506.835 1507.573 1508.310 1509.048 1509.785 1510.523 1511.260
2050 1511.998 1512.735 1513.473 1514.210 1514.948 1515.686 1516.423 1517.161 1517.898 1518.636
2060 1519.374 1520.111 1520.849 1521.586 1522.324 1523.061 1523.799 1524.536 1525.274 1526.011
2070 1526.749 1527.487 1528.224 1528.962 1529.699 1530.437 1531.174 1531.912 1532.649 1533.387
2080 1534.125 1534.862 1535.600 1536.337 1537.075 1537.812 1538.550 1539.288 1540.025 1540.763
2090 1541.500 1542.238 1542.975 1543.713 1544.450 1545.188 1545.926 1546.663 1547.401 1548.138
2100 1548.876 1549.613 1550.351 1551.089 1551.826 1552.564 1553.301 1554.039 1554.776 1555.514
2 801 850.00 de/us 11

Nm 0 1 2 3 4 5 6 7 8 9
2110 1556.251 1556.989 1557.727 1558.464 1559.202 1559.939 1560.677 1561.414 1562.152 1562.889
2120 1563.627 1564.365 1565.102 1565.840 1566.577 1567.315 1568.052 1568.790 1569.528 1570.265
2130 1571.003 1571.740 1572.478 1573.215 1573.953 1574.690 1575.428 1576.166 1576.903 1577.641
2140 1578.378 1579.116 1579.853 1580.591 1581.328 1582.066 1582.803 1583.541 1584.279 1585.016
2150 1585.754 1586.491 1587.229 1587.967 1588.704 1589.442 1590.179 1590.917 1591.654 1592.392
2160 1593.129 1593.867 1594.604 1595.342 1596.080 1596.817 1597.555 1598.292 1599.030 1599.768
2170 1600.505 1601.243 1601.980 1602.718 1603.455 1604.193 1604.930 1605.668 1606.406 1607.143
2180 1607.881 1608.618 1609.356 1610.093 1610.831 1611.568 1612.306 1613.043 1613.781 1614.519
2190 1615.256 1615.994 1616.731 1617.469 1618.207 1618.944 1619.682 1620.419 1621.157 1621.894
2200 1622.632 1623.369 1624.107 1624.844 1625.582 1626.320 1627.057 1627.795 1628.532 1629.270
2210 1630.007 1630.745 1631.482 1632.220 1632.958 1633.695 1634.433 1635.170 1635.908 1636.646
2220 1637.383 1638.121 1638.858 1639.596 1640.333 1641.071 1641.808 1642.546 1643.283 1644.021
2230 1644.759 1645.496 1646.234 1646.971 1647.709 1648.447 1649.184 1649.922 1650.659 1651.397
2240 1652.134 1652.872 1653.609 1654.347 1655.084 1655.822 1656.560 1657.297 1658.035 1658.772
2250 1659.510 1660.247 1660.985 1661.722 1662.460 1663.198 1663.935 1664.673 1665.410 1666.148
2260 1666.885 1667.623 1668.361 1669.098 1669.836 1670.573 1671.311 1672.048 1672.786 1673.523
2270 1674.261 1674.999 1675.736 1676.474 1677.211 1677.949 1678.686 1679.424 1680.162 1680.899
2280 1681.637 1682.374 1683.112 1683.849 1684.587 1685.324 1686.062 1686.800 1687.537 1688.275
2290 1689.012 1689.750 1690.487 1691.225 1691.962 1692.700 1693.437 1694.175 1694.913 1695.650
2300 1696.388 1697.125 1697.863 1698.601 1699.338 1700.076 1700.813 1701.551 1702.288 1703.026
2310 1703.763 1704.501 1705.239 1705.976 1706.714 1707.451 1708.189 1708.926 1709.664 1710.401
2320 1711.139 1711.876 1712.614 1713.352 1714.089 1714.827 1715.564 1716.302 1717.040 1717.777
2330 1718.515 1719.252 1719.990 1720.727 1721.465 1722.202 1722.940 1723.677 1724.415 1725.153
2340 1725.890 1726.628 1727.365 1728.103 1728.841 1729.578 1730.316 1731.053 1731.791 1732.528
2350 1733.266 1734.003 1734.741 1735.479 1736.216 1736.954 1737.691 1738.429 1739.166 1739.904
2360 1740.641 1741.379 1742.116 1742.854 1743.592 1744.329 1745.067 1745.804 1746.542 1747.280
2370 1748.017 1748.755 1749.492 1750.230 1750.967 1751.705 1752.442 1753.180 1753.917 1754.655
2380 1755.393 1756.130 1756.868 1757.605 1758.343 1759.080 1759.818 1760.555 1761.293 1762.031
2390 1762.768 1763.506 1764.243 1764.981 1765.719 1766.456 1767.194 1767.931 1768.669 1769.406
2400 1770.144 1770.881 1771.619 1772.356 1773.094 1773.832 1774.569 1775.307 1776.044 1776.782
2410 1777.520 1778.257 1778.995 1779.732 1780.470 1781.207 1781.945 1782.682 1783.420 1784.157
2420 1784.895 1785.633 1786.370 1787.108 1787.845 1788.583 1789.320 1790.058 1790.795 1791.533
2430 1792.271 1793.008 1793.746 1794.483 1795.221 1795.958 1796.696 1797.434 1798.171 1798.909
2440 1799.646 1800.384 1801.121 1801.859 1802.596 1803.334 1804.072 1804.809 1805.547 1806.284
2450 1807.022 1807.759 1808.497 1809.234 1809.972 1810.710 1811.447 1812.185 1812.922 1813.660
2460 1814.397 1815.135 1815.873 1816.610 1817.348 1818.085 1818.823 1819.560 1820.298 1821.035
2470 1821.773 1822.510 1823.248 1823.986 1824.723 1825.461 1826.198 1826.936 1827.674 1828.411
2480 1829.149 1829.886 1830.624 1831.361 1832.099 1832.836 1833.574 1834.312 1835.049 1835.787
2490 1836.524 1837.262 1837.999 1838.737 1839.474 1840.212 1840.949 1841.687 1842.425 1843.162
2500 1843.900 1844.637 1845.375 1846.113 1846.850 1847.588 1848.325 1849.063 1849.800 1850.538
2510 1851.275 1852.013 1852.750 1853.488 1854.226 1854.963 1855.701 1856.438 1857.176 1857.914
2520 1858.651 1859.389 1860.126 1860.864 1861.601 1862.339 1863.076 1863.814 1864.552 1865.289
2530 1866.027 1866.764 1867.502 1868.239 1868.977 1869.714 1870.452 1871.189 1871.927 1872.665
2540 1873.402 1874.140 1874.877 1875.615 1876.353 1877.090 1877.828 1878.565 1879.303 1880.040
2550 1880.778 1881.515 1882.253 1882.990 1883.728 1884.466 1885.203 1885.941 1886.678 1887.416
2560 1888.153 1888.891 1889.628 1890.366 1891.104 1891.841 1892.579 1893.316 1894.054 1894.792
2570 1895.529 1896.267 1897.004 1897.742 1898.479 1899.217 1899.954 1900.692 1901.429 1902.167
2580 1902.905 1903.642 1904.380 1905.117 1905.855 1906.593 1907.330 1908.068 1908.805 1909.543
2590 1910.280 1911.018 1911.755 1912.493 1913.230 1913.968 1914.706 1915.443 1916.181 1916.918
2600 1917.656 1918.393 1919.131 1919.868 1920.606 1921.344 1922.081 1922.819 1923.556 1924.294
2610 1925.031 1925.769 1926.507 1927.244 1927.982 1928.719 1929.457 1930.194 1930.932 1931.669
2620 1932.407 1933.145 1933.882 1934.620 1935.357 1936.095 1936.832 1937.570 1938.307 1939.045
2630 1939.783 1940.520 1941.258 1941.995 1942.733 1943.470 1944.208 1944.946 1945.683 1946.421
2640 1947.158 1947.896 1948.633 1949.371 1950.108 1950.846 1951.583 1952.321 1953.059 1953.796
2650 1954.534 1955.271 1956.009 1956.747 1957.484 1958.222 1958.959 1959.697 1960.434 1961.172
2660 1961.909 1962.647 1963.385 1964.122 1964.860 1965.597 1966.335 1967.072 1967.810 1968.547
2670 1969.285 1970.022 1970.760 1971.498 1972.235 1972.973 1973.710 1974.448 1975.186 1975.923
2680 1976.661 1977.398 1978.136 1978.873 1979.611 1980.348 1981.086 1981.823 1982.561 1983.299
2690 1984.036 1984.774 1985.511 1986.249 1986.986 1987.724 1988.462 1989.199 1989.937 1990.674
2700 1991.412 1992.149 1992.887 1993.625 1994.362 1995.100 1995.837 1996.575 1997.312 1998.050
2710 1998.787 1999.525 2000.262 2001.000 2001.738 2002.475 2003.213 2003.950 2004.688 2005.426
2720 2006.163 2006.901 2007.638 2008.376 2009.113 2009.851 2010.588 2011.326 2012.063 2012.801
2730 2013.539 2014.276 2015.014 2015.751 2016.489 2017.226 2017.964 2018.701 2019.439 2020.177
2740 2020.914 2021.652 2022.389 2023.127 2023.865 2024.602 2025.340 2026.077 2026.815 2027.552
2750 2028.290 2029.027 2029.765 2030.502 2031.240 2031.978 2032.715 2033.453 2034.190 2034.928
2760 2035.666 2036.403 2037.141 2037.878 2038.616 2039.353 2040.091 2040.828 2041.566 2042.303
2770 2043.041 2043.779 2044.516 2045.254 2045.991 2046.729 2047.466 2048.204 2048.941 2049.679
2780 2050.417 2051.154 2051.892 2052.629 2053.367 2054.104 2054.842 2055.580 2056.317 2057.055
2790 2057.792 2058.530 2059.267 2060.005 2060.742 2061.480 2062.218 2062.955 2063.693 2064.430
2800 2065.168 2065.905 2066.643 2067.380 2068.118 2068.856 2069.593 2070.331 2071.068 2071.806
12 2 801 850.00 de/us

Nm 0 1 2 3 4 5 6 7 8 9
2810 2072.543 2073.281 2074.019 2074.756 2075.494 2076.231 2076.969 2077.706 2078.444 2079.181
2820 2079.919 2080.656 2081.394 2082.132 2082.869 2083.607 2084.344 2085.082 2085.820 2086.557
2830 2087.295 2088.032 2088.770 2089.507 2090.245 2090.982 2091.720 2092.458 2093.195 2093.933
2840 2094.670 2095.408 2096.145 2096.883 2097.620 2098.358 2099.095 2099.833 2100.571 2101.308
2850 2102.046 2102.783 2103.521 2104.259 2104.996 2105.734 2106.471 2107.209 2107.946 2108.684
2860 2109.421 2110.159 2110.896 2111.634 2112.372 2113.109 2113.847 2114.584 2115.322 2116.059
2870 2116.797 2117.535 2118.272 2119.010 2119.747 2120.485 2121.222 2121.960 2122.698 2123.435
2880 2124.173 2124.910 2125.648 2126.385 2127.123 2127.860 2128.598 2129.335 2130.073 2130.811
2890 2131.548 2132.286 2133.023 2133.761 2134.499 2135.236 2135.974 2136.711 2137.449 2138.186
2900 2138.924 2139.661 2140.399 2141.136 2141.874 2142.612 2143.349 2144.087 2144.824 2145.562
2910 2146.299 2147.037 2147.774 2148.512 2149.250 2149.987 2150.725 2151.462 2152.200 2152.937
2920 2153.675 2154.413 2155.150 2155.888 2156.625 2157.363 2158.100 2158.838 2159.575 2160.313
2930 2161.051 2161.788 2162.526 2163.263 2164.001 2164.738 2165.476 2166.214 2166.951 2167.689
2940 2168.426 2169.164 2169.901 2170.639 2171.376 2172.114 2172.852 2173.589 2174.327 2175.064
2950 2175.802 2176.539 2177.277 2178.014 2178.752 2179.490 2180.227 2180.965 2181.702 2182.440
2960 2183.177 2183.915 2184.653 2185.390 2186.128 2186.865 2187.603 2188.340 2189.078 2189.815
2970 2190.553 2191.291 2192.028 2192.766 2193.503 2194.241 2194.978 2195.716 2196.453 2197.191
2980 2197.929 2198.666 2199.404 2200.141 2200.879 2201.616 2202.354 2203.092 2203.829 2204.567
2990 2205.304 2206.042 2006.779 2207.517 2208.254 2208.992 2209.729 2210.467 2211.205 2211.942
3000 2212.680 2213.417 2214.155 2214.893 2215.630 2216.368 2217.105 2217.843 2218.580 2219.318
3010 2220.055 2220.793 2221.531 2222.268 2223.006 2223.743 2224.481 2225.218 2225.956 2226.693
3020 2227.431 2228.168 2228.906 2229.644 2230.381 2231.119 2231.856 2232.594 2233.332 2234.069
3030 2234.807 2235.544 2236.282 2237.019 2237.757 2238.494 2239.232 2239.969 2240.707 2241.445
3040 2242.182 2242.920 2243.657 2244.395 2245.132 2245.870 2246.608 2247.345 2248.083 2248.820
3050 2249.558 2250.295 2251.033 2251.771 2252.508 2253.246 2253.983 2254.721 2255.458 2256.196
3060 2256.933 2257.671 2258.408 2259.146 2259.884 2260.621 2261.359 2262.096 2262.834 2263.572
3070 2264.309 2265.047 2265.784 2266.522 2267.259 2267.997 2268.734 2269.472 2270.209 2270.947
3080 2271.685 2272.422 2273.160 2273.897 2274.635 2275.372 2276.110 2276.847 2277.585 2278.323
3090 2279.060 2279.798 2280.535 2281.273 2282.010 2282.748 2283.486 2284.223 2284.961 2285.698
3100 2286.436 2287.173 2287.911 2288.648 2289.386 2290.124 2290.861 2291.599 2292.336 2293.074
3110 2293.811 2294.549 2295.287 2296.024 2296.762 2297.499 2298.237 2298.974 2299.712 2300.449
3120 2301.187 2301.925 2302.662 2303.400 2304.137 2304.875 2305.612 2306.350 2307.087 2307.825
3130 2308.562 2309.300 2310.038 2310.775 2311.513 2312.250 2312.988 2313.726 2314.463 2315.201
3140 2315.938 2316.676 2317.413 2318.151 2318.888 2319.626 2320.364 2321.101 2321.839 2322.576
3150 2323.314 2324.051 2324.789 2325.526 2326.264 2327.002 2327.739 2328.477 2329.214 2329.952
3160 2330.689 2331.427 2332.165 2332.902 2333.640 2334.377 2335.115 2335.852 2336.590 2337.327
3170 2338.065 2338.802 2339.540 2340.278 2341.015 2341.753 2342.490 2343.228 2343.966 2344.703
3180 2345.441 2346.178 2346.916 2347.653 2348.391 2349.128 2349.866 2350.604 2351.341 2352.079
3190 2352.816 2353.554 2354.291 2355.029 2355.766 2356.504 2357.241 2357.979 2358.717 2359.454
3200 2360.192 2360.929 2361.667 2362.405 2363.142 2363.880 2364.617 2365.355 2366.092 2366.830
3210 2367.567 2368.305 2369.042 2369.780 2370.518 2371.255 2371.993 2372.730 2373.468 2374.205
3220 2374.943 2375.681 2376.418 2377.156 2377.893 2378.631 2379.368 2380.106 2380.844 2381.581
3230 2382.319 2383.056 2383.794 2384.531 2385.26 9 2386.006 2386.744 2387.481 2388.219 2388.957
3240 2389.694 2390.432 2391.169 2391.907 2392.645 2393.382 2394.120 2394.857 2395.595 2396.332
3250 2397.070 2397.807 2398.545 2399.282 2400.020 2400.758 2401.495 2402.233 2402.970 2403.708
3260 2404.445 2405.183 2405.920 2406.658 2407.396 2408.133 2408.871 2409.608 2410.346 2411.083
3270 2411.821 2412.559 2413.296 2414.034 2414.771 2415.509 2416.246 2416.984 2417.721 2418.459
3280 2419.197 2419.934 2420.672 2421.409 2422.147 2422.884 2423.622 2424.360 2425.097 2425.835
3290 2426.572 2427.310 2428.047 2428.785 2429.522 2430.260 2430.998 2431.735 2432.473 2433.210
3300 2433.948 2434.685 2435.423 2436.160 2436.898 2437.635 2438.373 2439.111 2439.848 2440.586
3310 2441.323 2442.061 2442.799 2443.536 2444.274 2445.011 2445.749 2446.486 2447.224 2447.961
3320 2448.699 2449.437 2450.174 2450.912 2451.649 2452.387 2453.124 2453.862 2454.599 2455.337
3330 2456.075 2456.812 2457.550 2458.287 2459.025 2459.762 2460.500 2461.238 2461.975 2462.713
3340 2463.450 2464.188 2464.925 2465.663 2466.400 2467.138 2467.875 2468.613 2469.351 2470.088
3350 2470.826 2471.563 2472.301 2473.039 2473.776 2474.514 2475.251 2475.989 2476.726 2477.464
3360 2478.201 2478.939 2479.677 2480.414 2481.152 2481.889 2482.627 2483.364 2484.102 2484.839
3370 2485.577 2486.314 2487.052 2487.790 2488.527 2489.265 2490.002 2490.740 2491.478 2492.215
3380 2492.953 2493.690 2494.428 2495.165 2495.903 2496.640 2497.378 2498.115 2498.853 2499.591
3390 2500.328 2501.066 2501.803 2502.541 2503.278 2504.016 2504.754 2505.491 2506.229 2506.966
3400 2507.704 2508.441 2509.179 2509.917 2510.654 2511.392 2512.129 2512.867 2513.604 2514.342
3410 2515.079 2515.817 2516.554 2517.292 2518.030 2518.767 2519.505 2520.242 2520.980 2521.718
3420 2522.455 2523.193 2523.930 2524.668 2525.405 2526.143 2526.880 2527.618 2528.355 2529.093
3430 2529.831 2530.568 2531.306 2532.043 2532.781 2533.518 2534.256 2534.993 2535.731 2536.469
3440 2537.206 2537.944 2538.681 2539.419 2540.156 2540.894 2541.632 2542.369 2543.107 2543.844
3450 2544.582 2545.319 2546.057 2546.794 2547.532 2548.270 2549.007 2549.745 2550.482 2551.220
3460 2551.957 2552.695 2553.433 2554.170 2554.908 2555.645 2556.383 2557.120 2557.858 2558.595
3470 2559.333 2560.071 2560.808 2561.546 2562.283 2563.021 2563.758 2564.496 2565.233 2565.971
3480 2566.708 2567.446 2568.184 2568.921 2569.659 2570.396 2571.134 2571.872 2572.609 2573.347
3490 2574.084 2574.822 2575.559 2576.297 2577.034 2577.772 2578.510 2579.247 2579.985 2580.722
3500 2581.460 2582.197 2582.935 2583.672 2584.410 2585.148 2585.885 2586.623 2587.360 2588.098
2 801 850.00 de/us 13

Nm 0 1 2 3 4 5 6 7 8 9
3510 2588.835 2589.573 2590.311 2591.048 2591.786 2592.523 2593.261 2593.998 2594.736 2595.473
3520 2596.211 2596.948 2597.686 2598.424 2599.161 2599.899 2600.636 2601.374 2602.112 2602.849
3530 2603.587 2604.324 2605.062 2605.799 2606.537 2607.274 2608.012 2608.750 2609.487 2610.225
3540 2610.962 2611.700 2612.437 2613.175 2613.912 2614.650 2615.387 2616.125 2616.863 2617.600
3550 2618.338 2619.075 2619.813 2620.551 2621.288 2622.026 2622.763 2623.501 2624.238 2624.976
3560 2625.713 2626.451 2627.188 2627.926 2628.664 2629.401 2630.139 2630.876 2631.614 2632.351
3570 2633.089 2633.827 2634.564 2635.302 2636.039 2636.777 2637.514 2638.252 2638.990 2639.727
3580 2640.465 2641.202 2641.940 2642.677 2643.415 2644.152 2644.890 2645.627 2646.365 2647.103
3590 2647.840 2648.578 2649.315 2650.053 2650.791 2651.528 2652.266 2653.003 2653.741 2654.478
3600 2655.216 2655.953 2656.691 2657.428 2658.166 2658.904 2659.641 2660.379 2661.116 2661.854
3610 2662.591 2663.329 2664.066 2664.804 2665.542 2666.279 2667.017 2667.754 2668.492 2669.229
3620 2669.967 2670.705 2671.442 2672.180 2672.917 2673.655 2674.392 2675.130 2675.867 2676.605
3630 2677.343 2678.080 2678.818 2679.555 2680.293 2681.030 2681.768 2682.506 2583.243 2683.981
3640 2684.718 2685.456 2686.193 2686.931 2687.668 2688.406 2689.144 2689.881 2690.619 2691.356
3650 2692.094 2692.831 2693.569 2694.306 2695.044 2695.781 2696.519 2697.257 2697.994 2698.732
3660 2699.469 2700.207 2700.945 2701.682 2702.420 2703.157 2703.895 2704.632 2705.370 2706.107
3670 2706.845 2707.583 2708.320 2709.058 2709.795 2710.533 2711.270 2712.008 2712.745 2713.483
3680 2714.221 2714.958 2715.696 2716.433 2717.171 2717.908 2718.646 2719.384 2720.121 2720.859
3690 2721.596 2722.334 2723.071 2723.809 2724.546 2725.284 2726.021 2726.759 2727.497 2728.234
3700 2728.972 2729.709 2730.447 2731.185 2731.922 2732.660 2733.397 2734.135 2734.872 2735.610
3710 2736.347 2737.085 2737.823 2738.560 2739.298 2740.035 2740.773 2741.510 2742.248 2742.985
3720 2743.723 2744.460 2745.198 2745.936 2746.673 2747.411 2748.148 2748.886 2749.624 2750.361
3730 2751.099 2751.836 2752.574 2753.311 2754.049 2754.786 2755.524 2756.261 2756.999 2757.737
3740 2758.474 2759.212 2759.949 2760.687 2761.424 2762.162 2762.900 2763.637 2764.375 2765.112
3750 2765.850 2766.587 2767.325 2768.062 2768.800 2769.538 2770.275 2771.013 2771.750 2772.488
3760 2773.225 2773.963 2774.700 2775.438 2776.176 2776.913 2777.651 2778.388 2779.126 2779.864
3770 2780.601 2781.339 2782.076 2782.814 2783.551 2784.289 2785.026 2785.764 2786.501 2787.239
3780 2787.977 2788.714 2789.452 2790.189 2790.927 2791.664 2792.402 2793.139 2793.877 2794.615
3790 2795.352 2796.090 2796.827 2797.565 2798.302 2799.040 2799.778 2800.515 2801.253 2801.990
3800 2802.728 2803.465 2804.203 2804.940 2805.678 2806.416 2807.153 2807.891 2808.628 2809.366
3810 2810.103 2810.841 2811.579 2812.316 2813.054 2813.791 2814.529 2815.266 2816.004 2816.741
3820 2817.479 2818.217 2818.954 2819.692 2820.429 2821.167 2821.904 2822.642 2823.379 2824.117
3830 2824.854 2825.592 2826.330 2827.067 2827.805 2828.542 2829.280 2830.018 2830.755 2831.493
3840 2832.230 2832.968 2833.705 2834.443 2835.180 2835.918 2836.656 2837.393 2838.131 2838.868
3850 2839.606 2840.343 2841.081 2841.818 2842.556 2843.293 2844.031 2844.769 2845.506 2846.244
3860 2846.981 2847.719 2848.457 2849.194 2849.932 2850.669 2851.407 2852.144 2852.882 2853.619
3870 2854.357 2855.094 2855.832 2856.570 2857.307 2858.045 2858.782 2859.520 2860.258 2860.995
3880 2861.733 2862.470 2863.208 2863.945 2864.683 2865.420 2866.158 2866.896 2867.633 2868.371
3890 2869.108 2869.846 2870.583 2871.321 2872.058 2872.796 2873.533 2874.271 2875.009 2875.746
3900 2876.484 2877.221 2877.959 2878.697 2879.434 2880.172 2880.909 2881.647 2882.384 2883.122
3910 2883.859 2884.597 2885.334 2886.072 2886.810 2887.547 2888.285 2889.022 2889.760 2890.497
3920 2891.235 2891.973 2892.710 2893.448 2894.185 2894.923 2895.660 2896.398 2897.135 2897.873
3930 2898.611 2899.348 2900.086 2900.823 2901.561 2902.298 2903.036 2903.773 2904.511 2905.249
3940 2905.986 2906.724 2907.461 2908.199 2908.937 2909.674 2910.412 2911.149 2911.887 2912.624
3950 2913.362 2914.099 2914.837 2915.574 2916.312 2917.050 2917.787 2918.525 2919.262 2920.000
3960 2920.737 2921.475 2922.212 2922.950 2923.687 2924.425 2925.163 2925.900 2926.638 2927.375
3970 2928.113 2928.851 2929.588 2930.326 2931.063 2931.801 2932.538 2933.276 2934.013 2934.751
3980 2935.489 2936.226 2936.964 2937.701 2938.439 2939.176 2939.914 2940.652 2941.389 2942.127
3990 2942.864 2943.602 2944.339 2945.077 2945.814 2946.552 2947.290 2948.027 2948.765 2949.502
4000 2950.240 2950.977 2951.715 2952.452 2953.190 2953.927 2954.665 2955.403 2956.140 2956.878
4010 2957.615 2958.353 2959.091 2959.828 2960.566 2961.303 2962.041 2962.778 2963.516 2964.253
4020 2964.991 2965.729 2966.466 2967.204 2967.941 2968.679 2969.416 2970.154 2970.891 2971.629
4030 2972.366 2973.104 2973.842 2974.579 2975.317 2976.054 2976.792 2977.530 2978.267 2979.005
4040 2979.742 2980.480 2981.217 2981.955 2982.692 2983.430 2984.167 2984.905 2985.643 2986.380
4050 2987.118 2987.855 2988.593 2989.331 2990.068 2990.806 2991.543 2992.281 2993.018 2993.756
4060 2994.493 2995.231 2995.969 2996.706 2997.444 2998.181 2998.919 2999.656 3000.394 3001.131
4070 3001.869 3002.606 3003.344 3004.082 3004.819 3005.557 3006.294 3007.032 3007.770 3008.507
4080 3009.245 3009.982 3010.720 3011.457 3012.195 3012.932 3013.670 3014.407 3015.145 3015.883
4090 3016.620 3017.358 3018.095 3018.833 3019.570 3020.308 3021.046 3021.783 3022.521 3023.258
4100 3023.996 3024.733 3025.471 3026.208 3026.946 3027.684 3028.421 3029.159 3029.896 3030.634
4110 3031.371 3032.109 3032.846 3033.584 3034.322 3035.059 3035.797 3036.534 3037.272 3038.010
4120 3038.747 3039.485 3040.222 3040.960 3041.697 3042.435 3043.172 3043.910 3044.647 3045.385
4130 3046.123 3046.860 3047.598 3048.335 3049.073 3049.810 3050.548 3051.285 3052.023 3052.760
4140 3053.498 3054.236 3054.973 3055.711 3056.448 3057.186 3057.924 3058.661 3059.399 3060.136
4150 3060.874 3061.611 3062.349 3063.086 3063.824 3064.562 3065.299 3066.037 3066.774 3067.512
4160 3068.249 3068.987 3069.725 3070.462 3071.200 3071.937 3072.675 3073.412 3074.150 3074.887
4170 3075.625 3076.363 3077.100 3077.838 3078.575 3079.313 3080.050 3080.788 3081.525 3082.263
4180 3083.000 3083.738 3084.476 3085.213 3085.951 3086.688 3087.426 3088.164 3088.901 3089.639
4190 3090.376 3091.114 3091.851 3092.589 3093.326 3094.064 3094.802 3095.539 3096.277 3097.014
4200 3097.752 3098.489 3099.227 3099.964 3100.702 3101.439 3102.177 3102.915 3103.652 3104.390
14 2 801 850.00 de/us

Nm 0 1 2 3 4 5 6 7 8 9
4210 3105.127 3105.865 3106.603 3107.340 3108.078 3108.815 3109.553 3110.290 3111.028 3111.765
4220 3112.503 3113.240 3113.978 3114.716 3115.453 3116.191 3116.928 3117.666 3118.404 3119.141
4230 3119.879 3120.616 3121.354 3122.091 3122.829 3123.566 3124.304 3125.042 3125.779 3126.517
4240 3127.254 3127.992 3128.729 3129.467 3130.204 3130.942 3131.679 3132.417 3133.155 3133.892
4250 3134.630 3135.367 3136.105 3136.843 3137.580 3138.318 3139.055 3139.793 3140.530 3141.268
4260 3142.005 3142.743 3143.480 3144.218 3144.956 3145.693 3146.431 3147.168 3147.906 3148.643
4270 3149.381 3150.118 3150.856 3151.594 3152.331 3153.069 3153.806 3154.544 3155.281 3156.019
4280 3156.757 3157.494 3158.232 3158.969 3159.707 3160.444 3161.182 3161.919 3162.657 3163.395
4290 3164.132 3164.870 3165.607 3166.345 3167.083 3167.820 3168.558 3169.295 3170.033 3170.770
4300 3171.508 3172.245 3172.983 3173.720 3174.458 3175.196 3175.933 3176.671 3177.408 3178.146
4310 3178.883 3179.621 3180.358 3181.096 3181.833 3182.571 3183.309 3184.046 3184.784 3185.521
4320 3186.259 3186.997 3187.734 3188.472 3189.209 3189.947 3190.684 3191.422 3192.159 3192.897
4330 3193.635 3194.372 3195.110 3195.847 3196.585 3197.322 3198.060 3198.798 3199.535 3200.273
4340 3201.010 3201.748 3202.485 3203.223 3203.960 3204.698 3205.436 3206.173 3206.911 3207.648
4350 3208.386 3209.123 3209.861 3210.598 3211.336 3212.073 3212.811 3213.549 3214.286 3215.024
4360 3215.761 3216.499 3217.237 3217.974 3218.712 3219.449 3220.187 3220.924 3221.662 3222.399
4370 3223.137 3223.875 3224.612 3225.350 3226.087 3226.825 3227.562 3228.300 3229.037 3229.775
4380 3230.512 3231.250 3231.988 3232.725 3233.463 3234.200 3234.938 3235.676 3236.413 3237.151
4390 3237.888 3238.626 3239.363 3240.101 3240.838 3241.576 3242.313 3243.051 3243.789 3244.526
4400 3245.264 3246.001 3246.739 3247.477 3248.214 3248.952 3249.689 3250.427 3251.164 3251.902
4410 3252.639 3253.377 3254.115 3254.852 3255.590 3256.327 3257.065 3257.802 3258.540 3259.277
4420 3260.015 3260.752 3261.490 3262.228 3262.965 3263.703 3264.440 3265.178 3265.916 3266.653
4430 3267.391 3268.128 3268.866 3269.603 3270.341 3271.078 3271.816 3272.553 3273.291 3274.029
4440 3274.766 3275.504 3276.241 3276.979 3277.716 3278.454 3279.191 3279.929 3280.667 3281.404
4450 3282.142 3282.879 3283.617 3284.354 3285.092 3285.830 3286.567 3287.305 3288.042 3288.780
4460 3289.517 3290.255 3290.992 3291.730 3292.468 3293.205 3293.943 3294.680 3295.418 3296.156
4470 3296.893 3297.631 3298.368 3299.106 3299.843 3300.581 3301.318 3302.056 3302.793 3303.531
4480 3304.269 3305.006 3305.744 3306.481 3307.219 3307.956 3308.694 3309.431 3310.169 3310.906
4490 3311.644 3312.382 3313.119 3313.857 3314.594 3315.332 3316.070 3316.807 3317.545 3318.282
4500 3319.020 3319.757 3320.495 3321.232 3321.970 3322.708 3323.445 3324.183 3324.920 3325.658
4510 3326.395 3327.133 3327.870 3328.608 3329.346 3330.083 3330.821 3331.558 3332.296 3333.033
4520 3333.771 3334.509 3335.246 3335.984 3336.721 3337.459 3338.196 3338.934 3339.671 3340.409
4530 3341.146 3341.884 3342.622 3343.359 3344.097 3344.834 3345.572 3346.310 3347.047 3347.785
4540 3348.522 3349.260 3349.997 3350.735 3351.472 3352.210 3352.948 3353.685 3354.423 3355.160
4550 3355.898 3356.635 3357.373 3358.110 3358.848 3359.585 3360.323 3361.061 3361.798 3362.536
4560 3363.273 3364.011 3364.749 3365.486 3366.224 3366.961 3367.699 3368.436 3369.174 3369.911
4570 3370.649 3371.386 3372.124 3372.862 3373.599 3374.337 3375.074 3375.812 3376.550 3377.287
4580 3378.025 3378.762 3379.500 3380.237 3380.975 3381.712 3382.450 3383.187 3383.925 3384.663
4590 3385.400 3386.138 3386.875 3387.613 3388.350 3389.088 3389.825 3390.563 3391.301 3392.038
4600 3392.776 3393.513 3394.251 3394.989 3395.726 3396.464 3397.201 3397.939 3398.676 3399.414
4610 3400.151 3400.889 3401.626 3402.364 3403.102 3403.839 3404.577 3405.314 3406.052 3406.789
4620 3407.527 3408.264 3409.002 3409.740 3410.477 3411.215 3411.952 3412.690 3413.427 3414.165
4630 3414.903 3415.640 3416.378 3417.115 3417.853 3418.590 3419.328 3420.065 3420.803 3421.541
4640 3422.278 3423.016 3423.753 3424.491 3425.229 3425.966 3426.704 3427.441 3428.179 3428.916
4650 3429.654 3430.391 3431.129 3431.866 3432.604 3433.342 3434.079 3434.817 3435.554 3436.292
4660 3437.029 3437.767 3438.504 3439.242 3439.979 3440.717 3441.455 3442.192 3442.930 3443.667
4670 3444.405 3445.143 3445.880 3446.618 3447.355 3448.093 3448.830 3449.568 3450.305 3451.043
4680 3451.781 3452.518 3453.256 3453.993 3454.731 3455.468 3456.206 3456.943 3457.681 3458.419
4690 3459.156 3459.894 3460.631 3461.369 3462.106 3462.844 3463.582 3464.319 3465.057 3465.794
4700 3466.532 3467.269 3468.007 3468.744 3469.482 3470.219 3470.957 3471.695 3472.432 3473.170
4710 3473.907 3474.645 3475.383 3476.120 3476.858 3477.595 3478.333 3479.070 3479.808 3480.545
4720 3481.283 3482.021 3482.758 3483.496 3484.233 3484.971 3485.708 3486.446 3487.183 3487.921
4730 3488.658 3489.396 3490.134 3490.871 3491.609 3492.346 3493.084 3493.822 3494.559 3495.297
4740 3496.034 3496.772 3497.509 3498.247 3498.984 3499.722 3500.459 3501.197 3501.935 3502.672
4750 3503.410 3504.147 3504.885 3505.622 3506.360 3507.098 3507.835 3508.573 3509.310 3510.048
4760 3510.785 3511.523 3512.260 3512.998 3513.736 3514.473 3515.211 3515.948 3516.686 3517.423
4770 3518.161 3518.898 3519.636 3520.374 3521.111 3521.849 3522.586 3523.324 3524.062 3524.799
4780 3525.537 3526.274 3527.012 3527.749 3528.487 3529.224 3529.962 3530.699 3531.437 3532.175
4790 3532.912 3533.650 3534.387 3535.125 3535.862 3536.600 3537.337 3538.075 3538.813 3539.550
4800 3540.288 3541.025 3541.763 3542.500 3543.238 3543.976 3544.713 3545.451 3546.188 3546.926
4810 3547.663 3548.401 3549.138 3549.876 3550.614 3551.351 3552.089 3552.826 3553.564 3554.302
4820 3555.039 3555.777 3556.514 3557.252 3557.989 3558.727 3559.464 3560.202 3560.939 3561.677
4830 3562.415 3463.152 3563.890 3564.627 3565.365 3566.102 3566.840 3567.577 3568.315 3569.052
4840 3569.790 3570.528 3571.265 3572.003 3572.740 3573.478 3574.216 3574.953 3575.691 3576.428
4850 3577.166 3577.903 3578.641 3579.378 3580.116 3580.854 3581.591 3582.329 3583.066 3583.804
4860 3584.541 3585.279 3586.016 3586.754 3587.492 3588.229 3588.967 3589.704 3590.442 3591.179
4870 3591.917 3592.655 3593.392 3594.130 3594.867 3595.605 3596.342 3597.080 3597.817 3598.555
4880 3599.292 3600.030 3600.768 3601.505 3602.243 3602.980 3603.718 3604.456 3605.193 3605.931
4890 3606.668 3607.406 3608.143 3608.881 3609.618 3610.356 3611.094 3611.831 3612.569 3613.306
4900 3614.044 3614.781 3615.519 3616.256 3616.994 3617.731 3618.469 3619.207 3619.944 3620.682
2 801 850.00 de/us 15

Nm 0 1 2 3 4 5 6 7 8 9
4910 3621.419 3622.157 3622.895 3623.632 3624.370 3625.107 3625.845 3626.582 3627.320 3628.057
4920 3628.795 3629.532 3630.270 3631.008 3631.745 3632.483 3633.220 3633.958 3634.695 3635.433
4930 3636.171 3636.908 3637.646 3638.383 3639.121 3639.858 3640.596 3641.333 3642.071 3642.809
4940 3643.546 3644.284 3645.021 3645.759 3646.496 3647.234 3647.971 3648.709 3649.447 3650.184
4950 3650.922 3651.659 3652.397 3653.135 3653.872 3654.610 3655.347 3656.085 3656.822 3657.560
4960 3658.297 3659.035 3659.772 3660.510 3661.248 3661.985 3662.723 3663.460 3664.198 3664.935
4970 3665.673 3666.410 3667.148 3667.886 3668.623 3669.361 3670.098 3670.836 3671.573 3672.311
4980 3673.049 3673.786 3674.524 3675.261 3675.999 3676.736 3677.474 3678.211 3678.949 3679.687
4990 3680.424 3681.162 3681.899 3682.637 3683.374 3684.112 3684.850 3685.587 3686.325 3687.062
5000 3687.800 3688.537 3689.275 3690.012 3690.750 3691.488 3692.225 3692.963 3693.700 3694.438
16 2 801 850.00 de/us

Umrechnungstabelle fur Druckeinheiten von Gasen, Dampfen

und Flussigkeiten
2801094
Conversion table for units of pressure in gases, steam and fluids

mit 1 Pa = 1 N/m2 = 1 kp/m2 = 0,102 kp/m2
9,81
Pa bar kp/m2 at atm Torr
1 Pa (= 1 N/m2) = 1 10-5 0,102 0,102 x 10-4 0,987 x 10-5 0,0075
1 bar (= 0,1 MPa) = 100 000 = 105 1

10 200 1,02 0,987 750
(= 1000 mbar)
1 kp/m2 = 9,81 9,81 x 10-5 1 10-4 0,968 x 10-4 0,0736
1 at (= 1 kp/cm2) = 98 100 0,981 10 000 1 0,968 736
1 atm (= 760 Torr) = 101 325 1,013 10 330 1,033 1 760

(= 1013 mbar)
1 Torr (= 1 atm) = 133 0,00133 13,6 0,00136 0,00132 1

760
2 801 850.00 de/us 17

Umrechnungstabelle fur Einheiten von Energie, Arbeit und Warmemenge

Conversion table for units of power, ernergy and heat quantity
mit 1 Nm = 1 kp m = 0,102 kp m
9,81
J kJ kW h kcal PS h kp m
1 J (= 1 Nm = 1 Ws) = 1 0,001 2,78 x 10-7 2,39 x 10-4 3,77 x 10-7 0,102
1 kJ = 1000 1 2,78 x 10-4 0,239 3,77 x 10-4 102
1 kW h = 3 600 000 3 600 1 860 1,36 367 000
1 kcal = 4 200 4,2 0,00116 1 0,00158 427
1 PS h = 2 650 000 2 650 0,736 632 1 270 000
1 kp m = 9,81 0,00981 2,72 x 10-6 0,00234 3,7 x 10-6 1
18 2 801 850.00 de/us

Umrechnungstabelle fur Einheiten der mechanischen Spannung (Festigkeit)

Conversion table for units of mechanical stress (strength)
mit 1 Pa = 1 N/m2 = 1 kp/m2 = 0,102 kp/m2
9,81
Pa N/mm2 daN/cm2 daN/mm2 kp/cm 2 kp/mm2
1 Pa (= 1 N/m2) = 1 10-6 10-5 10-7 0,102 x 10-4 0,102 x 10-6
1 N/mm2 (=1 M Pa) = 1 000 000 1 10 0,1 10,2 0,102
1 daN/cm2 (= 1 bar) = 100 000 0,1 1 0,01 1,02 0,0102
1 daN/mm2 (= 1 hbar) = 10 000 000 10 100 1 102 1,02
1 kp/cm2 (= 1 at) = 98 100 0,0981 0,981 0,00981 1 0,01
1 kp/mm2 = 9 810 000 9,81 98,1 0,981 100 1
2 801 850.00 de/us 19

Praktisch gleichwertige Einheiten fur

Druck und mechanische Spannung (Festigkeit)
2801095
Practically equivalent units for pressure and mechanical stress (strength)

mit 1 N = 0,1 kp bzw. 1 kp = 10 N = 1 daN
1 daN/mm2 1 daN/cm2 1 kN/cm2 1 kp/mm2 1 kp/cm2
= 1 kp/mm2 _ 1 kp/cm2
~ = 1 daN/mm2 _ 1 daN/mm2
~ = 1 at
= 1 kN/cm2 _ 1 at
~ = 1 hbar _ 1 kN/cm2
~ _ 1 daN/cm2
~
= 1 hbar = 1 bar ~ 1 kp/mm2

_ _ 1 hbar
~ _ 1 bar
~
1 kbar 1 hbar 1 bar 1 mbar 1 bar
= 1 hN/mm2 = 1 daN/mm2 = 1 daN/cm2 = 1 cN/cm2 = 1 dN/m2
= 10 kN/cm2 = 1 kN/cm2 _ 1 kp/cm2

~ _ 1 p/cm2
~
= 1 Mp/cm2 _ 1 kp/mm2
~ _ 1 at
~ _ 1 kp/m2
~
100
20 2 801 850.00 de/us

Temperatur - Einheiten und Umrechungsformeln 2801096
Units of temperature and conversion formulas
Einheiten Umrechnung in
Units Conversion into
Benennung
o o o
Nomenclature K C R F
Kurzzeichen
Symbol
Kelvin K 1 (K-273,16o) 4/5 (K-273,16o) 9/5 (K-273,16o)+32o
o o
Celsius C C+273,16o 1 4/5 oC 9/5 oC+32o
o
Reaumur
R 5/4 oR+273,16o 5/4 oR 1 9/4 oR+32o
o
Fahrenheit F 5/9 (oF-32o)+ 273,16o 5/9 (oF-32o) 4/9 (oF -32o) 1
Beispiel: Umrechnung von o

R in oC : oC = 5/4 oR
Example: Conversion from
Die Grundeinheit der Temperatur ist Kelvin (K).

The fundamental temperature unit is the Kelvin (K).
Als Formelzeichen wird T verwandt.

The symbol used is the T.
Die ebenfalls benutzte absolute Temperatur degree (Grad) Rankin errechnet sich zu:
The equally used Rankine temperature scale for absolute temperatures is related to K
as follows:
o
Rank = 9/5 K.
2 801 850.00 de/us 21


Power, energy and heat flow
1 Nm/s = 1 kp m/s = 0,102 kp m/s
9,81
W kW kcal/s kcal/h kp m/s PS HP
1W=
(= 1 N m/s 1 0,001 2,39 x 10-4 0,860 0,102 0,00136 0,00134
= 1 J/s)
1 kW = 1 000 1 0,239 860 102 1,36 1,341
1 kcal/s = 4 190 4,19 1 3600 427 5,69 5,61
1 kcal/h = 1,16 0,00116 1 1 0,119 0,00158 0,00156

3600
1 kp m/s = 9,81 0,00981 0,00234 8,43 1 0,0133 0,0131
1 PS = 736 0,736 0,176 632 75 1 0,9863
1 HP = 746 0,746 0,178 641,8 76,09 1,0145 1
1 kp m/s = 3600 kp m/h 1 kp m/h = 1 kp m/s

3 600
22 2 801 850.00 de/us

Geschwindigkeiten
Speed
1 km / h = 0,27778 m / s 1m/s = 3,6 km / h
1 mile / h = 1,60934 km / h 1 km / h = 0,62137 mile / h
1 kn (Knoten) = 1,852 km / h 1 km / h = 0,53996 kn
1 ft / min = 0,3048 m / min 1 m / min = 3,28084 ft / min
Umrechnung von Conversion for
km / h m/s km / h mile / h kn ft / min km / h mile / h km / h

(mph) (mph)
in in in in in in in in in
m/s km / h mile / h km / h km / h m / min Zeit / km Zeit / km Zeit / 100 km
10 2,78 36,0 6,21 16,1 18,52 3,05 6 min 3 min 44 s 10 h

20 5,56 72,0 12,4 32,2 37,04 6,10 3 min 1 min 52 s 5h
30 8,33 108 18,6 48,3 55,56 9,14 2 min 1 min 15 s 3 h 20 min
40 11,1 144 24,9 64,4 74,08 12,2 1 min 30 s 55,9 s 2 h 30 min
50 13,9 180 31,1 80,5 92,60 15,2 1 min 12 s 44,7 s 2h

60 16,7 216 37,3 96,6 111 18,3 1 min 37,3 s 1 h 40 min
70 19,4 252 43,5 113 130 21,3 51,4 s 32,0 s 1 h 26 min
80 22,2 288 49,7 129 148 24,4 45 s 28,0 s 1 h 15 min
90 25,0 324 55,9 145 167 27,4 40 s 24,9 s 1 h 6,7 min
100 27,8 360 62,1 161 185 30,5 36 s 22,0 s 1h

110 30,6 396 68,4 177 --- 33,5 32,7 s 20,3 s 54 min 33 s
120 33,4 432 74,6 193 --- 36,6 30 s 18,6 s 50 min
130 36,1 468 80,8 209 --- 39,6 27,7 s 17,2 s 46 min 9 s
140 38,9 504 87,0 225 --- 42,7 25,7 s 16,0 s 42 min 51s
150 41,7 540 93,2 241 --- 45,7 24 s 14,9 s 40 min

160 44,4 576 99,4 257 --- 48,8 22,5 s 14,0 s 37 min 30 s
170 47,2 612 106 274 --- 51,8 21,2 s 13,2 s 35 min 18 s
180 50,0 648 112 290 --- 54,9 20,0 s 12,4 s 33 min 20 s
190 52,8 684 118 306 --- 57,9 18,9 s 11,8 s 31 min 35 s
200 55,6 720 124 322 --- 61,0 18 s 11,2 s 30 min

250 59,4 900 155 402 --- 76,2 14,4 s 8,9 s 26 min
300 83,3 1080 186 483 --- 91,4 12 s 7,5 s 20 min
400 111 1440 249 644 --- 122 9s 5,8 s 15 min
500 139 1800 311 805 --- 152 7,2 s 4,5 s 12 min
600 167 2160 373 966 --- 183 6s 3,7 s 10 min

800 222 2880 497 1287 --- 244 4,5 s 2,8 s 7 min 30 s
1000 278 3600 621 1609 --- 305 3,6 s 2,2 s 6 min
1200 333 1) --- 746 --- --- 366 3s --- 5 min
1400 389 --- 870 --- --- 427 2,6 s --- 4 min 17 s
Die Machzahl Ma (keine gesetzliche Einheit) gibt an, wieviel mal schneller ein Korper
sich bewegt als der Schall.
Ma = 1,3 bedeutet also 1,3fache Schallgeschwindigkeit.
The Mach number "Ma" (no official unit of measurement) gives the factor by which a body is faster, than the speed
of sound.
Thus "Ma" = 1.3 means 1.3 times as fast as the speed of sound.
1) Etwa Schallgeschwindigkeit in Luft.

Approximate velocity of sound in the air.
2 801 850.00 de/us 23

Masseeinheiten (Gewichte)
Units of mass (weight)
grain dram oz lb long cwt sh cwt long tn sh tn
in in in in in in in in
g g g kg kg kg t t
1,0 0,0648 1,77 28,3 0,454 50,8 45,4 1,02 0,907

1,1 0,0713 1,95 31,2 0,499 55,9 49,9 1,12 0,998
1,2 0,0778 2,13 34,0 0,544 61,0 54,4 1,22 1,09
1,3 0,0842 2,30 36,9 0,590 66,0 59,0 1,32 1,18
1,4 0,0907 2,48 39,7 0,635 71,1 63,5 1,42 1,27
1,5 0,0972 2,66 42,5 0,680 76,2 68,0 1,52 1,36

1,6 0,104 2,83 45,4 0,726 81,3 72,6 1,63 1,45
1,7 0,110 3,01 48,2 0,771 86,4 77,1 1,73 1,54
1,8 0,117 3,19 51,0 0,816 91,4 81,6 1,83 1,63
1,9 0,123 3,37 53,9 0,862 96,5 82,2 1,93 1,72
2,0 0,130 3,54 56,7 0,907 102 90,7 2,03 1,81

2,1 0,136 3,72 59,5 0,953 107 95,3 2,13 1,91
2,2 0,143 3,90 62,4 0,998 112 99,8 2,24 2,00
2,3 0,149 4,08 65,2 1,04 117 104 2,34 2,09
2,4 0,156 4,25 68,0 1,09 122 109 2,44 2,18
2,5 0,162 4,43 70,9 1,13 127 113 2,54 2,27

2,6 0,168 4,61 73,7 1,18 132 118 2,64 2,36
2,7 0,175 4,78 76,5 1,22 137 122 2,74 2,45
2,8 0,181 4,96 79,4 1,27 142 127 2,84 2,54
2,9 0,188 5,14 82,2 1,32 147 132 2,95 2,63
3,0 0,194 5,32 85,0 1,36 152 136 3,05 2,72

3,2 0,207 5,67 90,7 1,45 163 145 3,25 2,90
3,4 0,220 6,02 96,4 1,54 173 154 3,45 3,08
3,6 0,233 6,38 102 1,63 183 163 3,66 3,27
3,8 0,246 6,73 108 1,72 193 172 3,86 3,45
4,0 0,259 7,09 113 1,81 203 181 4,06 3,63

4,2 0,272 7,44 119 1,91 213 191 4,27 3,81
4,4 0,285 7,80 125 2,00 224 200 4,47 3,99
4,6 0,298 8,15 130 2,09 234 209 4,67 4,17
4,8 0,311 8,50 136 2,18 244 218 4,88 4,35
5,0 0,324 8,86 142 2,27 254 227 5,08 4,54

5,2 0,337 9,21 147 2,36 264 236 5,28 4,72
5,4 0,350 9,57 153 2,45 274 245 5,49 4,90
5,6 0,363 9,92 159 2,54 284 254 5,69 5,08
5,8 0,376 10,3 164 2,63 295 263 5,89 5,26
6,0 0,389 10,6 170 2,72 305 272 6,10 5,44

6,5 0,421 11,5 184 2,95 330 295 6,60 5,90
7,0 0,454 12,4 198 3,18 356 318 7,11 6,35
7,5 0,486 13,3 213 3,40 381 340 7,62 6,80
8,0 0,518 14,2 227 3,63 406 363 8,13 7,26

8,5 0,551 15,1 241 3,86 432 386 8,64 7,71
9,0 0,583 15,9 255 4,08 457 408 9,14 8,16
9,5 0,616 16,8 269 4,31 483 431 9,65 8,62
Die Tabelle gilt auch fur

dezimale Vielfache und Teile.
The table is also valid for decimal multiples and fractions.
Beispiele: 1 lb = 0,454 kg; 5 long ton = 5,08 t; 42 oz = 1190 g.

Example: 1 lb = 0,454 kg; 5 long ton = 5,08 t; 42 oz = 1190 g.
24 2 801 850.00 de/us

Volumeneinheiten, Durchflumenge
Units of volume, flow rates
in3 ft3 yd3 pt liq pt gal gal ft3 / min

(UK) (US) (UK) (US) cfm
in in in in in in in in
cm3 l m3 l l l l m3 / h
1,0 16,4 28,3 0,765 0,568 0,473 4,55 3,79 1,70

1,1 18,0 31,2 0,841 0,625 0,520 5,00 4,16 1,87
1,2 19,7 34,0 0,918 0,682 0,568 5,46 4,54 2,04
1,3 21,3 36,8 0,994 0,739 0,615 5,91 4,92 2,21
1,4 22,9 39,6 1,07 0,796 0,662 6,36 5,30 2,38
1,5 24,6 42,5 1,15 0,852 0,710 6,82 5,68 2,55

1,6 26,2 45,3 1,22 0,909 0,757 7,27 6,06 2,72
1,7 27,9 48,1 1,30 0,966 0,804 7,73 6,44 2,89
1,8 29,5 51,0 1,38 1,02 0,852 8,18 6,81 3,06
1,9 31,1 53,8 1,45 1,08 0,899 8,64 7,19 3,23
2,0 32,8 56,6 1,53 1,14 0,946 9,09 7,57 3,40

2,1 34,4 59,5 1,61 1,19 0,994 9,55 7,95 3,57
2,2 36,1 62,3 1,68 1,25 1,04 10,0 8,33 3,74
2,3 37,7 65,1 1,76 1,31 1,09 10,5 8,71 3,91
2,4 39,3 68,0 1,83 1,36 1,14 10,9 9,09 4,08
2,5 41,0 70,8 1,91 1,42 1,18 11,4 9,46 4,25

2,6 42,6 73,6 1,99 1,48 1,23 11,8 9,84 4,42
2,7 44,3 76,5 2,06 1,53 1,28 12,3 10,2 4,59
2,8 45,9 79,3 2,14 1,59 1,32 12,7 10,6 4,76
2,9 47,5 82,1 2,22 1,65 1,37 13,2 11,0 4,93
3,0 49,2 85,0 2,29 1,70 1,42 13,6 11,4 5,10

3,2 52,4 90,6 2,45 1,82 1,51 14,6 12,1 5,44
3,4 55,7 96,3 2,60 1,93 1,61 15,5 12,9 5,78
3,6 59,0 102 2,75 2,05 1,70 16,4 13,6 6,12
3,8 62,3 108 2,91 2,16 1,80 17,3 14,4 6,46
4,0 65,6 113 3,06 2,27 1,89 18,2 15,1 6,80

4,2 68,8 119 3,21 2,39 1,99 19,1 15,9 7,14
4,4 72,1 125 3,36 2,50 2,08 20,0 16,7 7,48
4,6 75,4 130 3,52 2,61 2,18 20,9 17,4 7,82
4,8 78,7 136 3,67 2,73 2,27 21,8 18,2 8,16
5,0 81,9 142 3,82 2,84 2,37 22,7 18,9 8,50

5,2 85,2 147 3,98 2,96 2,46 23,6 19,7 8,84
5,4 88,5 153 4,13 3,07 2,56 24,6 20,4 9,18
5,6 91,8 159 4,28 3,18 2,65 25,5 21,2 9,52
5,8 95,1 164 4,43 3,30 2,74 26,4 22,0 9,85
6,0 98,3 170 4,59 3,41 2,84 27,3 22,7 10,2

6,2 102 176 4,74 3,52 2,93 28,2 23,5 10,5
6,4 105 181 4,89 3,64 3,03 29,1 24,2 10,9
6,6 108 187 5,05 3,75 3,12 30,0 25,0 11,2
6,8 111 193 5,20 3,86 3,22 30,9 25,7 11,6
7,0 115 198 5,35 3,98 3,31 31,8 26,5 11,9

7,5 123 212 5,73 4,26 3,55 34,1 28,4 12,7
8,0 131 227 6,12 4,55 3,79 36,4 30,3 13,6

8,5 139 241 6,50 4,83 4,02 38,6 32,2 14,4
9,0 148 255 6,88 5,11 4,26 40,9 34,1 15,3

9,5 156 269 7,26 5,40 4,50 43,2 36,0 16,1
Beispiele: 1 in3 = 16,4 cm3; 3 gal (UK) = 13,6 l

Example: 1 in3 = 16,4 cm3; 3 gal (UK) = 13,6 l
2 801 850.00 de/us 25

Kraftstoffverbrauch
Fuel consumption
1 g / PS h = 1,3596 g / kW h 1 g / kW h = 0,7355 g / PS h
1 lb / HP H = 608,277 g / kW h 1 g / kW h = 0,001644 lb / HP H
1 liq pt / HP H = 634,545 cm3 / kW h 1 cm3 / kW h = 0,001576 liq pt / HP H
1 pt (UK) HP H = 762,049 cm3 / kW h 1 cm3 / kW h = 0,001312 pt (UK) / HP H
Umrechnung von Umrechnung von Umrechnung von

Conversion for Conversion for Conversion for
g/PS h g/kW h lb liq pt pt (UK) miles miles

HP H HP H HP H gal (US) gal (UK)
in in in in in in in
g / kW h g / PS h g / kW h cm3 / kW h cm 3 / kW h l / 100 km l / 100 km
100 136,0 73,55 0,10 60,83 63,45 76,20 10 23,5 28,2

120 163,2 88,26 0,15 91,24 95,18 114,3 11 21,4 25,7
140 190,3 103,0 12 19,6 23,5
160 217,5 117,7 0,20 121,7 126,9 152,4 13 18,1 21,7
180 244,7 132,4 0,25 152,1 158,6 190,5 14 16,8 20,2
200 271,9 147,1 0,30 182,5 190,4 228,6 15 15,7 18,8

220 299,1 161,8 0,32 194,6 203,1 243,9 16 14,7 17,7
240 326,3 176,5 0,34 206,8 215,7 259,1 17 13,8 16,6
260 353,5 191,2 0,36 219,0 228,4 274,3 18 13,1 15,7
280 380,7 205,9 0,38 231,1 241,1 289,6 19 12,4 14,9
300 407,9 220,6 0,40 243,3 253,8 304,8 20 11,8 14,1

320 435,1 235,4 0,42 255,5 266,5 320,1 22 10,7 12,8
340 462,3 250,1 0,44 276,6 279,2 335,3 24 9,80 11,8
360 489,5 264,8 0,46 279,8 291,9 350,5 26 9,05 10,9
380 516,6 279,5 0,48 292,0 304,6 365,8 28 8,40 10,1
400 543,8 294,2 0,50 304,1 317,3 381,0 30 7,84 9,42

420 571,0 308,9 0,52 316,3 330,0 396,3 32 7,35 8,83
440 598,2 323,6 0,54 328,5 342,7 411,5 34 6,92 8,31
460 625,4 338,3 0,56 340,6 355,3 426,7 36 6,53 7,85
480 652,6 353,0 0,58 352,8 368,0 442,0 38 6,19 7,43
500 679,8 367,7 0,60 365,0 380,7 457,2 40 5,89 7,06

520 707,0 382,5 0,62 377,1 393,4 472,5 42 5,60 6,73
540 734,2 397,2 0,64 389,3 406,1 487,7 44 5,35 6,42
560 761,4 411,9 0,66 401,5 418,8 503,0 46 5,11 6,14
580 788,6 426,6 0,68 413,6 431,5 518,2 48 4,90 5,88
600 815,8 441,3 0,70 425,8 444,2 533,4 50 4,70 5,65

650 883,7 478,1 0,75 456,2 475,9 571,5 55 4,28 5,14
700 951,7 514,8 0,80 486,6 507,6 609,6 60 3,92 4,71
750 1020 551,6 0,85 517,0 539,4 647,7 70 3,36 4,04
800 1088 588,4 0,90 547,4 571,1 685,8 80 2,94 3,53
900 1224 661,9 0,95 577,9 602,8 723,9 90 2,61 3,14
Beispiel: Beispiel: Beispiel:

Example: Example: Example:
240 g / PS h = 326,3 g / kW h 0,68 liq pt / HP H = 431,5 cm3 / kW h 18 miles / gal (US) = 13,1 l / 100 km
26 2 801 850.00 de/us

BERECHNUNGSBEISPIELE
CALCULATION EXAMPLES
Steigungswinkel
Angles of slope
Fahrgeschwindigkeiten
Travel speeds
V = 360 V= km/h
t t = Sekunden auf 100 m
Seconds needed for 100 m
Beispiel: Bei einer konstanten Geschwindigkeit werden fur

eine Strecke von 100 m 18 Sekunden benotigt.

Example: At a constant speed, a travel time of 18 seconds is needed for a distance of 100 meters.
V(km/h) = 360 = 20 km/h

18
2 801 850.00 de/us 27

Hydraulische Leistungen Drehzahlen von Hydraulikmotoren

(Pumpen/Motoren) Speeds of hydraulic motors
Hydraulic outputs (pumps/motors)
P=pQ P= kW n = Vp np n = Drehzahl in U/min (min-1)

600 p = bar VM motor speed in rpm
Q= l/min Vp = Geometrisches Fordervolumen

der Pumpe in cm3/U
geometrical displacement of the
Beispiel: Von einer Pumpe mit einer effektiven For-
pump in cm3/revolution
dermenge von Q = 80 l/min soll bei einem np = Drehzahl der Pumpen in U/min
Pumpendruck von p = 300 bar die (min-1)
Leistung berechnet werden. turning speed of the pump in rpm
VM= Geometrisches Schluckvolumen
Example: For a pump with an effective discharge
des Motors in cm3/U
rate of Q = 80 l/min, at a pressure of
geometrical displacement of the
p = 300 bar the output is to be calculated.
motor in cm3/rpm
P(kW) = 300 80 = 40 kW
600 Beispiel: Gegeben sind Pumpendrehzahl np = 2150
min - 1 ,geometrisches F ordervolumen

Pumpe Vp = 11 cm3/U und das
geometrische Schluckvolumen des Motors
VM = 8 cm3/U
Example: For a given pump speed np = 2,150 rpm,
Zylinder-Hubzeiten a geometrical displacement of the pump
Stroking times of cylinders Vp = 11 cm3/rpm and a geometrical dis-
placement of the motor of VM = 8
cm3/rpm we obtain
t = VZyl. 60 t = Sekunden/Seconds
Qp VZyl.= Volumen des(r) Zylinder in dm3
Volume of the cylinder(s) in dm3 n = 11 2150 = 2956 min-1
8
Qp = theoretische Fordermenge
der
Pumpe(n) in l/min
theoretical discharge rate of the
pump(s) in l/min
Beispiel: Gegeben sind Pumpenfordermenge

Qp = 80 l/min und Zylindervolumen
VZyl. = 10 dm3
Example: For a given pump discharge rate of Qp =
80 l/min and a cylinder volume of VZyl. =
10 dm3 we obtain
t(Sek.) = 10 60 = 7,5 Sekunden

80 Seconds
28 2 801 850.00 de/us

ANZIEHDREHMOMENTE
Allgemeine Hinweise
In den nachfolgenden Tabellen sind die Anziehdrehmomente fur

Schrauben mit metrischem Gewinde
DIN 13 - 13.
Die Konstruktion kann von Fall zu Fall von der Norm abweichende Anziehdrehmomente festlegen. Deshalb
sind die in den Tabellen genannten Werte nur dann anzuwenden, wenn in der Betriebsanleitung Kapitel
"Inspektion und Wartung", im Technischen Handbuch oder in der Zeichnung keine anderen Werte
angegeben sind.
Die Festlegung der Anziehdrehmomente richtet sich nicht nur nach der Schraubenqualitat,
sie ist auch von der
Reibung im Gewinde und von der Auflage des Schraubenkopfes abhangig.
Deshalb sind bei der Berechnung
von Anziehdrehmomenten je nach Schraubenausfuhrung und Zustand unterschiedliche Reibungszahlen
( gesamt) zu verwenden.
1. Reibungszahl gesamt = 0,10:

Schraube und/oder Mutter galvanisch verzinkt (Oberflachenschutz
A3B).

Schraube schwarzvergutet
oder phoshatiert.
Mutter blank.
Gewinde geolt.


Schrauben mit flussiger
Schraubensicherung z.B. Loctite 242, 243, entsprechend der Verarbeitungsvorschrift.
Die entsprechenden Zeilen sind in den Tabellen zusatzlich
mit einem "L" gekennzeichnet.
Die drei Zahlen sind mittlere Reibungswerte.

Die errechneten Anziehdrehmomente MA gelten fur
das Anziehen der Schrauben von Hand.
Maeinheiten
Die in den Tabellen angegebenen Anziehdrehmomente sind in Nm (Newtonmeter) angegeben. Werden

Drehmomentschlussel
alterer
Bauart verwendet, mussen
die Nm in die fruher
verwendete Einheit kpm (Kilopon-
dmeter) umgerechnet werden. Diese Umrechnung ist problemlos, da 1 kpm fast genau 10 Nm entsprechen
(genauer Umrechnungsfaktor 1 kpm = 9,81 Nm). Diese geringfugige
Differenz kann vernachlassigt
werden, so
da bei einer Umrechnung der in Nm angegebene Wert lediglich durch 10 dividiert werden mu.
Beispiel: 1840
1840 Nm = = 184 kpm
10
2 801 850.00 de/us 29

TIGHTENING TORQUES
General information
The following tables contain the tightening torques for screws with a DIN 13 - 13 metric thread.
The construction dept. may specify in certain cases tightening torques other than those set out in the standard.
The values set out in the tables are therefore applicable unless otherwise specified in the "Inspection
and servicing" chapter of the operating instructions, the Technical Handbook or the drawings.
The tightening torques specified do not only depend on the screw grade, but also on the friction at the thread
and the bearing face of the screw head. Therefore, different friction coefficients ( total) depending on the type
and condition of the screws used must be applied when calculating tightening torques.
1. Friction coefficient total = 0.10:

screw and/or nut electro-galvanized (surface protection A3B).

screw black-plated or phosphatized
nut bright
thread oiled

screws with liquid screw fixer, e.g. Loctite 242, 243, in acc. with application instructions.
The corresponding column is marked in the tables with an "L".
The three figures given are mean friction coefficients.

The calculated tightening torques MA are valid for tightening of the screws by hand
Units of measurement
The tightening torques specified in the tables are expressed in Nm (newtonmeter). If older torque wrenches are
used for tightening, the Nm values must be converted to the formerly used kpm (kilopondmeter) unit. The
conversion is simple since 1 kpm is almost exactly the same as 10 Nm (exact coversion factor: 1 kpm = 9.81
Nm). The small difference can be ignored so that for conversion purposes the Nm value must only be divided
by 10.
Example: 1840
1840 Nm = = 184 kpm
10
30 2 801 850.00 de/us

Schrauben mit Regelgewinde nach DIN 13 - 13

Bolts with standard thread DIN 13 - 13
Gewinde- Festigkeits- Anziehdrehmomente MA in Nm

Nenn klasse Tightening torques MA in Nm
Thread Material gesamt gesamt gesamt
nominal quality total total total
1) 2)
0,10 0,12 0,16 (L)3)
M5 8.8 4,9 5,5 6,5

10.9 7,3 8,1 9,5
12.9 8,5 9,5 11,2
M6 8.8 8,5 9,5 11,2

10.9 12,5 14 16,5
12.9 14,5 16,5 19,5
M8 8.8 20,5 23 27
10.9 30 34 40
12.9 35 40 47
M 10 8.8 41 46 55
10.9 60 68 80
12.9 71 79 94
M 12 8.8 71 79 94
10.9 104 117 140
12.9 195 215 260
M 16 8.8 170 195 230

10.9 250 280 340
12.9 300 330 400
M 20 8.8 350 390 470

10.9 490 560 670
12.9 580 650 780
M 24 8.8 600 670 800

10.9 850 960 1140
12.9 1000 1120 1350
M 30 8.8 1190 1350 1600

10.9 1700 1900 2300
12.9 2000 2250 2700
M 36 8.8 2100 2350 2800

10.9 3000 3300 4000
12.9 3500 3900 4700
1)
Schraube und/oder Mutter galvanisch verzinkt (A3B).
Screw and/or nut electro-galvanized.
2)
Schraube schwarz vergutet
oder phosphatiert, Gewinde geolt.

Screw black-plated or phosphatized, thread oiled.
3)
Schraubensicherung z.B. Loctite 242, 243.
Screws with liquid screw fixer, e.g. Loctite 242, 243.
2 801 850.00 de/us 31

Schrauben mit metrischem Feingewinde DIN 13 - 13

Bolts with metric fine thread DIN 13 - 13
Gewinde- Festigkeits- Anziehdrehmomente MA in Nm

Nenn klasse Tightening torques MA in Nm
Thread Material gesamt gesamt gesamt
1) 2)
0,10 0,12 0,16 (L)3)
M 8x1 8.8 22 24,5 30
10.9 32 36 43
12.9 38 43 51
M 10x1 8.8 45 52 62
10.9 67 76 91
12.9 78 89 107
M 10x1,25 8.8 43 49 58
10.9 64 72 86
12.9 74 84 100
M 12x1,25 8.8 77 87 104
10.9 112 125 150
12.9 130 150 180
M 14x1,5 8.8 121 135 165

10.9 175 200 240
12.9 205 235 280
M 16x1,5 8.8 180 205 250

10.9 270 300 370
12.9 310 360 430
M 20x1,5 8.8 380 430 530

10.9 540 620 750
12.9 630 720 880
M 22x1,5 8.8 510 580 700

10.9 720 820 1000
12.9 840 960 1170
M 24x2 8.8 640 730 890

10.9 920 1040 1250
12.9 1070 1220 1500
M 27x2 8.8 940 1070 1300
10.9 1350 1500 1850
12.9 1550 1800 2150
M 30x2 8.8 1370 1490 1740

10.9 1940 2120 2480
12.9 2270 2480 2900
1)
Schraube und/oder Mutter galvanisch verzinkt (A3B).
2)
Schraube schwarz vergutet
oder phosphatiert, Gewinde geolt.

Screw black-plated or phosphatized, thread oiled.
3)
Schraubensicherung z.B. Loctite 242, 243.
32 2 801 850.00 de/us

Anziehdrehmomente fur SAE Flanschsystem 2801097
Tightening torques for SAE flange-system
Schrauben in mehreren Durchgangen

anziehen. * *
Reihenfolge: 1, 2, 3, 4
Tighten bolts in several stages. * *

Sequence: 1, 2, 3, 4
Gewinde SW Anziehdrehmoment
Thread Wrench size Tightening
M 10 11 mm 60 Nm
M 12 13 mm 100 Nm
M 14 15 mm 160 Nm
M 16 19 mm 250 Nm
** Siehe THB "Armaturen, Rohr- und Schlauchleitungen".

See THB "Fittings, pipes and hoses".
Anzugswinkel
Tightening angles
6 = 1 min.
30 = 5 min.
45 = 7,5 min.
60 = 10 min.
90 = 15 min.
135 = 22,5 min.
220 = 36,7 min.
2 801 850.00 de/us 33

Notizen / Notes 2800145
34 2 801 850.00 de/us

G
A General information ............................................ 30
Allgemeine Hinweise .......................................... 29 Geschwindigkeiten ............................................ 23
Angles of slope .................................................. 27

H
ANZIEHDREHMOMENTE .................................. 29
Hydraulic outputs (pumps/motors) ...................... 28
Anziehdrehmomente fur
SAE Flanschsystem .... 33
Hydraulische Leistungen (Pumpen/Motoren) .... 28
Anzugswinkel...................................................... 33
K
B
.................. 5
BERECHNUNGSBEISPIELE ............................ 27
Kraftstoffverbrauch ............................................ 26
Bolts with metric fine thread DIN 13 - 13 ............ 32
Bolts with standard thread DIN 13 - 13 .............. 31

L
................ 22
C
CALCULATION EXAMPLES .............................. 27
M
Conversion for units of area ................................ 7
Masseeinheiten (Gewichte) ................................ 24
Conversion for units of length .............................. 6
Conversion from foot (Fuss) and inch (Zoll) to P

metric measures .................................................. 8
Power, energy and heat flow .............................. 22
Conversion from newtonmeter "Nm" into foot
pounds "ft.lb." ...................................................... 9 Practically equivalent units for pressure and
mechanical stress (strength) .............................. 20
Conversion table for units of mechanical
stress (strength).................................................. 19 Praktisch gleichwertige Einheiten fur
Druck
und mechanische Spannung (Festigkeit) .......... 20
Conversion table for units of power, ernergy
and heat quantity ................................................ 18
Q
Conversion table for units of pressure in gas-
es, steam and fluids............................................ 17 Quantities of force, energy and power .................. 5
CONVERSIONS TABLES .................................... 6 Quantities of space and mass .............................. 3
D R
Drehzahlen von Hydraulikmotoren .................... 28 Raum - und Massegroen
.................................... 3
F S
Fahrgeschwindigkeiten ...................................... 27 Schrauben mit metrischem Feingewinde DIN
13 - 13 ................................................................ 32
FOREWORD ........................................................ 1
Schrauben mit Regelgewinde nach DIN 13 -
Fuel consumption .............................................. 26 13........................................................................ 31
SI - AND ADDITIONAL UNITS ............................ 3

SI - UND WEITERE GROSSEN .......................... 3
Speed ................................................................ 23
Speeds of hydraulic motors ................................ 28
Steigungswinkel.................................................. 27
Stroking times of cylinders .................................. 28
T
Temperatur - Einheiten und Umrechungsfor-
meln .................................................................... 21
Tightening angles .............................................. 33
TIGHTENING TORQUES .................................. 30
Tightening torques for SAE flange-system ........ 33
Time-related quantities ........................................ 4
Travel speeds .................................................... 27
U
........................ 7
Umrechnung von foot (Fuss) und inch (Zoll) in

Meter .................................................................... 8

........................ 6
Umrechnung von Newtonmeter "Nm" in Foot

Pounds "ft.lb." ...................................................... 9
Druckeinheiten von
Gasen, Dampfen
und Flussigkeiten
.................. 17
Einheiten der
mechanischen Spannung (Festigkeit) ................ 19
Einheiten von Ener-
gie, Arbeit und Warmemenge
............................ 18
UMRECHNUNGSTABELLEN .............................. 6
Units of mass (weight) ........................................ 24
Units of temperature and conversion formulas .. 21
Units of volume, flow rates.................................. 25
V
Volumeneinheiten, Durchflumenge .................. 25
VORWORT .......................................................... 1
Z
Zeitgroen
............................................................ 4
Zylinder-Hubzeiten ............................................ 28
EC 130
2 801 941.00 de/us

SERVICE DATA
Vorwort .............................................................................................................................. 1
Foreword
Motor .................................................................................................................................. 3
Engine
Getriebe .............................................................................................................................. 4
Transmission gears
Hydraulikanlage .................................................................................................................. 5
Hydraulic system
und Einstelldaten .............................................................................................. 5
Pruf-
Checking and setting data
Arbeitspumpe ............................................................................................................ 7
Working pump
Schwenkpumpe ........................................................................................................ 8
Swing pump
Zusatzpumpe 2-fach - Greifer drehen / Vorsteuerung .............................................. 9
Double additional pump - Grab rotating / Servo
Hydraulikmotoren .................................................................................................... 10
Hydraulic motors
Betriebsstoffe.................................................................................................................... 11
Service fluids
Wartungs- und Verschleiteile.......................................................................................... 12
Servicing and wear parts
Verschleigrenzen............................................................................................................ 13
Wear limits
Fahrwerksteile ........................................................................................................ 13
Crawler components
Zulassiges
Lagerspiel ...................................................................................................... 14
Permissible bearing play
Drehverbindung ...................................................................................................... 14
Swing bearing
Anziehdrehmomente ........................................................................................................ 14
Tightening torques
Ca. Gewichte .................................................................................................................... 16
Approx. weights
SERVICE DATA
BLANK PAGE
SERVICE DATA
VORWORT FOREWORD
Jede Person, die mit der Inbetriebnahme, Anyone involved with commissioning, op-
Bedienung, Inspektion und Wartung der erating, inspecting and servicing the con-
Baumaschine befat ist, mu - bevor sie struction machine must read through and
die ersten Handgriffe ausfuhrt
- die "BE- acquaint himself with the "OPERATING
TRIEBSANLEITUNG" und besonders das MANUAL" - and especially the Section
Kapitel "GRUNDLEGENDE SICHERHEIT- "FUNDAMENTAL SAFETY INSTRUCTIONS"
SHINWEISE" gelesen und verstanden - before starting work.
haben.
Die "Service Daten" enthalten Angaben, die fur The "Service Data" contains details which are
Kundendienstmitarbeiter wichtig sind. Maschinen- important to the service staff. Data included in
daten, die an anderer Stelle der Dokumentation other parts of the general documentation have
aufgefuhrt
sind, werden hier nicht wiederholt. Zur been left aside. The set of documents for an
Dokumentation einer Baumaschine gehoren:
construction machine includes:
Betriebsanleitung Teil 1 - 5 Operating manual parts 1 - 5
Motor-Betriebsanleitung Operating instructions for engine
Ersatzteilliste fur
Maschine und Motor Spare parts list for machine and engine
Matabelle oder Mablatt "Technische Daten" Dimension Table or Dimension Sheet

der Baumaschine. "Technical Data".
Zur Dokumentation im weiteren Sinne gehoren

"Technical Handbooks" (THB) and "Service In-
auch "Technische Handbucher"
(THB) und "Ser- formation" bulletins (si) are, furthermore, to be
vice Informationen" (si). considered as supplements to the general docu-
mentation.
In dieser Broschure
sind die Daten der Hilfsagg- Data regarding auxiliary units for operating an-
regate zum Betrieb von Zusatz- oder Sonderaus- cillary or special systems, as well as data on
rustungen
sowie Daten von Einzelgeraten
nicht machines produced only in small numbers, have
aufgefuhrt.
not been included.
Die aufgefuhrten
Fullmengen
der Betriebsmittel Filling quantities are only approximate figures in-
sind ca.-Angaben, die Dispositionshilfe sein sol- tended to help in stockholding the various fluids
len. Jedes Aggregat besitzt geeignete Kontrollein- and agents. Each unit has appropriate checking
richtungen, z. B. Peilstab oder Kontrollschrauben, systems, e.g. dipstick or checking screws, with
mit denen die exakte Befullung
gepruft
wird. which the exact filling level can be checked.
Die in den Kapiteln aufgefuhrten

Sach-Nrn. The Part Nos. given in the sections are
nicht zum Bestellen von Ersatzteilen ver- not to be used when ordering spare parts.
wenden. Sie sollen nur dokumentieren, auf They are only intended to identify the
welches Bauteil sich die nachstehenden component being referred to. When order-
Daten beziehen. Zur Ersatzteilbestellung ing spare parts, use only the Part Nos.
die zur Maschine gehorende
Ersatzteilliste given in the spare parts lists.
verwenden.
2 801 941.00 de/us 1

SERVICE DATA
BLANK PAGE
2 2 801 941.00 de/us

SERVICE DATA
Motor
Engine
Einheit EC 130
Unit Nr. / No. 11 701 -
Hersteller und Typ 4BT 3.9-C

Manufacturer and model
Arbeitsweise Viertakt-Dieselmotor mit Aufladung

undDirekteinspritzung
Type Four-stroke Diesel engine with turbochar-
ging and directinjection
Standardleistung ISO 3046/1-IFN kW 63

Standard rated output ISO 3046/1-IFN
Nenndrehzahl (bei Vollast) min -1 2200

Rated speed (at full load) rpm
Leerlaufdrehzahl min -1 1000

Idling speed rpm
Hohe Leerlaufdrehzahl min -1 2450

High idling speed rpm
Zundfolge
1-5-3-6-2-4
Firing sequence
Drehrichtung Auf Schwungrad gesehen links

Direction of rotation Anti-clockwise when looking atflywheel
Ventilspiel Einla/Ausla (bei kaltem Motor) mm / mm 0,25 / 0,51

Valve clearance: inlet and exhaust (engine cold) inch / inch 0.01 / 0.02
Verdichtungsverhaltnis
17.5 : 1
Compression ratio

Oldruck
Oil pressure
bei 950 min-1 (Mindestdruck) bar / psi 0.7 / 10

at 950 rpm (Minimum allowable)
bei 2200 min-1 (Mindestdruck) bar / psi 2.76 / 40

at 2200 rpm (Minimum allowable)

Offnungsbereich - Thermostat C 82 - 93
Thermostat at opening range F 180 - 200
2 801 941.00 de/us 3

SERVICE DATA
Getriebe
Transmission gears
Fahrgetriebe EC 130
Final drive Nr. / No. 11 701 -
Bauart 3-stufiges Planetengetriebe

Type 3-stages planetary gearbox
Typ F30/101/P30-MB/F/K 1)
Model
Sach-Nr. 2759946
Part No. 73180412

Ubersetzung i = 101,516
Ratio
Sach-Nr. Hydraulikmotor 2458937

Part No. hydraulic motor 73179496
Schwenkgetriebe EC 130
Swing gear Nr. / No. 11 701 -
Bauart 2-stufiges Planetengetriebe

Type 2-stages planetary gearbox
Typ S5/25/K30-L
Model
Sach-Nr. 2759700
Part No. 73177723

Ubersetzung i = 24.52
Ratio
Sach-Nr. Hydraulikmotor 2403125

Part No. hydraulic motor 73175616
1)
siehe Typenschild
see data plate
4 2 801 941.00 de/us

SERVICE DATA
Hydraulikanlage
Hydraulic system
Pruf-
und Einstelldaten Einheit EC 130
Checking and setting data Unit Nr. / No. 11 701
Servosteuerdruck / Servo pressure bar / psi 45 / 653
Primardruckabsicherung
fur
Arbeitspumpen bar 320 / 360
Primary pressure relief for working pumps psi 4644 / 5225
Sekundardruckabsicherung
fur
- Auslegerzylinder / boom cylinder bar / psi 380 / 5515
Secondary pressure relief for
- Stielzylinder / stick cylinder bar / psi 380 / 5515
- Loffelzylinder
/ backhoe cylinder bar / psi 380 / 5515
- Fahrmotor / travel motor bar / psi 380 / 5515
Schwenkkreis - Arbeitsdruck max. (Druckabschneidung) bar 390

Swing circuit working pressure max. (pressure cut-off) psi 5660
- Speisedruck / charge pressure bar / psi 20 / 290
- Sekundardruck
/ secondary pressure bar / psi 420 / 6095
- Steuerdruck bei reduzierter Schwenkleistung bar / psi 18,5 / 268
control pressure by reduced swing performance
Kraftverstarker
/ Force booster
- Primardruckabsicherung
(Druckzuschaltstufe) bar 360
primary pressure relief (pressure boost stage) psi 5225
- Sekundardruckabsicherung
fur
- Auslegerzylinder bar 380
Secondary pressure relief for boom cylinder psi 5515
- Stielzylinder bar 380
stick cylinder psi 5515
- Loffelzylinder
bar 380
backhoe cylinder psi 5515
Steuerkolbenhub Steuerblock - Ausrustung

/ Fahren mm 11 1,2)
Piston stroke control block - equipment / travelling inch 0.43 1,2)
Steuerkolbenhub Steuerblock - Verstellzylinder mm 9 1)

Piston stroke control block - adjusting cylinder inch 0.35 1)
Vorspannventil fur
Tankleitung Steuerblock / Hydraulikolbeh alter
bar 5
Pressurizing valve for control block / oil reservoir line psi 73

Bypassventil - Offnungsdruck (Filterkammer) bar 1,5
By-pass valve cracking pressure (filter chamber) psi 22
Vorspannventil - Hydraulikolbeh
alter
bar 0,35 - 0,45
Pressurizing valve on oil reservoir psi 5 - 6.5
1)
Hubwege der Steuerkolben aus Nullage gemessen
Piston stroke measured from the neutral position
2)
bei Funktion "Ausleger senken" = 9 mm
for function "lower boom" = 0.35 inch
2 801 941.00 de/us 5

SERVICE DATA
Pruf-
und Einstelldaten Einheit EC 130-
Checking and setting data Unit Nr. / No. 11 701 -
Grenzlastregler-Daten Arbeitspumpen
Load limit governor-data Working pumps
kW 2 x 69
Strom durch Y10 / Druckwert

Y10 current / pressure
EC 1 HEAVY 100 % 440 / 21.5
Power stage
EC 2 ECO 90 % mA/bar 510 / 25.5
Power stage
EC 3 LIFT 65 % 600 / 32.7
Power stage
DSF Druckschalter-Fahren aktiviert 475 / 24

Pressure switch-travelling activated
DSH Druckschalter-Hammer aktiviert mA/bar 600 / 31.4
Pressure switch-hammer activated
DSS Druckschalter-Sondereinrichtung aktiviert 600
Pressure switch-optional equipment activated
Elektrische Drehzahlverstellung Verstellmotorstrom / Drehzahlwert

Electric speed control adjusting motor current / revolution
ED 1 HEAVY 3551) / 2200
ED 2 ECO mA/min-1 3801) / 2100
ED 3 LIFT mA/rpm 4201) / 1900
1)
Stromwert so einstellen, da Drehzahl erreicht wird
Adjust current until engine speed is reached
6 2 801 941.00 de/us

SERVICE DATA
Arbeitspumpe Einheit EC 130

Working pump Unit Nr./No. 11 701 -
Bauart Verstelldoppelpumpe mit Einzelreglern

Type Variable - displacement twin pump with
individual governors
Typ A8VO55LA1
Model
Sach-Nr. 4530535
Part No. 73179494
Geometrisches Fordervolumen
cm3/U 54,8
Displacement cc/rev.
Reglerubersteuerung
(GLR = Grenzlastregler) bar 5 - 40
Governing pressure (GLR = load limit governor) psi 72 - 580
Betriebsdrehzahl (= Nenndrehzahl Dieselmotor) min -1 2200

Operating speed (= rated speed of engine) rpm
ordermenge
Olf min. (bei Betriebsdrehzahl) l / min 15
Oil flow min. (at operating speed) gal / min 3.96
ordermenge
Olf max. (bei Betriebsdrehzahl) l / min 117
Oil flow max. (at operating speed) gal / min 30.87
2 801 941.00 de/us 7

SERVICE DATA
Schwenkpumpe Einheit EC 130

Swing pump Unit Nr./ No. 11 701 -
Bauart Verstellpumpe mit Drehwerkssteuerung

Type Variable-displacement pump with pressure
limitation
Typ A4VG40DWD
Model
Sach-Nr. 1295040
Part No. 73177238
cm3/U 40

ordermenge
Olf (bei Betriebsdrehzahl) l / min 85
Oil flow (at operating speed) gal / min 22.5
Speisepumpe Schwenkkreis
Filling pump swing circuit
cm3/U 8,4

ordermenge
Olf (bei Betriebsdrehzahl) l / min 18
Oil flow (at operating speed) gal / min 4.8
8 2 801 941.00 de/us

SERVICE DATA
Zusatzpumpe 2-fach Einheit EC 130

Double additional pump Unit Nr. / No. 11 701
Funktion Kuhler
Vorsteuerung
Function Radiator Servo
Bauart Zahnradpumpe
Type Gear-type pump
Typ / Model W9A2-08-06-R-3-F-07-NE 129
Sach-Nr. / Part-No. 2224970 / 73171849
cm3/U 8.0 6.0
Antrieb durch Schwenkpumpe

Drive Swing pump
Betriebsdrehzahl (EC 130) min -1 2200

(bei Nenndrehzahl Dieselmotor)
Operating speed rpm
(at rated speed of engine)
ordermenge
Olf (EC 130) l / min 16.7 12.5
(bei Betriebsdrehzahl)
Oil flow (at operating speed) gal / min 4.4 3.3
2 801 941.00 de/us 9

SERVICE DATA
Hydraulikmotoren Einheit EC 130

Hydraulic motors Unit Nr. / No. 11 701-
Funktion Fahrmotor
Function Travel motor
Bauart Verstellmotor mit Schragachsentriebwerk

Type Variable-displacement bent-axis motor
Typ / Model A6VE55HZ3/63W
Sach-Nr. / Part No. 2458937 / 73179496
Geometrisches Schluckvolumen
Displacement
- Kriechgang 55
precision gear cm3/U
- Schnellgang cc/rev. 23
overdrive
Fahrbremsventil Sach-Nr. integriert in Motor

Travel retarder Part No. motor integrated
- Typ / Model
- Druckeinstellung bar 400
pressure setting psi 5515
Hydraulikmotoren Einheit EC 130

Hydraulic motors Unit Nr. / No. 11 701 -
Funktion Schwenkmotor
Function Swing motor
Bauart Axialkolbenmotor mit konstantem Schluckvolumen

Type Fixed-displacement, axial piston motor motor
Typ / Model F12 - 30
Sach-Nr. / Part No. 2403125 / 73175616
Geometrisches Schluckvolumen cm3/U 30

Betriebsdrehzahl min -1 ---
Operating speed rpm
10 2 801 941.00 de/us

SERVICE DATA
Betriebsstoffe
Service fluids
EC 130
Nr. / No. 11 701 -
Ca. Fullmenge
Wechsel nach 2)
Qualitat
Liter Betriebsstunden 2) Grade
Approx. quantity Operating hours Sach-Nr.2)
gallons between changes Part No.
Dieselmotor (einschl. Filter) 11.5 1) 250 2) SAE 15W-40

Engine (including filter) 3.04 1)
Kraftstofftank 190 siehe "Motor-Betriebsanleitung"

Fuel tank 50.3 see "Engine Instruction Manual"
Kuhlfl
ussigkeit
19 2000 3) siehe "Motor-Betriebs-
anleitung"
Cooling fluid 5 see "Engine Instruction
Manual"
Hydraulikanlage 250 3000 4) Multigrade

Hydraulic system 66.1 Hydraulic-Oil
Tank/reservoir 150 / 39.7 73175843
Schwenkgetriebe 3.5 3000 4) Multigrade

Swing gear 0.92 Gear-Oil
73175844
Fahrgetriebe 2 x 3.5 3000 4) Multigrade

Final drive 2 x 0.92 Gear-Oil
73175844
Leitrad 2 x 0.4 Nur bei Reparatur Motorol

SAE 40
Idler 2 x 0.1 Only after repair Motor oil SAE 40
Laufrolle 0.3 Nur bei Reparatur Motorol

SAE 40
Bottom roller 0.1 Only after repair Motor oil SAE 40
Stutzrolle
4 x 0.2 Nur bei Reparatur Motorol
SAE 40
Top roller 4 x 0.05 Only after repair Motor oil SAE 40
Drehverbindung 6 kg Bei Neufullung

NLGI-Nr. 2 5)
Swing bearing 13.2 lb On refilling 731758456)
731710217)
1)
Fullmengen

beziehen sich auf Olwechsel, nicht auf Erstbefullung

Filling quantities are valid for oil changes and not for first filling
2)
Siehe auch "Betriebsanleitung"
See also "Operating Instructions"
3)
Spatestens
nach 2 Jahren
After 2 years at the latest
4)
Spatestens
nach 3 Jahren
After 3 years at the latest
5)
Bei Umgebungstemperaturen unter 0C Fett NLGI-Nr. 1 oder 0 verwenden.
At ambient temperatures below 32F use grease NLGI-No. 1 or 0.
6)
1 kg - Gebinde
1 kg - container
7)
0,4 kg - Kartusche
0,4 kg - cartridge
2 801 941.00 de/us 11

SERVICE DATA
Wartungs- und Verschleiteile
Servicing and wear parts
EC 130
Nr. / No. 11 701 -
Sach-Nr.1) Wechsel nach Betriebsstunden2)

Part No. Oper. hours between changes
Luftansauganlage (FHG 12)

Air intake system (FHG 12)
- Hauptfilterelement 73175974 Bei Bedarf
main filter element As required
- Sicherheitsfilterelement 73176005 Bei Bedarf
safety filter element As required
Hydraulikanlage / Hydraulic system

Filterelement - Speisepumpe Schwenkkreis 2 x 73170668 3000
bzw. Servopumpe
Filter element - filling pump swing circuit
resp. servo pump
- Stutzring
/ support ring 2 x 73170671
- O-Ring 2 x 73170669
Hydraulikolbeh
alter
/ Hydraulic oil reservoir
Rucklauffilterelement
10 m (absolut) 1 x 73177168 500
Return flow filter element 10 m (absolutely)
- O-Ring 1 x 73171650
Bypaventil / Bypass valve 1 x 73170277 3000
- O-Ring 1 x 73170290
Entluftungsventil
/ Air bleed valve 1 x 73170286 500
1)
Die aufgefuhrten
Sach-Nrn. beziehen sich auf Seriengerate.
Sonderausstattungen sind nicht beruck-

sichtigt.
Ersatzteile nur aus der geratebezogenen
Ersatzteilliste bestellen.
Listed parts numbers refer to series configuration. Special attachments are not considered.
Spare parts must only be ordered from the machine-related list.
2)
Siehe auch "Betriebsanleitung"
See also "Operating Instructions"
12 2 801 941.00 de/us

SERVICE DATA
Verschleigrenzen
Wear limits
EC 130
Nr. / No. 11 701 -
Fahrwerksteile Kettentyp Neu (mm) Verschlei 100% (mm)

Crawler components Chain model New (inch) Wear 100% (inch)
D4D 685.8 / 27 697.5 / 27.468
Kettenlange
(4 Glieder)/ Chain stretch (4 links)
D4D 96 / 3.781 88 / 3.468
Kettengliedhohe/
Chain link height
D4D 155 / 6.109 142 / 5.593
Laufrolle / Bottom roller
D4D 140 / 5.515 128 / 5.031
Stutzrolle
/ Top roller
D4D 53,8 / 2.125 50,8 / 2
Kettenbuchse/ Chain bushing
2 801 941.00 de/us 13

SERVICE DATA
Zulassiges
Lagerspiel
Permissible bearing play
Drehverbindung EC 130
Swing bearing Nr. / No. 11 701 -
Zahnflankenspiel min. Drehverbindung - Schwenkgetrieberitzel 0,3 +0,2 mm

Min. flank play swing bearing slew pinion 0.01+0,008 inch
Anziehdrehmomente
Tightening torques
EC 130
Nr. / No. 11 701 -
Laufrolle Gewindegroe
M 16 1) / 12.9 / SW 24
Bottom roller Thread size
Sach-Nr. 73171578
Part No.
Anziehdrehmoment 330 Nm
Tightening torque 243 lbft
Stutzrolle
Gewindegroe
M 16 / 10.9 / SW 24
Top roller Thread size
Sach-Nr. 73176997
Part No.
Bodenplatte Gewindegroe
M 14 x 1,5 1) / 12.9 / SW 22
Track pad Thread size
3-Steg-Bodenplatte
Triple-grouser truck-pad
Sach-Nr. 73177002
Part No.
Fahrgetriebe Gewindegroe
M 16 x 45 / 10.9 / SW 24
Final drive Thread size
Sach-Nr. 73172206
Part No.
Kettenrad- Gewindegroe
M 16 x 55 2) / 10.9 / SW 24
Fahrgetriebe Thread size
Sprocket- Sach-Nr. 73177037
final drive Part No.
1) 2)
Sechskantschraube, leicht geolt
Schraubensicherung
Hex. hd. screw. lightly oiled z.B. Loctite 242, 243.
Screws with liquid screw fixer, e.g. Loctite 242,
243
14 2 801 941.00 de/us

SERVICE DATA
Anziehdrehmomente
Tightening torques
EC 130
Nr. / No. 11 701 -
Schwenkgetriebe Gewindegroe
M 16 x 85 / 10.9 / SW 24
Swing gear Thread size
Sach-Nr. 73175474
Part No.
Unterwagen Oberwagen
Undercarriage Superstructure
Drehverbindung Gewindegroe
M 16 x 65 / 10.9 / SW 24 M 16 x 90 / 10.9 / SW 24
Swing bearing Thread size
Sach-Nr. 73175533 73171642
Part No.
Anziehdrehmoment 250 Nm 250 Nm
Tightening torque 184 lbft 184 lbft
Gegengewicht Gewindegroe
M 301) / 12.9 / SW 46
Counter weight Thread size
Sach-Nr. 73171671
Part No.
Motorlagerung Gewindegroe
M 10 x 40 / 10.9 / M 12 x 50 / 10.9 / M 16 x 1,5 / 10.9 /
SW 17 SW 19 SW 24
Engine bracket Thread size
Sach-Nr. 73170567 73176143 73176028
Part No.
Anziehdrehmoment 60 Nm 105 Nm 250 Nm
Tightening torque 44 lbft 77 lbft 184 lbft
1)
Sechskantschraube, leicht geolt

Hex. hd. screw, lightly oiled
2 801 941.00 de/us 15

SERVICE DATA
Ca. Gewichte
Approx. weights
Einheit EC 130
Unit Nr./ No. 11 701 -
Motor / Engine kg / lb 350 / 772
Fahrgetriebe (einschl.Fahrmotor) kg / lb 115 / 254

Final drive (including travel motor)
Kettenrad / Sprocket kg / lb 50 / 110
Laufrolle / Bottom roller kg / lb 33 / 73
Stutzrolle
/ Top roller kg / lb 18 / 40
Drehverbindung / Swing bearing kg / lb 143 / 315
Schwenkgetriebe (einschl. Schwenkmotor) kg / lb 80 / 177

Swing gear (including swing motor)
Arbeitspumpe / Working pump kg / lb 60 / 132
Schwenkpumpe / Swing pump kg / lb 31 / 68
Steuerblock Arbeitsausrustung
kg / lb 150 / 340
Control valve working equipment
Auslegerzylinder / Boom cylinder kg / lb 119 / 264
Stielzylinder / Stick cylinder kg / lb 188 / 418
Loffelzylinder
/ Backhoe cylinder kg / lb 107 / 236
Gegengewicht / Counter-weight kg / lb 2310 / 5088
16 2 801 941.00 de/us

SPECIAL TOOLS ...................................................................................................................................... 1
Foreword.................................................................................................................................................... 1
PCS tester (Fig.1)

Big leather test case with contents .......................................................................................................... 2
Solenoid valve tester (Fig.2) .................................................................................................................... 3
Measuring adapter (Figs. 3 and 4) .......................................................................................................... 3
Vacuum pump (Fig. 5) .............................................................................................................................. 4
Environment-protection plugs (not shown) .......................................................................................... 4
Pressure gauge ........................................................................................................................................ 5
Stroke-measuring device ........................................................................................................................ 5
Cylinder tools
Fitting suspension .................................................................................................................................. 6
Protective sleeve .................................................................................................................................... 6
Gearbox tools ............................................................................................................................................ 7
VACUUM PUMP
Connecting the vacuum pump ................................................................................................................ 8
SPECIAL TOOLS 2461764
Foreword
This chapter describes the recommended special
tools needed for repairing the machine. These
tools are not included in the machines tool-kit.
All tools described can be obtained from the
spare-parts service. The ordering procedure is
the same as for normal spare parts.
The tool-kit is described under assembly no.
92.020 of the spare-parts list.
73179380 03 1
PCS tester (Fig.1)
Fig. 1
Big leather test case with contents

Individual parts
PCS - tester with leather case: 73175280 Couplings: 4 x 73175288
Printer : 73177879 Mains adapter: 73180157
Printer power supply : 73180160 RAM-Card, multi-lingual 73175292
Battery printer : 73180161 Case, big: 73175291
Printing paper, spare roll: 73175286 Case, small (for tester only): 73176679
Cable - printer: 73175285 Leather case: 73176680
Adapter cable - printer : 73177880
Cable - OOC: 73175281
Cable - sensors: 4 x 73175284
Measuring hose: 4 x 73175289
Pressure sensor 600 bars: 2 x 73175283
Pressure gauge connection: 4 x 73175287
2 03 73179380
Solenoid valve tester (Fig.2) Measuring adapter (Figs. 3 and 4)

Application: Application:
Checking of solenoid valves Checking the electrical function of proportional

valves.
Part No. 73176681 Part No. 73176682
Fig. 2 Fig. 3
Fig. 4
73179380 03 3
Vacuum pump (Fig. 5) Environment-protection plugs
(not shown)
Application: Application
The vaccuum pump prevents the hydraulic reser- Conical rubber plugs for closing lines and ports
voir from being emptied when removing hydraulic when using a vaccum pump
lines or pumps.
Part Nos.:
Box, complete 73176697
Box 73176698
Set, complete 73176710
10 plugs 4-8 mm 73176708
10 plugs 6-10 mm 73176709
10 plugs 9-13 mm 73176700
10 plugs 11-15 mm 73176701

Fig. 5 10 plugs 14-19 mm 73176702
Part Nos. 10 plugs 16-21 mm 73176703
1 - Vacuum pump, complete 73176683 10 plugs 19-24 mm 73176704
2 - Terminal clamp, positive pole 73176687 10 plugs 22-27 mm 73176705
3 - Cable lug 73176689 10 plugs 25-31 mm 73176707
4 - Terminal clamp, negative pole 73176688
5 - Hose-clamp 73176692
6 - 1.1 m hose 73176685
7 - Hose-clamp 73176693
8 - Filter 73173674
9 - 0.13 m hose 73176685
10 - Tube 73176694
11 - Buffer 73176696
12 - Tube 73176695
4 03 73179380
Pressure gauge Stroke-measuring device
Measuring of hydraulic pressures, not necessary Measuring the stroking length of control pistons,
if PCS tester is available e.g. in the 6-way control block
Fig. 6
Part Nos.
Pressure gauge, 0-60 bars 73176711
Pressure gauge, 0-400 bars 73176712 Fig. 7
Pressure gauge, 0-600 bars 73176713 Part No. 73176716
Measuring hose, 2000 mm 73176714
Measuring hose adapter 73176715
73179380 03 5
Cylinder tools
Fitting suspension Protective sleeve
Suspension for piston rods as fitting aid Sleeve for the protection of pistons
Fig. 8 Fig. 10
Part Nos.: Part Nos.:
M 75x3 73176717 Piston 130 73176721
M 95x3 73176718 Piston 140 73176722
Protective sleeve Piston 150 73176724
Application:
Sleeve for the protection of piston rod threads
Fig. 9
Part Nos.:
M 75x3 73176719
M 95x3 73176720
6 03 73179380
Gearbox tools
Traveling gearbox
Application:
Removal and fitting of traveling gearboxes
Part Nos.
Set-nut S1 - M 135 x 2 73176138
Special key S2 73176142
Fitting sleeve S3 73176139
Swing gearbox
Application
Removal and fitting of swing gearboxes.
Part Nos.
No. Fig. Gearbox type Part No. Designation

(item)
S1 2 S5 73176971 Fitting punch

S 10 73176972
S 13 73176973
S 16 73176973
73176974
S2 4 S5 73176726 Fitting cover

5 S 10 73176727
5 S 13 73176728
6 S 16 73176729
S3 20 S5 73176975 Fitting sleeve

S 10 73176976
S 13, S 16 73176976
S4 22 S 5, S 10 73176730 Device
S 13, S 16
S6 21 S5 73176731 Adjusting nut

S 10 73176732
S 13, S 16 73176733
S7 24 S5 73176734 Fitting insert

S 10 73176735
S 13, S16 73176736
S9 S 5, S 10 73176725 Fitting set brake S 5 / S 10

including:
S 9.1 2 fitting plates
S 9.2 2 hex screws M 6 x 12
S 9.3 2 cylinder-head screws M 6 x 25
S 9.4 1 hex bolt M 16 x 120
with hex nut M 16
73179380 03 7
VACUUM PUMP
During the removal of hydraulic lines and hydrau- Lay cable (5) to the batteries. Connect first the
lic pumps, hydraulic oil will flow out of the hydrau- positive terminal (6) to the positive pole and
lic reservoir. For this reason, a vacuum pump for then the negative terminal (7) to the negative
the machine is available as an option which pre- pole of the battery.
vents emptying of the hydraulic reservoir when
Switch on the vacuum pump (3) with switch (8).
properly used.
The oil in the hydraulic system will first be
The pump can be ordered under P/N 73176683.
drawn back into the hydraulic reservoir before
For more extensive repair operations, a box con-
air is constantly sucked into the reservoir
taining a complete set of environment protection
through the oil filling so that the oil surface is
plugs can be ordered under P/N 73176697.
bubbling. The vacuum thus created prevents
These plugs can be used to close the dismantled
the hydraulic reservoir from being emptied. The
lines.
pressure indicated by gauge (9) must be 0.2
bars. If the pressure indicated is different, use
Connecting the vacuum pump
rotary switch (10) to set the correct pressure.
The vacuum pump is connected to the vehicle
batteries. The pumping operations should there-
fore be carried on only for a short time, e.g. for
changing hoses or for fitting the supplied environ- Before carrying out any works as, for in-
ment-protection plugs. stance, replacing hydraulic lines, close all
openings with the environment-protection
Depressurize the hydraulic reservoir. To do so, plugs. Do not stop the vacuum pump
screw out drain plug (1, Fig. 1). while plugging the openings.
Screw out the breather filter (2, Fig. 1). Shut off the vacuum pump when the work is
finished.
Disconnect cable (5) from the battery. Disconnect
first the negative cable and then the positive one
from the respective battery poles.
Remove the pump by proceding in reverse order.
Fig. 1
Place the vacuum pump (3) on top of the hy-

draulic reservoir. The pump must be installed
above the oil level.
Press hose connection (4) gently into opening

(2).
8 03 73179380
B
Big leather test case with contents ...................... 2
C
Connecting the vacuum pump .............................. 8
Cylinder tools ........................................................ 6
E
Environment-protection plugs (not shown) .......... 4
F
Fitting suspension ................................................ 6
Foreword .............................................................. 1
G
Gearbox tools ...................................................... 7
M
Measuring adapter (Figs. 3 and 4)........................ 3
P
PCS tester (Fig.1) ................................................ 2
Pressure gauge .................................................... 5
Protective sleeve .................................................. 6
S
Solenoid valve tester (Fig.2) ................................ 3
SPECIAL TOOLS ................................................ 1
Stroke-measuring device ...................................... 5
V
VACUUM PUMP .................................................. 8
Vacuum pump (Fig. 5) .......................................... 4

UNDERCARRIAGE .................................................................................................................................... 1
Foreword.................................................................................................................................................... 1
Safety Instructions
Danger in the event of non-obser-vance of the safety instructions.......................................................... 1
Rules for safety at work .......................................................................................................................... 2
Travel system
General.................................................................................................................................................... 6
Components of the travel system ............................................................................................................ 6
Wear limits .............................................................................................................................................. 8
Track chain
Releasing track tension .......................................................................................................................... 9
Opening the track chain ........................................................................................................................ 10
Closing the track chain .......................................................................................................................... 11
Replacing track links ............................................................................................................................ 12
Repair preparations .............................................................................................................................. 12
Track - direction of travel ...................................................................................................................... 14
Tensioning the track chain .................................................................................................................... 15
Crawler chain - Checking tension .......................................................................................................... 15
Idler
Components of the idler ........................................................................................................................ 17
Assembly of the idler ............................................................................................................................ 18
Bottom rollers
Components of the bottom roller .......................................................................................................... 20
Top roller
Components of the top roller (Fig. 1) .................................................................................................... 22
Sprocket
Components of the sprocket (Fig. 1) .................................................................................................... 25
Travel gearbox
Removal and installation ...................................................................................................................... 26
Track pads
Replacing track pads ............................................................................................................................ 27
Duo-cone seals ...................................................................................................................................... 28

UNDERCARRIAGE 2796425
Foreword Safety Instructions

The "Technical Specifications" manual contains Danger in the event of non-obser-vance
important information for personnel servicing the of the safety instructions
machine. Machine specifications listed elsewhere
in the machine documents are not always re-
peated in this book.
The documentation includes: This hydraulic excavator has been built in

accordance with state-of-the-art standards
the operating instructions and the recognized safety rules.
the spare-parts list However, operating the machine if a fault
is suspected or has occurred, or carrying
the dimension table with the technical data of out repair work inexpertly may
the machine. - endanger the lives of persons in con-
tact with it
The present brochure does not contain the speci-
fications of auxiliary units for the operation of - damage the machine and other prop-
additional or optional equipment or the specifica- erty.
tions of individual machines. The hydraulic excavator must be stopped
immediately on any damage being sus-
The refilling quantities specified for consumables pected or occurring to ensure that the
are approximate quantities which are intended as safety of the operator, of other persons at
a help for planning consumable requirements. the place of use or of other material prop-
Each unit is equipped with suitable checking de- erty is not compromised.
vices, e.g. dipstick or checking plugs, permitting
the operator to check proper filling of the units. All components are carefully co-ordinated.
spare parts.
73179380 04 1
Rules for safety at work
Personnel Personnel
The machine must not be started by un- Personal protective gear and working
authorized persons. clothing:
It must therefore be secured. Wear a safety helmet, safety footwear and
gloves.
Observe the accident prevention regula-
tions. Wear closely fitting working clothing
when working on the machine.
The hydraulic excavator may be operated,
serviced or repaired only by specially Loose, wide garments may catch on ma-
trained and authorized personnel with the chine parts and result in injury.
appropriate technical know-how. If the work to be carried out requires aux-
If such know-how is lacking, meticulous iliaries, e.g. marshallers, the competences
instruction must be given by experienced of each individual helper must be clearly
personnel. defined beforehand.
The personnel must have read and under- The individual responsibilities must be
stood the operating instructions and in meticulously observed to avoid unclear
particular the chapter competences endangering safety.
"Fundamental Safety Instructions".
Only such persons may start up the ma-
chine during assembly work in order to Tools and auxiliaries
adjust the attachments. Tools, hoists, slings, trestles and other
Incorrect operation of the machine or the devices must be in a reliable, safe state.
attachments may give rise to life-threaten- Metal splinters may cause injury when at-
ing situations. tachment bolts are being driven in or out.
During all works, always observe the A brass or copper mandrel should there-
start-up and shut-down procedures pre- fore be used for this purpose, and gog-
scribed in the operating instructions. gles must be worn.
For climbing onto or off the machine, use
only the ladders, steps, platforms and
handrails provided for this purpose.
Always keep ladders, steps and platforms
in a non-slip state.
Remove any oil, grease, earth, clay, snow,
ice and other foreign matter immediately.
2 04 73179380
Securing the working equipment Hydraulic and lubricating system

Before carrying out assembly work, the Always observe the safety regulations ap-
machine and the attachments must be se- plicable to the product when handling
cured against inadvertent and unauthoriz- oils, greases and other chemical sub-
ed starting, e.g. by placing chocks under stances.
the wheels or tracks and by standing the Unused but open bores, pipelines and
working equipment on the ground. hose connections must be closed in a
Stand the working equipment on the pressure-tight manner.
ground in such a way that no movements Refill collected hydraulic oil back into the
can be made when mechanical or hydrau- hydraulic system only through the return-
lic connections become detached. flow filters.
Secure any equipment or component Dispose of waste oil without polluting the
which is to be mounted or dismantled or environment.
whose position is to be changed using
hoists or appropriate slinging/supporting Observe the correct working sequence
devices to prevent them from moving, when fitting or replacing components or
slipping or falling inadvertently. equipment.
Systems and units (e.g. pipes, accumula- The working sequence has been specified
tors, etc.) must be properly depressurized and tested by qualified experts.
before being opened. Replace defective, mechanically prestres-
Protective devices on moving machine sed units only as an entirety. Never open
parts may be opened or removed only them.
when the drive unit is stationary and pro- In exceptional cases, open only when the
tected against inadvertent starting. system and the operating sequence are
Before recommissioning, all protective de- precisely known. The Technical Manual
vices must be refitted. contains no information on such work.
When the machine is at operating tem-
Before carrying out assembly work, the perature, the consumables are at least at
machine and the equipment must be se- the same temperature. Precautions must
cured against inadvertent starting, e.g. by therefore be taken to prevent burning or
placing chocks under the wheels or scalding.
tracks and by standing the working equip-
ment on the ground. Be careful when handling acids, e.g. bat-
tery acid. Acid splashes may injure the
eyes and the skin.
Do not smoke when handling flammable
liquids.
Be careful with naked flames and un-
protected light.
Not only fuel but also other consumables
often have a low flash point and catch fire
easily.
73179380 04 3
Conversions or modifications to the Recommissioning

machine Prior to recommissioning:
Unauthorized conversions or modifica- - Grease all lubricating points.
tions of the hydraulic excavator are for- - heck all oil levels and make the neces-
bidden for reasons of safety. sary corrections.
The nominal pressure of pressure relief - Carry out function checks of all
valves must not be modified. repaired components.
Do not remove the lead seals from pres- - Check all functions of the excavator in-
sure-relief valves and pressure accumula- cluding the brakes during a test run.
tors. Release the hydraulic excavator for re-
commissioning only after all functions
have been found to work perfectly.
4 04 73179380
BLANK PAGE
73179380 04 5
Travel system 2800525
General
The hydraulic excavator is equipped with a low-maintenance tractor type travel system.
The track pads are bolted onto the track chain.
Components of the travel system
Fig. 1
6 04 73179380
Item Quan. Description Weight Torque

kg / lb Thread Material Wrench MA Torque
size grade size Nm lbft.
mm
1 56 Hex. bolt M 16 12.9 24 300 221
2 14 Bottom roller 33 / 75
3 2 Track chain 349 / 786
4 16 Hex. bolt M 16 10.9 24 250 184
5 4 Top roller 18 / 41
6 90 Track pad 15 / 33
7 360 Nut M 14 x 1,5
8 360 Hex. bolt M 14 x 1.5 12.9 22 235 174
9 2 Master pin
10 1 Chain segment
11 4 Sealing washer
12 4 End washer
13 2 End bushing
73179380 04 7
Wear limits
Wear on the track components is due to move- Track components must be replaced when they
ment, loading and ground contact, as well as to have worn down to between 75 and 100%. Sud-
the hardness (abrasiveness) of the ground. den failure is otherwise pre-programmed.
Wear can also be increased by the following Careful and regular measurements are necessary
factors: to determine the extent of wear and to be ready
for component exchange when it is necessary.
- Unstable position of excavator because of un-
Before measuring components, clean them thor-
even ground.
oughly. Measure at several points. It is not the
- One-sided stressing of the tracks when turning average, but the maximum wear value that is to
on the spot. be taken as wear limit.
- Travelling long distances with the sprockets at Because the wear life between 75 and 100% is
the front. low, we recommend that components be changed
- Driving over obstacles. as a preventive measure as soon as the 75%
limit has been reached. Exchange can take place
- Loose track pads. while other servicing is being carried out.
- High amount of travelling of more than 10% of
the operating hours. Wear limits see chapter 02, service data.
8 04 73179380
Track chain 2796427
Releasing track tension
Read and observe "Safety instructions"

before starting work on the track chain
and the chain tensioning device.
Wear protective glasses.
The chain tension grease is under high
pressure. Therefore, release the filler
valve carefully.
The grease flows out into the crawler
member. This prevents grease being
ejected uncontrolledly.
Fig. 2
Clean the track unit as described in section Place a ring spanner on the filler valve (Fig. 2).
"Cleaning the track unit".
Screw out filler valve, maximum two rotations.
Park the machine on a dry level surface. Grease from the chain tensioning device flows
out at the thread of the filler valve.
The track chain tension has been released
when grease no longer flows out of the filler
valve and maximum track chain sag is present
between the top rollers, and between top roller
and driven wheel/front idler.
Remove grease from track member and dis-

pose of it in an environmentally responsible
manner.
Close filler valve securely.
Tension track chain as described in section

"Tensioning the track chain".
Fig. 1
Reattach cover (Fig. 1).
Remove cover (Fig. 1).
Tension track chain of other track unit using
the same procedure.
The sag of both track chains should be iden-
tical.
73179380 04 9
Opening the track chain

The track chain can be opened e.g. to replace an Place wooden supporting material etc. under
idler or a travel gearbox as follows (Fig. 1): the master pin and slacken the track.
Fasten the track in order to prevent it from
Position the excavator in such a way that the falling down after being opened.
chain master pin (3) is positioned between the
idler (1) and the support roller (2).
The master pin (fig. 2) can be identified by the
bigger centric bores in its ends. Before opening the track chain has to be
slackened and secured against falling
down after being opened.
Remove the track pads above, in front of and

behind the master pin.
Apply track pin press (fig. 3) and press out the

master pin.
Fig. 1
Fig. 3
Fig. 2
10 04 73179380
Closing the track chain

Line up the track in such a way that the chain Spray the master pin with molykote (Part no.
links to be connected are positioned between 73171482). Position the master pin (Fig. 5) and
the idler and the support roller (Fig. 1). press it quickly into place.
Install the track pads.

Line up chain links by pressing in a centering
pin (Fig. 4) and place supports under the track. Tension the track.
Fig. 4 Fig. 5
73179380 04 11
Replacing track links

Repair preparations
The damaged link must be positioned between

idler (1, Fig. 1) and support roller (2, Fig. 1).
Place wooden supporting material etc. under The bores in the chain eyes (6) must not
the master pin. be damaged.
Slacken the track.

Open the bosses (7) at the top and bottom by
Fasten the track in order to prevent it from
flame-cutting. The bushing (5) must not be
falling down after being opened.
damaged in the process.
Knock off the track parts.
Before opening the track chain has to be Chase out pin (8). If the pin was damaged
slackened and secured against falling during flame-cutting of the boss the damaged
down after being opened. areas have to be ground smooth beforehand.
Flame-cut the outstanding ends (appr. 10 mm)

of the bushing (5) and grind smooth.
Removal (Fig. 6)
Remove the track pad of the damaged link as Assembly (Fig. 7)

well as the pad before and behind it.
Fit in new chain segment with four end disks
Flame-cut pin (4) and bushing (5) close to the (9) and washers (10) and align it using the
chain links. centering pin (Fig. 4).
Fig. 6 Fig. 7
Knock out the pin remainders (4.1) using a drift Support chain segment with wooden blocks.
punch; if necessary, cut beforehand with a car-
bon electrode ("Arc-air" procedure). Press in two master pins (4, 8, Fig. 6).
For the "Arc-air" procedure cf. Technical hand- Remove wooden blocks.
book "Welding for maintenance and repair",
Part no. 2 114 500. Tension track again.
Install track pads, tighten bolts with required

torque.
12 04 73179380
New parts needed:
To replace a chain segment the following parts

are needed:
1 chain segment (Fig. 8)
2 master pins
2 end washers
4 sealing washers
Fig. 8
73179380 04 13
Track - direction of travel

When replacing a track chain, make sure that the A wrongly fitted track chain wears quickly on the
track is fitted in the correct direction. outer edges of the chain bushings and causes
wear on the sprocket teeth. Thus the service life
Designations: is reduced drastically.
A Direction of travel
1 Track chain
2 Track pad
3 Sprocket
4 Idler
Fig. 9
14 04 73179380
Tensioning the track chain Crawler chain - Checking tension
Read and observe "Safety instructions" Read and observe "Safety instructions"
before starting work on the track chain before starting work on the track chain
and the chain tensioning device. and the chain tensioning device.
Check the tension of the track chain. Clean the track unit.
Drive the machine a distance of approx. twice

the length of the track unit. The chain ten-
sioning device can tension the track chain
evenly.
Park the machine on a dry level surface.
Place a flat board on the track chain between

the track carrier rollers (Fig. 12).
Fig. 10
Remove cover (Fig. 10).
Clean filler valve of chain tensioning device (2,

Fig. 11).
Fig. 12
Measure the greatest distance between board

and ridge of track shoe.
The measured value should be between 3 cm
and 4 cm (Fig. 12).
If the value is higher the track chain must be
tensioned.
If the value is smaller the track chain tension
must be released.
Fig. 11
Place filler element (1) of grease gun on filler

valve (2).
Inject grease until the track chain is correctly
tensioned.
Remove grease gun filler element. The filler

valve closes automatically.
Reattach cover (Fig. 10).
73179380 04 15
Idler 2800526
The idler is mounted in the two slider pieces,

which are guided in the track frame.
Never dismantle the tensioning cylinder as
With the idler the track is tensioned via spacer it is very higly pressurized.
piece and track tensioning cylinder.
Risk of life-threatening injury.
Always replace damaged cylinders as a
complete unit.
Fig. 1
16 04 73179380
Components of the idler

mm
1 2 Locking pin
2 2 Slider piece 5 / 12
3 2 Bushing
4 2 O-Ring
5 1 Shaft 12 / 27
6 1 Screw plug
7 1 Sealing ring
8 1 Idler 67 / 151
9 2 Duo-cone seal
10 1 Spacer piece 18 / 41
11 4 Lock washer
12 4 Hex. bolt M 16 8.8 24 170 126
13 1 Tensioning cylinder 50 / 113
14 1 Gasket
15 1 Sealing ring
16 1 Cylinder 21 / 48
17 2 Hex. bolt M 16 8.8 24 170 126
18 2 Lock washer
19 2 Hex. bolt M 16 8.8 24 170 126
20 2 Lock washer
21 1 Grease valve 1,3 / 3
22 1 Cover
23 2 Lock washer
24 2 Hex. bolt M8 8.8 13 20,5 15,12
73179380 04 17
Assembly of the idler

When assembling the idler the working sequence Insert idler shaft (5, Fig. 3).
has to be as follows:
Place idler onto suitable support (8, Fig. 1) and

completely press, respectively drive in bushing
(3, Fig. 1).
Fig. 3
Grease seal ring (4, Fig. 4) and place into slider

piece (2).
Fig. 1
Fit two halves of duo-cone seals (9, Fig. 2) into

idler (see chapter "Duo-cone seals").
Fig. 4
Fit half of duo-cone seal (9, Fig. 5) into slider

piece (2).
Fig. 2
Fig. 5
18 04 73179380
Clean indicated area of the idler shaft with deg- Turn idler and fill idler housing with oil according
reaser and cover with a thin layer of assembly to Operating Instruction.
paste.
Install second slider piece.
Assemble the first slider piece (2, Fig. 6) and the
shaft (5) with help of a lifting device.
Ensure that the slider piece is brought exactly

into position and the borings for the locking pin
(1, Fig. 7) in the slider piece and the shaft are
aligned.
Before assembling the duo-cone seal clean the

contact surface carefully and cover the contact
surface slightly with oil.
Do not oil the other areas of the duo-cone seals.
Fig. 8
Fig. 6
Install the locking pins (1). The grove in the lock-

ing pin has to show into the direction of the shaft.
Fig. 7
73179380 04 19
Bottom rollers 2800527
Bottom rollers have lifetime lubrication. They do The roller can be made fully operational by re-
not require any maintenance until the wear limits moving and cleaning it, and then filling it with
have been reached. fresh oil.
The rollers are sealed with duo-cone seals (8,

Fig. 1). Function and assembly of duo-cone seals
- see chapter "Duo-cone seal".
The majority of roller leaks is due to dirt that

enters through the labyrinth (see arrow, Fig. 2)
and penetrates into the duo-cone seals.
Components of the bottom roller

mm
1 1 Bottom roller 33 / 75
2 2 Bearing 3 / 10
3 2 Locking pin
5 1 Screw plug
6 1 Sealing ring
7 2 Bushing
8 2 Duo-cone seal
9 2 O-Ring
10 1 Axle 11 / 25
11 1 Roller 20 / 44
20 04 73179380
Fig. 1
Fig. 2
73179380 04 21
Top roller 2800528
On each track frame 2 top rollers are installed. The majority of roller leaks is due to dirt that
enters through the labyrinth (see arrow, Fig. 2)
Top rollers have lifetime lubrication. They do not and penetrates into the duo-cone seals.
require any maintenance until the wear limits
have been reached. The roller can be made fully operational by re-
moving and cleaning it, and then filling it with
The rollers are sealed with duo-cone seals (11, fresh oil.
Fig. 1). Function and assembly of duo-cone seals
- see chapter "Duo-cone seal".
Components of the top roller (Fig. 1)

mm
1 1 Top roller 18 / 41
2 4 Hex. bolt 95 - 70 - 83
112
3 1 Cover
4 1 Spacer
5 2 Hex. bolt 38 - 28 - 33
45
6 2 Washer
7 2 Bushing
8 1 Roller 11 / 25
9 1 Screw plug
10 2 Sealing
11 1 Sealing
12 1 Bearing
13 1 Axle 2/5
22 04 73179380
Fig. 1
Fig. 2
73179380 04 23
Sprocket 2800529
The sprocket is bolted to the travel gearbox. Installation
Assembly requirements
Removal and installation of the sprocket is pos-
sible with installed travel gearbox. Start assembly immediately after applica-
tion of the adhesive.
Tightening bolts
Hardening of the adhesive begins after
The thread and the contact surface of the bolt joining the metal surfaces under the ex-
head are to be slightly oiled. clusion of air and is generally completed
after approx. 48 hours at an ambient tem-
Contact surface perature of 68F.
Check the contact surface of sprocket and trav- The hardening process begins only after a
el gearbox for damage and clean with thinner considerable initial delay so that the fit-
(Part-no. 73171477) from paint and grease. ting operations may extend over a period
All contact surfaces must be cleaned down to of 8 hours maximum.
the bright metal and be dry and free from
grease. At temperatures of -50F it is necessary to
spray an activator (Part no. 73176145)
Thread holes onto the second contact surface, i.e. the
one without adhesive.
All thread holes in the travel gearbox have to
be cleaned with compressed air, carefully
checked for paint, rust and damage. If required The bolts have to be tightened crosswise with the
the threads are to be taped again. required torque.
Adhesive
When the sprocket is prepared for installation
apply a thin layer of adhesive (Part-no.
73176144) onto one of the contact surfaces.
Apply the adhesive appr. 10 mm clear of the
thread holes. When assembling the sprocket no
adhesive must reach the thread holes. The
penetration of adhesive into the thread hole
results in increased friction and thus in wrong
tightening of the bolts.
24 04 73179380
Fig. 1
Components of the sprocket (Fig. 1)

lb size grade size Nm lbft.
mm
1 1 Sprocket 47 / 104
2 2 Travel gearbox 139 / 313
3 18 Hex. bolt M 16 x 55 10.9 24 3401 2

511
1)
73179380 04 25
Travel gearbox 2796432
Removal and installation

The removal and installation of the travel gearbox is described in chapter 07.
26 04 73179380
Track pads 2796433
Replacing track pads
Fig. 1 Fig. 2
Replace worn or damaged crawler shoes imme- Screw new crawler shoe on. Ensure that the
diately to prevent damage to the crawler unit. nuts are correctly seated in the grooves in the
chain link (Fig. 2).
Screw out screws (Fig. 1) and remove damag-
ed crawler shoe. Tighten the fastening screws of the crawler
shoe using a torque wrench.
Smooth and clean bearing surfaces of crawler
chain and new crawler shoe.
Apply paraffine oil to bearing surfaces and then

apply silicon corundum powder, grain 120 -
150.
73179380 04 27
Duo-cone seals 2796434
Duo-cone seals (also referred to as steel-on-steel

seals) are used as shaft seals. The arrangement
of the seal is such that one steel ring, elastically
mounted in the fixed component, lies/runs axially
against a second steel ring that is also elastically
mounted, but this time in the rotating component.
Duo-cone seals are used in the excavators bot-

tom rollers, support rollers and idlers.
Leakages in such components are usually due to

damaged duo-cone seals. In case of leakages,
the duo-cone seals are to be changed imme-
diately.
Observe the following points when assembling Fig. 2

duo-cone seals:
Place one complete half (1) and (2) of the
The running surfaces "A" of the steel rings (1, duo-cone seal into/onto the rigid component
Fig. 1) must be completely free of scratches and one complete half into/onto the rotating
and scores. component (Fig. 3) - but without using any oil.
Clean all traces of oil and dust from running Make sure that distance "C" is equal all the
surfaces "A" and seating bevels "B". way around the seal.
All surfaces must be dry and free of rust, slag
and scale.
Fig. 3
Before fitting the two machine components (rig-

Fig. 1
id and rotating) together, carefully wipe the sur-
Draw rubber seal (2) onto steel ring (1, Fig. 2). faces "A" of the steel rings (1) to remove any
The rubber ring (2) is correctly positioned when foreign bodies or even finger-prints. Then apply
it sits twist-free parallel to the surface of the a drop of thin oil between the running surfaces,
steel ring (1). but without allowing oil to get onto the other
parts.
NEVER fit a new half of a duo-cone seal to

a used half.
When re-assembling used duocone seals,
make sure that pairs that were previously
installed together are kept together.
28 04 73179380
Replacing track pads .......................................... 27
A Rules for safety at work ........................................ 2
Assembly of the idler .......................................... 18

S
B Safety Instructions ................................................ 1
Bottom rollers .................................................... 20 Sprocket ............................................................ 24
C T
Closing the track chain ...................................... 11 Tensioning the track chain .................................. 15
Components of the bottom roller ........................ 20 Top roller ............................................................ 22
Components of the idler .................................... 17 Track - direction of travel .................................... 14
Components of the sprocket (Fig. 1) .................. 25 Track chain .......................................................... 9
Components of the top roller (Fig. 1) .................. 22 Track pads .......................................................... 27
Components of the travel system ........................ 6 Travel gearbox.................................................... 26
Crawler chain - Checking tension ...................... 15 Travel system ...................................................... 6
D U
Danger in the event of non-obser-vance of the UNDERCARRIAGE .............................................. 1
Duo-cone seals .................................................. 28 W

Wear limits ............................................................ 8
F
Foreword .............................................................. 1
G
General ................................................................ 6
I
Idler .................................................................... 16
O
Opening the track chain...................................... 10
R
Releasing track tension ........................................ 9
Removal and installation .................................... 26
Repair preparations ............................................ 12
Replacing track links .......................................... 12

SUPERSTRUCTURE ................................................................................................................................ 1
Foreword.................................................................................................................................................... 1
Safety Instructions
BALL-BEARING SWING BEARING

General information ................................................................................................................................ 7
Dismantling / installing the ball-bearing swing ring

Tools and aids ........................................................................................................................................ 8
Dismantling the swing bearing ................................................................................................................ 9
Installing the swing bearing .................................................................................................................. 11
Swing gearbox pinion / Checking the tooth flank clearance on the swing ring ...................................... 12
ENGINE, INSTALLATION ........................................................................................................................ 15
Removing and installing the diesel engine

Removing the diesel engine .................................................................................................................. 16
Installing the diesel engine .................................................................................................................... 17
ENGINE, COUPLING
Removing the coupling .......................................................................................................................... 20
Installing the coupling ............................................................................................................................ 21
SUPERSTRUCTURE 2796495


the spare-parts list However, operating the machine when a
fault is suspected or has occurred, or car-
the dimension table with the technical data of rying out repair work inexpertly may
tact with it
immediately when any damage is suspect-
The refilling quantities specified for consumables ed or occurring, to ensure that the safety
are approximate quantities which are intended as of the operator, other persons at the place
a help for planning consumable requirements. of use or other material property is not
Each unit is equipped with a suitable checking compromised.
devices, e.g. dipstick or checking plugs, permit-
ting the operator to check proper filling of the All components are carefully coordinated.
units. Trouble-free operation and a long service
spare parts.
73179380 05 1
Personnel Personnel
It must therefore be secured. Wear a safety helmet, safety footwear,
gloves and safety glasses.
If such know-how is lacking, meticulous iliaries, e.g. operators, the competences
adjust the attachments. Tools, hoists, slings, stands and other de-
Incorrect operation of the machine or the vices must be in a reliable, safe state.
During all works, always observe the A brass or copper drift should therefore
start-up and shut-down procedures pre- be used for this purpose, and safety
scribed in the operating instructions. glasses must be worn.
Remove any oil, grease, dirt, clay, snow,
2 05 73179380

the wheels or tracks and by setting the Unused but open bores, pipelines and
Set the working equipment on the ground pressure-tight manner.
in such a way that no movements can be Refill collected hydraulic oil back into the
made when mechanical or hydraulic con- hydraulic system only through the return-
nections become detached. flow filters.
perature, the consumables are at least at
the same temperature. Precautions must
therefore be taken to prevent burning or
scalding.
Be careful when handling acids, e.g. bat-
eyes and the skin.
liquids.
Be careful with open flames and unprotec-
ted light.
easily.
73179380 05 3

tions of the hydraulic excavator are for- - Check all oil levels and make the nec-
bidden for reasons of safety. essary corrections.
The nominal pressure of the pressure re- - Carry out function checks of all re-
lief valves must not be modified. paired components.
Do not remove the lead seals from - Check all functions of the excavator
pressure-relief valves and pressure accu- including the brakes during a test run.
mulators. Release the hydraulic excavator for re-
4 05 73179380
BLANK PAGE
73179380 05 5
BALL-BEARING SWING BEARING 2800740
Fig. 1

mm
1 1 Covering 9,3 / 21
2 1 Swing bearing 143 / 322
3 24 Spacer
4 26 Hex screw M 16x90 10.9 24 250 185
5 1 Seal
6 30 Hex screw M 16x65 10.9 24 250 185
7 30 Spacer
8 2 Washer
6 05 73179380
General information
The swing bearing of this machine is a single- The pinion of the swing gearbox engages in the
race ball bearing. It comprises a toothed outer teeth, allowing the superstructure to be swing on
raceway (1, Fig. 2), the inner raceway (2) and the the undercarriage.
balls running between them.
Lubricating nipples (3) are located on the circum-
The toothed outer raceway is secured to the un- ference of the swing bearing for lubrication of the
dercarriage with screws, and the inner raceway to slewing ring bearing. The teeth are lubricated
the superstructure (screws less in the swing gear- through a lubricating nipple at the A-frame (see
box area for design reasons). Owners Machine Manual).
Fig. 2
73179380 05 7
Dismantling / installing the ball-bearing swing ring 2800741
Tools and aids

Before the swing bearing can be replaced, the Also needed:
superstructure of the machine must be removed.
a spatula / three-square scraper to clean the
The following aids must be available for this pur- contact surfaces,
pose:
cleaning agent
two cranes (each with a load-bearing capacity
bonding agent (P/N 73171476) for bonding the
of 20.000 kg / 25 tons), support as in Fig. 3
ball-bearing slewing ring,
using lifting belts with a load-bearing capacity
of 20.000 kg (25 tons) to lift off the machine lubricating grease (P/N 73175845),
superstructure,
new fastening screws for the slewing ring (see
a crane and lifting tackle with a load-bearing spare-parts list)
capacity of at least 260 kg (600 lb) to lift and
move the ball-bearing slewing ring,
wrench / socket wrench, width across flats

24 mm,
torque wrench designed for a tightening torque

of 250 Nm (200 lbft).
Fig. 3
8 05 73179380
Dismantling the swing bearing

Depressurize hydraulic system.
Secure the undercarriage from inadvertent

Risk of accidents movement by chocking the tracks.
Lifting eyes are welded to some machine Take superstructure into the lifting tackle
components (e.g. to the counterweight (Fig. 3) and tighten lifting tackle, but do not lift
and to the boom). Never lift the entire superstructure.
machine by means of these eyes. They
are not designed for loads on this scale Disconnect all hydraulic lines to the undercar-
and may break. riage at the rotor.
The eyes may be used only for lifting the Dismantle the rotor locking element (Fig. 4).
respective component when installing it.
Fig. 4
73179380 05 9
Remove the bolts (6, Fig. 6) of ball-bearing Check the housing (1, Fig. 1) and seal (5) of
swing bearing at the superstructure. Keep the the swing bearing. Repair or replace if damag-
spacers (7) for re-use. The superstructure is ed.
now detached from the undercarriage.
Lift the superstructure carefully until the swing

gearbox pinion is free. Swing the superstruc-
ture away from the undercarriage.
Take the swing bearing into the lifting tackle

(Fig. 5) by inserting three lifting eye bolts at
120 degree intervals through the drilled holes
and holding them in place with nuts.
Remove the bolts (4, Fig. 6). Keep the spacers

(3) for re-use.
Lift the swing bearing from the undercarriage.
Fig. 5
Fig. 6
10 05 73179380
Installing the swing bearing

If a new swing bearing is to be installed, first Swing the bearing above the undercarriage,
remove the anti-corrosion coating. swing it above the contact surface without set-
ting it down. Screw in at least three new
Clean all contact surfaces on the superstruc- screws (4, Fig. 6) with spacers (3) as a guide.
ture and the undercarriage thoroughly. The Set down slewing ring carefully.
contact surfaces must be bright, dry and
grease-free. Remove any roughness and burrs. Remove lifting tackle from slewing ring.
Clean drilled holes in the undercarriage. Clean
the threaded holes on the superstructure care- Screw in the other new screws with the spac-
fully, checking threads and recutting them if ers and tighten crosswise with a torque wrench
damaged. (see table for tightening torque).
Mark tightened screws.
Apply a bonding agent (P/N 73171476) to the
contact surface on the undercarriage, using a Apply the bonding agent to the contact surface
paint roller, a hard brush or a plastic spatula. of the superstructure, as described above.
Apply grease generously to the teeth of the

swing bearing until the gaps between the teeth
are filled with grease.
Keep the bonding agent away from the
drilled holes. Any bonding agent in the Swing the superstructure above the undercar-
threads causes increased friction and con- riage and swing it above the swing bearing
sequently to invalidates the tightening without setting it down.
torque data.
Continue to lower the superstructure carefully,
guiding the pinion into the teeth.
Take the new swing bearing into the lifting
tackle. Turn inner and outer raceway until the Screw in at least three new screws (6, Fig. 6)
"S"-mark on the outer raceway is at 90 degrees with spacers (7) as a guide.
to the travelling direction, and the "S"-mark on Lower the superstructure carefully.
the inner raceway is opposite (Fig. 7).
Screw in the other new screws with spacers
and tighten crosswise with a torque wrench
(see table for tightening torque).
Mark tightened screws. (A screw cannot be
mounted in the slewing gearbox area for struc-
tural reasons).
Re-install the rotor locking element (Fig. 4).
Connect all hydraulic lines to the rotor.
Remove the lifting tackle from the superstruc-

ture.
Start up the machine and check all hydraulic

lines at the rotor for tightness.
Fig. 7
The bonding agent between slewing ring and
Swing bearings are hardened inductively. The undercarriage / superstructure increases the
"S"-mark marks those points between start and load capacity of the screwed connection while
end of raceway hardening, which, due to the sealing the joint gaps.
hardening process - could not be hardened. The The bonding agent hardens without exposure
swing bearing is therefore deliberately installed in to air. The ultimate strength is attained after six
such a way that those points are outside the hours. Only then may the machine be fully
main stress zone. loaded.
73179380 05 11
Swing gearbox pinion / Checking the tooth flank clearance on the swing ring
2800746
This work must be done only if the tooth flank If it does so, the manager signals to the oper-
clearance between the swing gearbox pinion and ator that he should swing the superstructure at
the swing bearing teeth are believed to be insuffi- minimum speed.
cient.
As soon as the lead strip is contacted by the
This may be the case, for example, if problems teeth, it must be released so that the hand is
have occurred in setting down the superstructure not caught in the teeth.
and securing it to the swing bearing. Swing the superstructure only until the lead
Insufficient tooth flank clearance may cause dam- strip has passed through the teeth (Fig. 8).
age to the swing bearing and swing gearbox.
Risk of injury
One person is under the machine while
the superstructure is being swing.
The following operations must be execut-
ed with extreme caution.
Three persons are needed: one sits on
the operators seat, one is under the su-
perstructure, and one acts as a manager.
All these persons must be within sight of
one another and be able to give and re-
ceive hand signals.
Remove the cover of the swing gearbox pinion.
Swing the superstructure until the teeth marked Fig. 8

with green paint are in front of the swing gear-
box pinion. Switch off the engine.
These green teeth mark the point where the
Measure the thickness of the lead strip; it
internal ring deviates most from the ideal circle,
should be at least 0.3+0.2 mm.
i.e. the part of the ring where the diameter is
smallest.
The person below the superstructure forces a

minimum 40 centimeter(12 inchs) long strip of
flat lead between the teeth of the pinion and of
the slewing ring.
The lead strip must run through the toothing
when the pinion engages in the green-marked
teeth (see Fig. 8).
12 05 73179380
BLANK PAGE
73179380 05 13
2800742
Fig. 1
14 05 73179380
ENGINE, INSTALLATION
Removing and installing the diesel engine
Legend to Fig. 1

mm
2 1 Bracket
3 1 Bracket
4 1 Engine with pumps ca. 600 /

env. 1323
6 8 Spacer
7 2 Spacer
8 8 Spacer
9 1 Combi-cooler water/oil
10 2 Hex screw M 10 10.9 17 60 44
11 8 Hex screw M 10 10.9 17 60 44
12 2 Hex screw M 16x1.5 10.9 24 250 184
13 8 Hex screw M 12 10.9 19 105 78
14 2 Washer
15 2 Bearing
General information
The diesel engine with the flange-mounted hy-
draulic pumps is resiliently mounted at three
points (Fig. 1): two brackets are bolted laterally
on the hydraulic pump side, and one bracket on
the opposite end face.
(Repair work on the engine is described in the

technical manual issued by the engine manufac-
turer).
73179380 05 15
Removing the diesel engine

The following aids must be available: Disconnect the batteries.
a crane and lifting tackle with a load-bearing Unscrew the holder for the compression
capacity of at least 1000 kg (1,5 tons) for lifting springs of the engine cover and fold the cover
and moving the engine, back towards the counterweight.
(Attention: the compression springs are preten-
lifting tackle matching the engine (see technical sioned).
manual issued by engine manufacturer),
Remove the housing plates from below the en-
wrench / socket wrench, width across flats 17, gine and the pump compartment.
19 mm and 24 mm,
Clean the engine.
a torque wrench designed for a tightening
torque of 250 Nm (185lbft). Mount lifting tackle for the engine (see tech-
nical manual issued by engine manufacturer).
Also needed:
Drain the hydraulic oil out of the hydraulic oil
a container to catch hydraulic oil (min. 200 l/55 reservoir and combi-cooler.
gal),
Drain the coolant out of the engine and the
a container to catch coolant (min. 35 l/10 gal), combi-cooler.
a standard tool kit for dismantling lines at the Disconnect the intake, pressure and control
hydraulic pumps. lines from the hydraulic pumps.
Disconnect the fuel, air and exhaust lines from

the engine.
Risk of injury from rotating fan blades and Disconnect all the electrical connections and
V-belts. Stop the engine before opening grounding wires from the engine.
the engine compartment.
Disconnect all the connections to the combi-
Risk of burns from hot parts of the en-
gine, exhaust system, hydraulic pumps cooler.
and coolers. Remove the bolts (12, Fig. 1) from the engine
Never start work until all components in bearings.
the engine compartment have cooled off.
Lift the engine and cooler out carefully.
Escaping consumables such as fuel, hy-

draulic oil, engine oil or coolant are an
environmental hazard.
Put adequately large containers in place
to catch them.
Catch drained-off fluids for re-use or dis-
card in accordance with environmental
regulations.
Close openings, lines and hoses.
This prevents contaminants from penetrat-
ing and damaging the engine and hydrau-
lic system.
16 05 73179380
Installing the diesel engine

Prior to installation:
Check the rubber bearings (15, Fig. 1) in the

brackets and the bolts of engine bearing; replace
if damaged.
Installation of the diesel engine is done in the

reverse sequence as the removal.
Align the engine.
Tighten the engine bearing bolts with a torque

wrench
(see table for tightening torques).
After installation:
Check the fuel, engine oil, coolant and hydraulic

oil level; top up if necessary.
Only then may the engine be started up.
Check all connections for tightness.
73179380 05 17
ENGINE, COUPLING 2800743
General information
The diesel engine output is transmitted to the The hub (1, Fig. 2) is pushed onto the splined
hydraulic pumps by means of a resilient coupling. shaft of the dual pump and secured with a clamp-
ing wedge (5). The clamping wedge is pressed
The coupling (4, Fig. 1) is fastened to the onto the splining with a stud (4).
flywheel of the engine.
Fig. 1

mm
1 1 Pump set 110 / 245
2 12 Hex screw M 10 x 35 10.9 17 60 44
3 8 Hex socket-head screw 3/8" - 16 8 Grade 1/2" 55 40
4 1 Coupling 10 / 22
5 1 Engine 450 / 992
18 05 73179380
Fig. 2

mm
1 1 Coupling hub
2 1 Intermediate ring
3 1 Coupling flange
4 1 Setscrew M10 x 20 45 H 8 26 19
5 1 Clamping wedge
73179380 05 19
Removing the coupling

The following aids must be available: Unscrew the holder for the compression
springs of the engine cover and fold the cover
a crane and lifting tackle with a load-bearing back towards the counterweight. (Attention:
capacity of at least 200 kg(500lb) for lifting and compression springs are pretensioned).
moving the engine,
Open the cover to the pump compartment.
a wrench / socket wrench, width across flats 17
mm, Unscrew the covering plates from below the
engine and pump compartment.
a hexagon-socket-screw key / hexagon-socket-
screw wrenches, width across flats 8 mm and Drain the hydraulic oil out of the hydraulic oil
1/2", reservoir and intake pipe.
a torque wrench designed for a tightening Disconnect the intake, pressure and control
torque of 60 Nm(45 lbft), lines from hydraulic pumps.
Also needed: Take the hydraulic pumps into a lifting tackle.
a container to catch hydraulic oil (min. 200 l/55 Remove the bolts (2, Fig. 1, page 20).
gal), Withdraw the hydraulic pumps from the cou-
a standard tool kit for dismantling lines at hy- pling and lift out.
draulic pumps. Remove the bolts (3) and remove the coupling
flange from the engine flywheel.
Loosen setscrew (4, Fig. 2, page 21).

Risk of injury from rotating fan blades and
Withdraw coupling hub (1) and resilient spacer
V-belts.
(2) from pump shaft.
Stop the engine before opening the en-
gine compartment.
Risk of burns from hot parts of the engine
and exhaust system,
hydraulic pumps and coolers.
Never start work until all components in
the engine compartment have cooled off.
Escaping consumables such as fuel, hy-

draulic oil, engine oil or coolant are an
environmental hazard.
Put adequately large containers in place
to catch them.
Catch drained-off fluids for re-use or dis-
card in accordance with environmental
regulations.
Close openings, lines and hoses.
This prevents contaminants from penetrat-
ing and damaging the engine and hydrau-
lic system.
20 05 73179380
Installing the coupling

Check all coupling components for damage;
replace any damaged components.
Push the coupling hub (1, Fig. 2) onto the

pump shaft as far as the limit stop, tighten the
setscrew (4) with a torque wrench
(see table for tightening torques).
Mount the coupling flange (4, Fig. 1) with the

bolts (3) on engine flywheel (see table for tight-
ening torques).
Insert resilient coupling element (2, Fig. 2).
Take the hydraulic pumps into the lifting tackle

and position them for installation so that the
coupling components engage.
Install the bolts (2, Fig. 1) and tighten them

with a torque wrench (see table for tightening
torques).
Connect the intake, pressure and control lines

to the hydraulic pumps.
Vent the air from the hydraulic pumps and the

hydraulic system (see Owners Manual).
73179380 05 21
Notes 2800145
22 05 73179380
T
B Tools and aids ...................................................... 8
BALL-BEARING SWING BEARING .................... 6
D
Danger in the event of non-obser-vance of the
Dismantling / installing the ball-bearing swing

ring........................................................................ 8
Dismantling the swing bearing .............................. 9
E
ENGINE, COUPLING ........................................ 18
ENGINE, INSTALLATION .................................. 15
F
Foreword .............................................................. 1
G
General information .................................. 7, 15, 18
I
Installing the coupling ........................................ 21
Installing the diesel engine ................................ 17
Installing the swing bearing ................................ 11
R
Removing and installing the diesel engine ........ 15
Removing the coupling ...................................... 20
Removing the diesel engine .............................. 16
Rules for safety at work ........................................ 2
S
Safety Instructions ................................................ 1
SUPERSTRUCTURE .......................................... 1
Swing gearbox pinion / Checking the tooth

flank clearance on the swing ring ...................... 12
Diesel engine
if required, engine manuals can be orederd.
73179380 06 1
BLANK PAGE
2 06 73179380
GEARBOXES ............................................................................................................................................ 1
Foreword.................................................................................................................................................... 1
Safety Instructions
Traveling Gearbox .................................................................................................................................... 5
Dismantling and Reassembling the Traveling Gearbox

Dismantling the Traveling Gearbox ........................................................................................................ 7
Reassembling the Traveling Gearbox .................................................................................................... 8
Swing Gearbox .......................................................................................................................................... 9
Dismantling and Reassembling the Swing Gearbox

Dismantling the Swing Gearbox ............................................................................................................ 11
Reassembling the Swing Gearbox ........................................................................................................ 11
Technical Handbook "Traveling Gearbox" .......................................................................................... 13
Technical Handbook "Swing Gearbox" ................................................................................................ 15

GEARBOXES 2796425


tact with it
spare parts.
73179380 07 1
Personnel Personnel
2 07 73179380

the wheels or tracks and by setting the Unused but open bores, pipelines and
Set the working equipment on the ground pressure- tight manner.
scalding.
eyes and the skin.
liquids.
ted light.
easily.
73179380 07 3

4 07 73179380
Traveling Gearbox
73179380 07 5
Dismantling and Reassembling the Traveling Gearbox 2800744
Fig. 1
Tabelle zu Fig. 1

mm
1 1 Traveling motor 26 / 57
2 18 Hex screw M16x55 10.9 24 3401) 2511)
3 18 Hex screw M16x45 10.9 24 250 184
4 18 Washer
5 1 Traveling gear 139 / 313
1)
Screws with liquid screw fixer, e.g. Loctite 242,
243.
6 07 73179380
Dismantling the Traveling Gearbox
The traveling gearbox must be dismantled to- Loosen the sprocket bolts (2, Fig. 1). Leave the
gether with the sprocket. Dismantle with the track sprocket fitted to the traveling gearbox with four
opened. hand-tight bolts.
Remove the traveling gearbox guard.
Disconnect the hydraulic lines from the travel-

ing motor (1, Fig. 2). Close open line openings
and housing ports.
Fig. 3
Release and open the track (refer to Chap-

ter 4).
Attach lifting tackle to the bore in the sprocket

Fig. 2 (see arrow, Fig. 3).
Loosen the traveling gearbox fixing bolts (3,

Fig. 1 - 3), remove the gearbox and the sprock-
et.
Take off the sprocket.
73179380 07 7
Reassembling the Traveling Gearbox

Thorougly remove any paint and grease from Mount the chain wheel.
the seating surfaces (A and B, Fig. 1) of the Turn the slightly oiled bolts (2, Fig. 4) in and
undercarriage frame, the sprocket and the trav- tighten them.
eling gearbox with thinner (Item No. 73171477).
Then check for damage. Proceed crosswise, mark tightened bolts.
Seating surfaces must be bright, dry and free
Re-close the track.
of grease.
Join the sprocket and the traveling gearbox and

align them.
Fix the sprocket to the gearbox by four bolts (2,

Fig. 1). Tighten the bolts by hand.
To make easier joining the traveling gearbox

into the frame, screw one M 20 x 1.5 stud bolt
into a tapped hole in the longitudinal beam for
guidance.
Apply a ring of adhesive (Item No. 73176144)

of about 1 mm in thickness around each
tapped gearbox bolt hole.
Fig. 4
Attach lifting tackle to the bore in the sprocket
(see arrow, Fig. 3), bring to fitting position and Re-connect the hydraulic lines (Fig. 2) and re-fit
align. the traveling gearbox guard.
Secure the traveling gearbox to the frame by Bleed the parking brake.
turning in a few hexagon bolts (3, Fig. 1 - 3).
Place sleeves (4) over all slightly oiled gearbox
bolts (3), turn them in and tighten them.
Proceed crosswise, mark tightened bolts.
Remove the sprocket bolts (2) and pull off the

chain wheel. Apply adhesive (Item No.
73176144) around each tapped hole.
Apply the adhesive at some distance to

the holes so that no adhesive can get to
the threads when the parts are joined.
Do not apply the adhesive before the
sprocket and the gearbox are ready for
assembling.
8 07 73179380
Swing Gearbox
73179380 07 9
Dismantling and Reassembling the Swing Gearbox 2800745
Fig. 5

mm
1 1 Line
2 1 Expansion reservoir
3 1 Speed sensor
4 1 Brake line
5 4 Hex. screw M10 10.9 17 801) 591)
6 12 Cyl. screw M16 10.9 16 250 184
7 1 Swing gearbox 80 / 182
8 2 Eye bolt
1)
10 07 73179380
Dismantling the Swing Gearbox Reassembling the Swing Gearbox

Disconnect the line (1, Fig. 1) of the expansion Thorougly remove any paint and grease from
reservoir (2) and close immediately to prevent the seating surfaces (A, Fig. 1) of the swing
any oil from escaping. gearbox and the superstructure frame with thin-
ner (Item No. 73171477). Then check for dam-
Disconnect the speed sensor (3). age.
Disconnect the line (4) for the superstructure Seating surfaces must be bright, dry and free
holding brake and close immediately. of grease.
Remove the bolts (5) and take off the swing Apply a ring of adhesive (Item No. 73171476)
motor. The motor can be placed onto the frame of about 1 mm in thickness around each
with its hydraulic lines connected. Manipulation tapped bolt hole (seating surface A of the su-
in the hydraulic system is thus not necessary. perstructure frame).
Remove the fixing bolts (6, Fig. 2).
Attach lifting tackle to the eye bolts (8) on the

swing gearbox (7) and dismantle. Apply the adhesive at some distance to
the holes so that no adhesive can get to
the threads when the parts are joined.
Do not apply the adhesive before the
gearbox is ready for assembling.
Attach lifting tackle to the gearbox, bring to

fitting position and set down without displace-
ment.
Turn in and tighten the bolts (6).

Proceed crosswise, mark tightened bolts.
Re-connect the line (1, Fig. 1) of the expansion

reservoir (2) and top up the gearbox with oil
according to the Operating Instructions.
Brush some lubricating paste (Item No.

73171484) over the driving pinion of the swing
motor and fit the motor.
Fig. 6 Secure the bolts (5) with liquid srew locking

agent (P/No. 73171473) and tighten.
Re-connect the brake line (4) and bleed the

superstructure holding brake.
73179380 07 11
BLANK PAGE
12 07 73179380
Technical Handbook "Traveling Gearbox"
73179380 07 13
BLANK PAGE
14 07 73179380
Technical Handbook "Swing Gearbox"
73179380 07 15
BLANK PAGE
16 07 73179380
D
Dismantling and Reassembling the Swing

Gearbox .............................................................. 10
Dismantling and Reassembling the Traveling

Gearbox ................................................................ 6
Dismantling the Swing Gearbox ........................ 11
Dismantling the Traveling Gearbox ...................... 7
F
Foreword .............................................................. 1
G
GEARBOXES ...................................................... 1
R
Reassembling the Swing Gearbox .................... 11
Reassembling the Traveling Gearbox .................. 8
S
Swing Gearbox .................................................... 9
T
Technical Handbook "Swing Gearbox" .............. 15
Technical Handbook "Traveling Gearbox" .......... 13
Traveling Gearbox ................................................ 5

Traveling Gearbox
Type F 17, F 20, F 25, F 30
2 796 999.00 us
FOREWORD .............................................................................................................................................. 1
DESCRIPTION .......................................................................................................................................... 3
GENERAL SAFETY INSTRUCTIONS ...................................................................................................... 4
Safety Instructions
General Working Instructions .................................................................................................................. 6
TRAVELING GEARBOX,
Preparatory Work .................................................................................................................................... 7
Dismantling the Traveling Gearbox on the Machine, after removing the track and drive sprocket .......... 8
Assembling the Travelling Gearbox ...................................................................................................... 16
Start-Up .................................................................................................................................................... 26
Multi-Disk Brake
Repairing the Brake .............................................................................................................................. 27
Removing the Multi-Disk Brake ............................................................................................................ 27
Replacing the Seals and the Disks ........................................................................................................ 27
Fitting the Multi-Disk Brake.................................................................................................................... 28
ANNEX .................................................................................................................................................... 29
Travelling Gearbox Components .......................................................................................................... 30
Multi-Disk Brake Components .............................................................................................................. 32
Screws, Tightening Torques and Locking ............................................................................................ 34
Special Tools and Accessories

Special Tools ........................................................................................................................................ 36
Sealing Compound and Locking Agent ................................................................................................ 36
Screw Tightening Torques

Bolts with standard thread .................................................................................................................... 37
Notes ........................................................................................................................................................ 39
TRAVELING GEARBOX
FOREWORD 2796435
With respect to the assembling sequence, the

travelling gearboxes are of identical design. Di-
mensions, weights, filling quantities and also the
number of individual components differ. This re-
sults in different setting dimensions, tightening
torques and special tools.
Deviations from the illustrations may occur.
2 796 999.00 us 1
TRAVELING GEARBOX
Fig. 1
2 2 796 999.00 us
TRAVELING GEARBOX
DESCRIPTION 2716766
The F 17, F 20, F 25, F 30 series gearboxes are The standard design of these gearboxes includes
three-stage planetary gear sets. an integrated multi-disk brake which serves as
stopping brake. It is actuated by spring force and
They are used as traveling gearboxes for ma- lifted by hydraulic oil.
chines with track traveling mechanisms and for
other applications. The hub of the brake is interlocked with the fixed
These gearboxes have the function of transmit- axle tube of the traveling gearbox, and the sleeve
ting high speeds and relatively low torques of the of the brake is connected with the drive shaft by
hydraulic motor into low speeds and high torques. spline shaft profile.
The gearboxes stand out for a particularly com- Compression springs press together outer and
pact and space-saving design. inner disks to create a non-positive connection
between the hub and the sleeve of the brake.
The hydraulic motor has been integrated into the The drive shaft is braked.
gearbox to such an extent as to be in a protected
position within the track width when used in hy- Actuating the "traveling" function applies, at the
draulic excavators. same time, pressure oil to the brake. The piston
will fully move against the cylinder cover, the
inner disk and the brake sleeve will be released.
The drive shaft will rotate without being braked.
2 796 999.00 us 3
TRAVELING GEARBOX
GENERAL SAFETY INSTRUCTIONS 2796419
Precautions and measures to protect the Check the Condition of Your Tools
repair personnel and other persons from
Do not use any tools that are not service-
life-threatening riskes or injuries and to
able and reliable.
prevent major damage to property.
Choose the tool suitable for your corre-
sponding work.
Improperly fitting wrenches may, for exam-
ple, slip off and cause injuries.
Instructions and precautions to prevent
damage to property.
Cleaning
Safety Instructions Clean the aggregates located within your
working range prior to beginning your
work.
Cleaning agents and solvents may pro-
Repair Personnel duce harmful and easily flammable vap-
ours.
The repair personnel must have special
knowledge and experience in the repair of Do not work with such agents in environ-
these or comparable gearboxes. ments that are not well ventilated, do not
inhale such vapours, do not smoke.
Avoid contact of your skin with solvents
Secure the Machine and cleaning agents.
Do not perform any repair work if the ma- Wear solvent-proof gloves.
chine is not properly secured and its com- Observe the instructions on the packing.
ponents are disengaged.
The Operating Instructions of the machine
provides clear information thereon.
Fasteners and Securing Elements

Personal Protecting Equipment and Check fasteners and securing elements
Workwear such as screws, nuts and washers before
re-using them.
Wear tight workwear when working on the
machine. Loose, wide clothes may catch Replace damaged parts.
on parts of the machine and cause in-
juries.
Wear a safety helmet, safety shoes, safety
gloves, safety glasses and, in case of
noise, ear protection.
4 2 796 999.00 us
TRAVELING GEARBOX
Handling Oil and Grease Environmentally Favorable Disposal

Contact of your skin with waste oil may be Dispose of oil, grease, cleaners, solvents
dangerous to your health. and oily components such as filters,
Avoid skin contact. Wear gloves and close cleaning rags, replaced wear parts and
workwear. useless machine parts in an environmen-
tally favourable manner and separate of
Thoroughly wash soiled skin with warm one another.
soap water and apply protective skin
cream. Do not use fuel or solvents to Do not add such materials to your normal
clean your skin. domestic waste.
If you have swallowed oil, do not vomit Fill such materials into the containers pro-
and consult a doctor immediately. vided for them.
Do not let oil and oily waste penetrate into
the ground or into waters to prevent pollu-
Apparent Oil Loss tion of the environment.
In case of apparent oil loss, repair the
leakage (or have it repaired) immediately.
Leaking oil endangers the environment!
Remove leak oil by an absorbent. Take the
oil absorbent and do not dispose of to-
gether with other waste.
2 796 999.00 us 5
TRAVELING GEARBOX
General Working Instructions 2796436
Clean all parts in suitable cleaner after Oil shafts, bearings, bushings etc. before
dismantling. Do not use water or a steam pressing them in.
jet as this will cause rust formation. Always replace seals such as O-rings.
Remove old sealing compound. Strictly observe all setting dimensions,
Mark screwed parts such as covers before test data and tightening torques for reas-
separating them. sembling.
Thoroughly check parts subject to wear Do not alter factory settings if bearings
such as bearings, thrust washers, if they and/or gears are not replaced.
are to be re-used. The inspection of an- Replace worn-out and defective compo-
tifriction bearings requires particular spe- nents in due time.
cial knowledge.
Do not use any parts other than ORIGINAL
Check gears for wear and the beginning of SPARE PARTS.
cracks.
All tools and measuring devices must be
Replace bearings damaged or destroyed in good condition.
during dismantling. Also, always replace
the outer race of tapered roller bearings.
Heat up bearings on heating plates or in
ovens if prescribed. Never heat up with an
open flame.
Shrunk-on parts must be re-driven after
cooling down to obtain proper fit.
6 2 796 999.00 us
TRAVELING GEARBOX
TRAVELING GEARBOX,
F 17, F 20, F 25, F 30 MODEL 2732975
Preparatory Work
Park the machine on a solid, level surface.
Secure the machine as described in the Op-
erating Instructions.
Open the chain on top in front of the sprocket
and let down to the ground and deposit.
Force up both travelling gearboxes and support
the undercarriage by suitable pieces of squared
timber.
Remove the sprocket.
2 796 999.00 us 7
TRAVELING GEARBOX
Dismantling the Traveling Gearbox on the Machine, after removing the track and
drive sprocket 2732976
Fig. 1
Drain the oil.
Fig. 2
Remove the traveling motor and place on a clean
support. Do not disconnect the hydraulic hoses
from the travelling motor if their length allows for
removal.
Fig. 3
Loosen the screws from the cover and remove.
Mark the cover and the case so it will be assem-
bled in the same location.
Fig. 4
Loosen the cover carefully.
8 2 796 999.00 us
TRAVELING GEARBOX
Fig. 5
Lift off the cover, remove the O-ring.
Fig. 6
Extract planetary stage 1 with the input shaft by
hand.
Fig. 7
Extract planetary stage 2.
Fig. 8
Extract planetary stage 3.
2 796 999.00 us 9
TRAVELING GEARBOX
Fig. 9
Loosen both fillister-head screws in the ring gear
by hard blows.
The screws are secured with Loctite.
Fig. 10
Turn out the fillister-head screws.
Fig. 11
Loosen the ring gear from the hub by hard blows.
Fig. 12
Take off the ring gear.
10 2 796 999.00 us
TRAVELING GEARBOX
Fig. 13
Remove the O-ring.
Fig. 14
From the opposite side (traveling motor), drive in
the brake with one or two light bumps, using an
aluminium or copper punch, so that the snap ring
is uncovered.
Fig. 15
Remove the snap ring with a bent scriber.
Fig. 16
Drive the brake out of the axle tube.
2 796 999.00 us 11
TRAVELING GEARBOX
Fig. 17
Lift out the brake by means of two long M6
screws. For rebuild information, refer to page 27.
Fig. 18
Drive the four locking points of the slotted round
nut out of the axle tube grooves by means of a
suitable cross-cut chisel.
Fig. 19
Slacken the slotted round nut with special span-
ner S2.
Fig. 20
Unscrew the slotted round nut with a pin spanner.
12 2 796 999.00 us
TRAVELING GEARBOX
Fig. 21
Remove the shim rings.
Fig. 22
Separate the hub from the axle tube by means of
two long-thread M 12 x 100 screws.
Fig. 23
Take off the hub.
Fig. 24
Remove the inner ring of the tapered roller bear-
ing from the hub.
2 796 999.00 us 13
TRAVELING GEARBOX
Fig. 25
Lever the slide ring out of the hub. Mind the seat
of the O-ring.
Improper seating of the O-rings, deformation or
pinching are causes of premature leakage on the
slide ring seal.
Fig. 26
Lever the second half of the slide ring seal off the
axle tube with a screwdriver.
Also mind the seat of the O-ring.
Fig. 27
Remove the O-rings from the slide rings
Thoroughly inspect the sealing faces of the two
slide rings. The rings have been lapped in pairs.
Even the slightest, hardly visible damage makes
the leakage reappear after reassembling.
14 2 796 999.00 us
TRAVELING GEARBOX
Always replace a slide ring seal after a running

time of 1500 hrs.
If slide rings are still in exellant condition, replace
the O-rings in any case.
For ordering numbers, please refer to the List of
Spare Parts.
Check the tapered roller bearing and replace, if
necessary. For gear repairing on site, tapered
roller bearings only have to be replaced rarely.
If necessary, rework the thread on the axle tube
with a thread restorer and clean thoroughly.
Always replace the slotted round nut!
Try on a new slotted round nut and the adjusting
nut (S1).
The new slotted nut must go freely across the
entire thread length of the axle tube.
Thoroughly debur the snap ring groove and the
pocket (brake oil duct) in the axle tube.
Clean and check all parts.
2 796 999.00 us 15
TRAVELING GEARBOX
Assembling the Travelling Gearbox 2796437
Fig. 28
16 2 796 999.00 us
TRAVELING GEARBOX
Fig. 29
Screw a new slotted round nut onto the axle tube
and fully tighten. Mark or, if possible, scribe this
position on the position of the axle tube and on
the flared flange of the slotted round nut. Remove
the slotted round nut.
Fig. 30
Place one slide ring of the slide ring seal onto the
axle tube together with the O-ring and press the
O-ring into the axle tube by means of a rounded
punch, at the same time applying some pressure
to the slide ring with your other hand.
Both rings of the slide ring seal as well as the
hub and the axle tube have small, plain shoulders
which ensure the proper position of the O-rings
(refer to the arrows in Fig. 28). The O-ring must
be pressed in carefully in small steps and in a
twist-free manner. Applying some pressure to the
slide ring by a second person is of advantage.
When the slide ring stays at its pressed-in posi-
tion, repress the O-ring all around and bring into
a uniform position.
Fig. 31
Check the seating and the pressure of the O-ring
by applying strong pressure to the slide ring.
2 796 999.00 us 17
TRAVELING GEARBOX
Fig. 32
Insert the second slide ring with the O-ring into
the hub in the same way.
The O-ring must be pressed in carefully in small
steps and in a twist-free manner.
When the slide ring stays at its pressed-in posi-
tion, repress the O-ring all around and bring into
a uniform position.
Fig. 33
Check the seating and the pressure of the O-ring
by applying strong pressure to the slide ring.
Clean the slide rings with a cleaning rag and oil.
Fig. 34
Place the hub onto the axle tube, press against
the rear tapered roller bearing and hold at this
position.
Excessive movement of the hub may entail
damage to the slide ring seal.
Holding the hub at this position by a second
person is of advantage.
Fig. 35
Insert the inner ring of the front tapered roller
bearing.
18 2 796 999.00 us
TRAVELING GEARBOX
Fig. 36
Drive the inner ring onto the seat of the axle
tube.
Fig. 37
Screw on adjusting nut S1.
Fig. 38
Apply special key S2 and have it held by a
second person.
Fig. 39
Tighten the adjusting nut with a torque spanner
(3/4" drive).
The following tightening torque values are speci-
fied for the adjustment of the initial tension of the
bearing:
Gearbox Tightening Torque MA

Model Nm (lbft)
F 17, F 20, F 25, 840 +

_ 25
F 30 (620 +
_ 18)
Remove spanner S2.
2 796 999.00 us 19
TRAVELING GEARBOX
Fig. 40
By means of a depth slide gauge, measure di-
mension B through the window of adjusting nut
S1 between adjusting nut S1 and the inner ring of
the tapered roller bearing; refer to Fig. 40.
Set digital depth slide gauge to "0".
Then, determine dimension A between the adjust-
ing nut and the axle tube.
Difference C = A - B
Record dimension C.
Read dimension C off the digital depth slide
gauge.
Remove adjusting nut S1.
Fig. 41
Fig. 42
Use a depth slide gauge and measure the collar -
dimension D - on the slotted round nut marked
before and record. Refer to Fig. 41.
Calculating the shim rings
X=D-C
Example:
D 5.60 mm
C - 5.12 mm
X 0.48 mm
Reounded up 0.50 mm
1 shim ring 0.30 mm
1 shim ring 0.20 mm
Always round up the calculated value.
Keep the number of shim rings fitted as small as
possible.
20 2 796 999.00 us
TRAVELING GEARBOX
Fig. 43
Fig. 44
Measure the shim rings.
Grease the shim rings and place them onto the
slotted round nut.
Always place the thicker shim ring towards the
slotted round nut. For three and more shim rings,
place the thinner one in the middle.
Fig. 45
Screw the slotted round nut with the shim rings
onto the axle tube.
2 796 999.00 us 21
TRAVELING GEARBOX
Fig. 46
Apply special spanner S2.
Tighten the slotted round nut until the marks pre-
viously made on the slotted round nut and the
axle tube, refer to Fig. 29, agree with each other.
This can be seen through the window in spanner
S2.
Fig. 47
Drive on the slotted round nut by applying ham-
mer shanks to special spanner S2
Fig. 48
Until the distance between the marks on the slot-
ted round nut and the axle tube is 10 - 15 mm.
Remove special spanner S2.
Fig. 49
Lock the slotted ring nut. For this purpose,
strongly stake the flared flange of the nut into the
four grooves of the axle tube.
22 2 796 999.00 us
TRAVELING GEARBOX
Fig. 50
Replace the seals on the brake.
Keep the positions of the seals as shown. Before
and behind the brake oil duct, the O-rings (163 +
164) are located, followed by the back-up rings
(162 + 165).
For F 17, F 20, F 25, F 30 traveling gearbox, one
steel ring (166) must be added as shown.
Offset the joints of the backing ring (165) and the
steel ring (166) by 180.
Oil the seals well.
Fig. 51
Lift the disk brake removed.
For this purpose, slowly and uniformly tighten two
M6 hexagon nuts on the long screws inserted for
dismantling until the piston sits on the cylinder
cover.
Fig. 52
Carefully insert the brake with the aid of the long
screws without damaging the seals.
Do not remove the screws (assembling aid).
Leave the brake lifted for fitting planetary stage I.
Fig. 53
Fully drive in the brake by light bumps, using an
aluminium or copper punch.
2 796 999.00 us 23
TRAVELING GEARBOX
Fig. 54
Insert the snap ring.
Offset the opening of the snap ring with respect
to the brake oil duct hole in the axle tube.
Fig. 55
Attach planetary stage 3.
Fig. 56
Neuen O-Ring einlegen und olen.

Fig. 57
Fit the axle tube with a new O-ring.
24 2 796 999.00 us
TRAVELING GEARBOX
Fig. 58
Secure the ring gear fastening screws with liquid
screw locking agent (P/No. 73171473) and tight-
en.
For the tightening torque, refer to Table 1 in the
Annex.
Fig. 59
Insert planetary stage 2.
Fig. 60
Insert planetary stage 1.
Insert the drive shaft and turn the shaft until the
teeth engage.
Fig. 61
Fit the cover with a new O-ring. Seal the parting
line between the cover and the ring gear with
cement (P/No. 73171476).
2 796 999.00 us 25
TRAVELING GEARBOX
Fig. 62
Turn in the screws and tighten.
Annex.
Fig. 63
Remove both M6 screws from the brake piston.
Fig. 64
Fit the travelling motor with a new O-ring.
Secure the ring gear fastening screws with liquid
screw locking agent (P/No. 73171473) and tight-
en.
Annex.
Start-Up
Fill the gearbox with gear oil according to the
Operating Instructions.
Vent the brake.
For this purpose, loosen the screwing of the
brake line on the gearbox for approx. one turn.
Then, by activating the "travelling right" or "trav-
elling left" functions, apply brake pressure and
allow the brake oil to come out until it emerges
free of bubbles.
26 2 796 999.00 us
TRAVELING GEARBOX
Multi-Disk Brake 2796438
Repairing the Brake

Fig. 1
Repairing the brake is restricted to:
replacing the seals when the oil level in the
traveling gearbox increases due to hydraulic oil
flowing in from the brake.
replacing the disk pack when the machine
keeps rolling on an inclined plane even though
the brake pressure is released.
Check the disks for wear when replacing the

seals.
Replace the seals when changing the disk pack.
Removing the Multi-Disk Brake

Refer to "Dismantling the Traveling Gearbox".
Replacing the Seals and the Disks

Fig. 2
The snap ring (155) and the cylinder cover

are under high spring load!
Uniformly pull the piston against the cover by

means of two M 6 x 20 fillister-head screws.
Same operation as lifting the brake. This will lock
the springs.
Remove the snap ring.
Pull the cylinder cover and the piston.
Remove the seals from the piston and the cyl-
inder.
Remove the outer and inner disks and check for
wear; replace the entire disk pack, if necessary.
Compare the number of disks removed with the
number of new ones.
When inserting new disks, begin and finish with
an outer disk.
Insert new seals into the grooves in the piston
and the cylinder.
2 796 999.00 us 27
TRAVELING GEARBOX
To make assembling easier, the Glydrings can be

warmed up to 176F in oil or water. The expan-
sion thus caused will reset after a short time, i. e.
place the warmed-up Glydring onto the piston,
but do not press the piston into the S3 mounting
sleeve or into the cylinder, respectively, before
the Glydring has "shrunk" back at room tempera-
ture.
Oil the new seals well.
Fig. 3
Push mounting sleeve S3 over the piston and the
Gydring into the direction of the arrow until the
piston protrudes 2 mm(1/16").
Fig. 4
Use mounting sleeve S3 to place the piston in
front of the hub and press the piston into the hub.
Insert the cylinder cover and re-press.
Insert the snap ring.
Remove both M 6 x 20 fillister-head screws.
For replacing the outer seals, refer to chapter
"Assembling the Traveling Gearbox".
Fitting the Multi-Disk Brake

Refer to "Assembling the Traveling Gearbox".
28 2 796 999.00 us
TRAVELING GEARBOX
ANNEX 2796439
2 796 999.00 us 29
TRAVELING GEARBOX
Travelling Gearbox Components
Fig. 1
30 2 796 999.00 us
TRAVELING GEARBOX
Item Qty. Description
001 1 Gearbox, Compl.

101 1 Planet Carrier
104 1 Ring Gear
105 1 Cover
108 1 Pinion
109 1 Pinion
110 1 Pinion
114 1 Thrust Washer
120 1 Axle Tube
121 1 Hub
122 1 Tapered Roller Bearing
123 1 Tapered Roller Bearing
126 1 Slotted Round Nut
129 1 Slide Ring Seal
131 1 Shim Ring, 0.1 mm
150 1 Brake
155 1 Snap Ring
162 1 O-Ring
163 2 Back-Up Ring
164 1 O-Ring
165 1 Back-Up Ring
180 12 Fillister-Head Screw
181 1 O-Ring
182 1 O-Ring
184 2 Fillister-Head Screw
185 1 O-Ring
190 2 Screw Plug
201 1 Set of Spur Gears
202 1 Thrust Washer
301 Set of Spur Gears
302 1 Thrust Washer
401 1 Set of Spur Gears
402 1 Thrust Washer
403 1 Travelling Motor
404 2 Hexagon Screw
2 796 999.00 us 31
TRAVELING GEARBOX
Multi-Disk Brake Components
Fig. 2
32 2 796 999.00 us
TRAVELING GEARBOX
Item Qty. Description
002 1 Brake, Compl.

003 1 Locking Ring
004 1 Hub
005 11 Outer Disk
006 10 Inner Disk
007 1 Sleeve
008 1 Seal
009 1 Piston
010 1 Seal
011 14 Compression Spring
012 14 Compression Spring
013 1 Cylinder Cover
014 1 Snap Ring
2 796 999.00 us 33
TRAVELING GEARBOX
Screws, Tightening Torques and Locking
Fig. 3
34 2 796 999.00 us
TRAVELING GEARBOX
Table 1
Gearbox Model: F 17, F 20, F 25, F 30
Screw Thread Quality Tightening Torque MA Screw Locking

Item (mm) Nm (lbft) P/No. 73171473
126 M 135 x 2 - - 1)
180 M8 12.9 40 (30) X
184 M 12 8.8 94 (69) X
190 M 16 x 1,5 - 35 (25) -
404 M 16 8.8 230 (170) X
1) Lock slotted round nut by staking.
2 796 999.00 us 35
TRAVELING GEARBOX
Special Tools and Accessories

Table 2
Special Tools
Adjusting Nut S1 - M 135 x 2 : P/No. 73176138
Special Spanner S2 (Fig. 1) : P/No. 73176142
Mounting Sleeve S3 (for brake : P/No. 73176139
seal)
Fig. 1
Table 3
Sealing Compound and Locking Agent
Liquid Screw Locking Agent : P/No. 73171473
3
- Container size 10 cm : P/No. 73171475
Sealing Compound / Cement : P/No. 73171476

- Container size 50 gr : P/No. 73176140
- Container size 250 gr : P/No. 73176141
36 2 796 999.00 us
TRAVELING GEARBOX

Bolts with standard thread DIN 13, sheet 33 (e.g. DIN 912, 931, 934)
Thread Material Tightening torques MA in Nm

1)
0.10 0.122) 0.16 (L)3)
M5 8.8 4.9 5.5 6.5

10.9 7.3 8.1 9.5
12.9 8.5 9.5 11.2
M6 8.8 8.5 9.5 11.2

10.9 12.5 14 16.5
12.9 14.5 16.5 19.5
M8 8.8 20.5 23 27
10.9 30 34 40
12.9 35 40 47
M 10 8.8 41 46 55
10.9 60 68 80
12.9 71 79 94
M 12 8.8 71 79 94
10.9 104 117 140
12.9 195 215 260
M 16 8.8 170 195 230

10.9 250 280 340
12.9 300 330 400
M 20 8.8 350 390 470

10.9 490 560 670
12.9 580 650 780
M 24 8.8 600 670 800

10.9 850 960 1140
12.9 1000 1120 1350
M 30 8.8 1190 1350 1600

10.9 1700 1900 2300
12.9 2000 2250 2700
M 36 8.8 2100 2350 2800

10.9 3000 3300 4000
12.9 3500 3900 4700
1)
2)
Screw black-plated or phophatized, thread oiled.
3)
2 796 999.00 us 37
TRAVELING GEARBOX

0.101) 0.122) 0.16 (L)3)
M 8x1 8.8 22 24.5 30
10.9 32 36 43
12.9 38 43 51
M 10x1 8.8 45 52 62
10.9 67 76 91
12.9 78 89 107
M 10x1.25 8.8 43 49 58
10.9 64 72 86
12.9 74 84 100
M 12x1.25 8.8 77 87 104

10.9 112 125 150
12.9 130 150 180
M 14x1.5 8.8 121 135 165

10.9 175 200 240
12.9 205 235 280
M 16x1.5 8.8 180 205 250
10.9 270 300 370
12.9 310 360 430
M 20x1.5 8.8 380 430 530

10.9 540 620 750
12.9 630 720 880
M 22x1.5 8.8 510 580 700

10.9 720 820 1000
12.9 840 960 1170
M 24x2 8.8 640 730 890

10.9 920 1040 1250
12.9 1070 1220 1500
M 27x2 8.8 940 1070 1300

10.9 1350 1500 1850
12.9 1550 1800 2150
M 30x2 8.8 1370 1490 1740

10.9 1940 2120 2480
12.9 2270 2480 2900
1)
2)
3)
38 2 796 999.00 us
TRAVELING GEARBOX
Notes
2 796 999.00 us 39
TRAVELING GEARBOX
40 2 796 999.00 us
Swing Gearbox
Type S 5, S 10
S 13, S 16
2 800 600.00 us
FOREWORD .............................................................................................................................................. 1
DESCRIPTION .......................................................................................................................................... 3
GENERAL SAFETY INSTRUCTIONS ...................................................................................................... 4
Safety Instructions.................................................................................................................................... 4
Swing gearboxes, types S 5, S 10, S 13, S 16

Preliminary measures .............................................................................................................................. 6
Dismantling the swing gearbox .............................................................................................................. 7
Assembling the swing gearbox .............................................................................................................. 13
Multiple-disk brake
Repairing the brake .............................................................................................................................. 29
Dismantling the multiple-disk brake ...................................................................................................... 29
Dismantling the multiple-disk brake S5/S10 .......................................................................................... 29
Assembling the multiple-disk brake S5/10 ............................................................................................ 30
Dismantling the multiple-disk brake S13/16 .......................................................................................... 32
Assembling the multiple-disk brake S13/16 .......................................................................................... 33
Installing the multiple-disk brake .......................................................................................................... 34
Bleeding the brake ................................................................................................................................ 34
ANNEX .................................................................................................................................................... 35
Swing gearbox components

Swing gearbox S 5, S 10 ...................................................................................................................... 36
Multiple-disk brake S 5, S10 .................................................................................................................. 38
Swing gearbox S 13, S 16 .................................................................................................................... 40
Multiple-disk brake S 13, S 16 .............................................................................................................. 42
Screws, tightening torques and screw fixer

Swing gearbox S 5, S 10 ...................................................................................................................... 44
Swing gearbox S 13, S 16 .................................................................................................................... 44

Bolts with standard thread .................................................................................................................... 46
Special tools and accessories

Special tools .......................................................................................................................................... 48
Sealing and securing compounds ........................................................................................................ 48
Cover (S2) ............................................................................................................................................ 49
Notes ........................................................................................................................................................ 53
SWING GEARBOX
FOREWORD 2796834
All swing gearboxes are subject to the same

assembly procedures. They differ only in dimen-
sion, weight, filling quantities and also in the num-
ber of individual parts and therefore require dif-
ferent setting tolerances, tightening torques and
special tools.
The gearboxes may deviate from those shown in

the pictures.
2 800 600.00 us 1
SWING GEARBOX
Fig. 1
2 2 800 600.00 us
SWING GEARBOX
DESCRIPTION 2796837
The swing gearboxes S 5, S 10 and S 13, S 16 The standard multiple-disk brake installed serves
are compact, two-stage planetary gears. The as a holding brake which is actuated by a com-
swing pinion engages the toothing of the swing pression spring and released hydraulically with oil
bearing between superstructure and undercar- under pressure. The multiple-disk brake is used
riage. This device permits swinging of the su- to hold the superstructure in place when it is
perstructure through 360. Depending on size, the already stationary and not to brake the super-
machine may also be equipped with two or more structure while it is still turning. The revolving
swing gearboxes at the same time. motion of the input shaft is monitored by a sensor
preventing the brake from being operated with the
The gearboxes are designed in such a way that shaft still turning.
swinging is started and stopped by an axial-piston
hydraulic motor. The gearbox also permits hy-
draulic "countering", i.e. reversing the direction of
movement while the superstructure is still in mo-
tion.
2 800 600.00 us 3
SWING GEARBOX
GENERAL SAFETY INSTRUCTIONS 2796419
Precautions and measures to protect the Check the Condition of Your Tools
repair personnel and other persons from
Do not use any tools that are not service-
life-threatening riskes or injuries and to
able and reliable.
prevent major damage to property.
Choose the tool suitable for your corre-
sponding work.
Improperly fitting wrenches may, for exam-
ple, slip off and cause injuries.
Instructions and precautions to prevent
damage to property.
Cleaning
Safety Instructions Clean the aggregates located within your
working range prior to beginning your
work.
Cleaning agents and solvents may pro-
Repair Personnel duce harmful and easily flammable vap-
ours.
The repair personnel must have special
knowledge and experience in the repair of Do not work with such agents in environ-
these or comparable gearboxes. ments that are not well ventilated, do not
inhale such vapours, do not smoke.
Avoid contact of your skin with solvents
Secure the Machine and cleaning agents.
Do not perform any repair work if the ma- Wear solvent-proof gloves.
chine is not properly secured and its com- Observe the instructions on the packing.
ponents are disengaged.
The Operating Instructions of the machine
provides clear information thereon. Fasteners and Securing Elements
Check fasteners and securing elements
such as screws, nuts and washers before
Personal Protecting Equipment and re-using them.
Workwear Replace damaged parts.
Wear tight workwear when working on the
machine. Loose, wide clothes may catch
on parts of the machine and cause in-
juries.
Wear a safety helmet, safety shoes, safety
gloves, safety glasses and, in case of
noise, ear protection.
4 2 800 600.00 us
SWING GEARBOX
Handling Oil and Grease Environmentally Favorable Disposal

Contact of your skin with waste oil may be Dispose of oil, grease, cleaners, solvents
dangerous to your health. and oily components such as filters,
Avoid skin contact. Wear gloves and close cleaning rags, replaced wear parts and
workwear. useless machine parts in an environmen-
tally favourable manner and separate of
Thoroughly wash soiled skin with warm one another.
soap water and apply protective skin
cream. Do not use fuel or solvents to Do not add such materials to your normal
clean your skin. domestic waste.
If you have swallowed oil, do not vomit Fill such materials into the containers pro-
and consult a doctor immediately. vided for them.
Do not let oil and oily waste penetrate into
the ground or into waters to prevent pollu-
Apparent Oil Loss tion of the environment.
In case of apparent oil loss, repair the
leakage (or have it repaired) immediately.
Leaking oil endangers the environment!
Remove leak oil by an absorbent. Take the
oil absorbent and do not dispose of to-
gether with other waste.
2 800 600.00 us 5
SWING GEARBOX
Swing gearboxes, types S 5, S 10, S 13, S 16 2796835
Preliminary measures
Park the machine on firm and level ground. For repairs and overhauls, the gearbox unit
should be completely removed for dismantling in
Lock the superstructure.
a workshop.
Set the working equipment on the ground. Only the swing brake can be repaired and/or
Depressurize the hydraulic system. replaced without being removed from the ma-
chine.
Secure the machine as described in the Op-
erating Instructions
6 2 800 600.00 us
SWING GEARBOX
Dismantling the swing gearbox 2796836
Fig. 1
Drain off oil through the drain plug.
Screw out the drain plug to remove any remain-
ing amounts of oil in the gearbox.
Mark all parts mounted together such as swing
motor/multiple-disk brake and multiple-disk
brake/ring gear with a prick punch.
Fig. 2
Loosen the hex bolts at the swing motor.
Lift off the swing motor.
Fig. 3
Remove the O-ring.
Fig. 4
Swing gearbox S 13, S 16 only:
The cylinder-head screws (339) and the

flange (333) are under high spring pres-
sure.
Loosen the cylinder-head screws only if the mul-

tiple-disk brake must be dismantled, too. See
chapter "Dismantling multiple-disk brake S 13/16".
2 800 600.00 us 7
SWING GEARBOX
Fig. 5
Loosen the cylinder-head screws of the multiple-
disk brake/ring gear unit.
Fig. 6
Lift off the multiple-disk brake.
Remove the O-ring from the big flange of the
multiple-disk brake.
Fig. 7
Remove the disk carrier.
Fig. 8
Withdraw the spur-wheel - sun wheel from plan-
etary stage I.
8 2 800 600.00 us
SWING GEARBOX
Fig. 9
Remove plantetary stage I.
Fig. 10
Loosen the two cylinder-head screws.
Screw both screws back into the flange 90
further down the rim (arrow) to dislodge the ring
gear.
These threaded holes are not existing in smaller
gearbox types.
Fig. 11
Lift off the ring gear.
Fig. 12
Remove planetary stage II.
2 800 600.00 us 9
SWING GEARBOX
Fig. 13
Drive the flange mortised at five places around
the circumference to secure the grooved ring nut
out of the toothing by means of a pointed punch
(scribing iron).
Fig. 14
Place the swing pinion with its housing into fitting
aid (S4) or clamp it in a vise with protective
plates between the jaws and the pinion.
Slacken the grooved ring nut with fitting wrench
(S7).
Fig. 15
Screw off the grooved nut with a caliper wrench.
Remove the adjusting shims and the Nilos ring.
Withdraw the O-ring from the housing.
Fig. 16
Place the housing on the support and press the
pinion shaft out of its bearings.
10 2 800 600.00 us
SWING GEARBOX
Fig. 17
Remove the tapered roller bearing.
Fig. 18
Drive the shaft seal out of the housing.
Withdraw both outer bearing rings from the hous-
ing if the tapered roller bearings are to be re-
placed.
Check the gearing and the multi-spline profiles of

the pinion shaft.
If a new pinion shaft is to be installed, both
tapered roller bearings must be replaced together.
In case the old pinion shaft is to be refitted with
new tapered roller bearings, the bearing remain-
ing on the pinion shaft during dismantling can be
removed as follows:
Split up the bearing cage and remove.
Place shaft upright with the multi-spline profiles at
the bottom.
Warm up the inner bearing ring with a flame until
it slides down on the shaft.
2 800 600.00 us 11
SWING GEARBOX
Fig. 19
Planetary gear set
Remove the snap rings.
Fig. 20
Draw off the spur wheels together with the bear-
ings using a suitable extracting tool.
Spur wheels = outer bearing ring, i.e. always
replace spur wheels and bearing together.
12 2 800 600.00 us
SWING GEARBOX
Assembling the swing gearbox 2796833
Fig. 1
Place the housing under a press.
Place the outer ring of the tapered roller bearing
(the broader of the two bearings) on the housing.
Fig. 2
Press the outer ring into the housing using a
suitable cover or fitting punch (S1).
Fig. 3
Put housing upside down. Insert the shaft seal
and press into the housing together with the fit-
ting cover (S2, Fig. 4 - 6).
Swing gearbox S 16 only:
Press two sealing rings into the housing.
Oil the sealing lip(s).
Fig. 4
Swing gearbox S 5
2 800 600.00 us 13
SWING GEARBOX
Fig. 5
Swing gearbox S 10, S 13
Fig. 6
Swing gearbox S 16
Fig. 7
Insert the outer ring of the second tapered roller
bearing and press into housing.
Fig. 8
Place the spacer ring on the swing pinion.
14 2 800 600.00 us
SWING GEARBOX
Fig. 9
Insert the Nilos ring.
The spacer ring has two boreholes to align with
the two punched dimples in the Nilos ring, see
arrows.
Fig. 10
Turn the Nilos ring so that the two dimples en-
gage in the spacer ring boreholes.
Fig. 11
Fig. 12
Heat up the inner ring of the tapered roller bear-
ing (the broader of the two bearings) to 120C
(248F), slide over pinion shaft shank and push
completely down the shaft.
2 800 600.00 us 15
SWING GEARBOX
Fig. 13
Screw new grooved nut onto the shank of the
pinion shaft to the limit stop.
Mark this position on the multi-spline profile and
on the grooved nut.
Screw off the grooved nut.
Fig. 14
Apply grease pressing it firmly into the bearing.
Use grease O&K P/N 73176968 only.
Fig. 15
The empty spaces in the tapered roller bearing
and those in the Nilos ring must be completely
filled with grease. Any excessive grease drops
into the gearing of the swing pinion and the swing
bearing after fitting of the gearbox.
Fig. 16
Fit the housing.
16 2 800 600.00 us
SWING GEARBOX
Fig. 17
Insert the inner ring of the tapered roller bearing.
Fig. 18
Press inner ring of bearing completely down the
housing using a suitable bushing or the fitting
sleeve (S3).
Fig. 19
Screw on the adjusting nut (S6).
Fig. 20
Fitting device (S4) for swing pinion assembly.
Different inserts are available depending on the
gearbox or the swing pinion.
2 800 600.00 us 17
SWING GEARBOX
Fig. 21
Place the housing with the swing pinion into the
fitting device (S4).
Fig. 22
Tighten adjusting nut (S6) with fitting insert (S7)
and the torque wrench (3/4" drive).
The following torques are prescribed for applying
the required bearing prestress:
Gearbox Tightening torque MA

type Nm (lbft)
S5 600 (443)
S 10 900 (664)
S 13 1100 (811)
S 16 1100 (811)
18 2 800 600.00 us
SWING GEARBOX
Fig. 23
Measure dimension B with a depth gauge
through the opening in adjusting nut (S6) be-
tween the adjusting nut and the inner ring of the
tapered roller bearing.
(Set digital measuring gauge to "0".)
Then, determine dimension A between the adjust-
ing nut and the collar of the pinion shaft.
Difference C = A - B
Note down dimension C.
(Read dimension C from the digital gauge.)
Screw off adjusting nut (S6).
Fig. 24
2 800 600.00 us 19
SWING GEARBOX
Fig. 25
Measure the collar with the depth gauge at the
previously marked grooved nut.
Note down dimension D.
Measure the thickness of the Nilos ring and note
down.
Calculation of the adjusting shims:
X=D-C
Example:
D 4.65 mm
C - 3.60 mm
Nilos ring - 0.50 mm
X 0.55 mm
rounded up 0.60 mm
2 adjusting shims 0.30 mm
Always round up calculated value.
Keep the number of adjusting shims installed as
low as possible.
Fig. 26
Fig. 27
Check the thickness of selected adjusting shims
by measuring a second time.
Slide Nilos ring (edge facing the bearing, see
above) and adjusting shims over the shank of the
pinion shaft and hold in this position.
Always place the thicker shim facing the nut. If
three or more shims are used, the thinner one
should be in the middle.
20 2 800 600.00 us
SWING GEARBOX
Fig. 28
Screw on the previously marked grooved nut.
In doing so, press the Nilos ring and the adjusting
shims against the nut collar to prevent them from
getting stuck in the undercut of the shaft.
Fig. 29
Swing gearbox S 5:
Tighten grooved nut with fitting insert (S7).
Tightening torque MA = 750 Nm (553 lbft).
Check the previously applied marks on the
grooved nut and the multi-spline profile. The dis-
tance between the marks must now be 10 - 15
mm, see below.
Fig. 30
Swing gearbox S 10, S 13, S 16:
Tighten the grooved nut until the previously ap-
plied marks on the nut and on the multi-spline
profile of the pinion shaft are in alignment.
Drive the grooved nut further down the shaft by
tapping with a hammer against fitting insert (S7)
until the spacing between the marks is 10 - 15
mm.
Fig. 31
2 800 600.00 us 21
SWING GEARBOX
Fig. 32
Securing the grooved nut.
To do so, stake the border flange of the nut at
five places into the indented profile of the shaft.
Fig. 33
The spur wheels and bearings of the planetary
gear sets are supplied as a completely pre-as-
sembled spare unit. We nevertheless include two
pictures to demonstrate fitting of the bearings.
Place spur wheels on the the workbench with the
broad chamfer facing the bench.
Place roller bearing (in PCV sleeve when new)
on the spur wheel with the rounded edge at the
inner ring facing downwards and center exactly.
Fig. 34
Hold the PCV sleeve firmly on the spur wheel.
Push the roller bearing with a suitable punch
straight down into the spur wheel until the snap
ring in the middle of the bearing engages with the
corresponding groove of the spur wheel, see
cross-section drawing.
Fig. 35
The cross-section shows that the broad chamfer
at the spur wheel and the rounded edge of the
inner bearing ring must face the rounded edges
at the stud of the planetary carrier.
22 2 800 600.00 us
SWING GEARBOX
Fig. 36
Place the disk into the carrier of planetary stage
II.
Fig. 37
Heat up the spur wheels with the bearings ca. 30
minutes in an oven at max. 100C (212F).
Place heated spur wheel with the broad cham-
fer downwards on the stud of the planetary car-
rier.
Planetary stage II has four or five planetary gears
depending on the type of gearbox.
Fig. 38
Press the bearing immediately fully down on the
stud using a suitable fitting sleeve.
Fig. 39
Install the snap rings.
2 800 600.00 us 23
SWING GEARBOX
Fig. 40
Place disk into the carrier of planetary stage I.
Fig. 41
Place heated spur wheels with the broad cham-
fer downwards on the studs of the planetary
carrier.
Fig. 42
Press the bearing immediately fully down on the
stud using a suitable fitting sleeve.
Fig. 43
Install the snap rings.
24 2 800 600.00 us
SWING GEARBOX
Fig. 44
Install planetary stage II.
Planetary stage II has four or five planetary gears
depending on the type of gearbox.
Fig. 45
Install the spur wheel (sun wheel).
Fig. 46
Set planetary stage I onto the gearing of the spur
wheel of planetary stage II.
Fig. 47
Install the pinion.
2 800 600.00 us 25
SWING GEARBOX
Fig. 48
Place the brake disk carrier on the pinion.
Fig. 49
Place a new O-ring into the circumferential
groove of the housing oiling the ring lightly.
Fig. 50
Pour liquid screw fixer P/N 73171473 into the
tapped holes.
For tapped pocket holes pour so much screw
fixer onto the bottom of the hole that the amount
of fixing agent displaced by the screw spreads
over the full tapping length of the hole.
Fig. 51
Install the ring gear.
Observe the marks applied on the ring
gear/housing during the dismantling operations.
26 2 800 600.00 us
SWING GEARBOX
Fig. 52
Tighten the two cylinder-head screws alternately.
The tightening torque is set out in table 1 in the
Annex.
Fig. 53
Place the O-ring into the circumferential groove
on the flange of the multiple-disk brake oiling the
ring lightly.
Fig. 54
Place multiple-disk brake on disk carrier and ring
gear.
Observe the marks applied on the brake/ring gear
during the dismantling operations.
Fig. 55
Secure the cylinder-head screws with liquid screw
fixer P/N 73171473 and tighten crosswise.
Annex.
2 800 600.00 us 27
SWING GEARBOX
Fig. 56
Apply grease on the O-ring seating plane on the
flange of the swing motor.
Fig. 57
Install a new O-ring.
Fig. 58
Install the swing motor.
Observe the marks applied on the motor/brake
during the dismantling operations.
Secure the screws with liquid screw fixer P/N
73171473 and tighten crosswise.
Annex.
Screw the drain plug back into the housing.

Fill gearbox with gearbox oil as indicated in the
operating instructions.
If possible, fill in oil through the drain plug to
prevent the formation of air pockets.
The swing gearbox types described must be filled
with oil up to the axial-piston motor to ensure that
the shaft gearing and the brake disks are running
in an oil bath.
28 2 800 600.00 us
SWING GEARBOX
Multiple-disk brake 2796839
Repairing the brake

The repair of the brake includes the following
operations:
Replacement of the piston seals when the oil
level in the swing gearbox rises due to an
inflow of hydraulic oil from the brake.
Replacement of the disk-set if the superstruc-
ture does not remain stationary in stopped con-
dition in spite of the applied brake.
Check and replacement of the compression
springs.
Dismantling the multiple-disk brake

See chapter "Dismantling the swing gearbox".

S5/S10
Fig. 1
Fig. 2
Place fitting plate (S9.1) on pressure disk (311).
Screw two hex bolts (S9.2) M 6 x 12, offset by
180 into the piston and pull the piston uniformly
towards the pressure disk. The springs are then
blocked.
Remove the retaining ring (304).
Withdraw the outer and inner brake disks.
Press fitting plate (S9.1) with the piston into the
housing until the snap ring (310) can be re-
moved.
Screw two cylinder-head bolts (S9.3) M 6 x 25
into the free boreholes of the piston offset by 90
with respect to the hex bolts (S9.2).
Remove the two hex bolts (S9.2).
Relieve the spring pressure by slackening the two
cylinder-head screws (S9.3) alternately by not
more than two turns.
Remove fitting plate, pressure disk and springs.
Drive the piston out of the housing from the
opposite side.
Remove the two seals (308 + 309).
2 800 600.00 us 29
SWING GEARBOX
Assembling the multiple-disk brake
S5/10
Fig. 3
To center the pressure disk (311), insert the pis-
ton, the springs and the pressure disk into the
housing.
Place the fitting plate (S9.1) on top and screw the
cylinder-head screws (S9.3) offset by 180 al-
ternately by not more than two turns into the
piston until the fitting plate is in contact with the
piston.
Screw two hex bolts (S9.2) into the free
boreholes of the piston offset by 90 with respect
to the cylinder-head screws.
Remove both cylinder-head screws (S9.3).
Withdraw the piston with the springs blocked from
the housing.
Fig. 4
Insert new seals (308 and 309).
Place both O-rings into the corresponding
grooves of the housing, extending the larger O-
ring (309) beforehand.
Insert the Glyd-rings. Press the larger Glyd-ring
(309) into kidney shape.
Fig. 5
Place the Glyd-ring (309) on the O-ring shaping it
into a circle.
Oil the seals, the cylinder and the piston with
hydraulic fluid.
30 2 800 600.00 us
SWING GEARBOX
Fig. 6
Insert the piston with the springs blocked and the
fitting plate (S.9.1) into the housing.
Force the piston with a spindle press carefully
down to the limit stop.
If no spindle press is available, the piston can
also be pressed into the housing by means of the
second fitting plate (S9.1) and the hex bolt (S9.4).
Fig. 7
Install the snap ring (310).
Fig. 8
Turn the housing upside down. Insert the outer
and the inner brake disks alternately by beginning
and ending always with an outer disk. Oil new
disks before installing them.
Align the gearing of the inner disks by means of
the disk carrier.
Engage the disk set together with the piston and
install the snap ring (304).
Turn the brake round and remove both hex bolts
(S9.2) and the fitting plate (S9.1).
2 800 600.00 us 31
SWING GEARBOX
S13/16
Fig. 1
The flange (333) and the cylinder-head

screws (339) are under high spring
pressure
Replace three of the existing cylinder-head

screws (339) - uniformly distributed over the cir-
cumference - by 5 mm longer cyliner-head
screws M 12 x 40.
Fig. 2
Remove also the remaining cylinder-head screws
(339).
Relieve the spring pressure by slackening the
newly installed longer cylinder-head screws uni-
formly (alternately by not more that one turn at a
time).
Lift off the flange (333).
Withdraw the disk carrier.
Remove the springs from the piston.
Turn the housing upside down.
Remove the snap ring (304).
Remove pressure disk and inner and outer brake
disks.
Drive the braking piston out of the housing.
Remove the seals (308 + 309) from the housing.
32 2 800 600.00 us
SWING GEARBOX
Assembling the multiple-disk brake
S13/16
Fig. 3
Insert the outer and the inner brake disks al-
ternately by beginning and ending always with an
outer disk. Oil new disks before installing them.
Install pressure disk (307).
Install snap ring (304).
Fig. 4
Trurn the housing round and install new seals
(308 and 309).
Extend both O-rings and place into the corre-
sponding grooves of the housing.
Press the Glyd-rings into kidney shape.
Fig. 5
Place Glyd-rings on the O-rings shaping them
into a circle.
Oil the seals, the cylinder and the piston with
hydraulic fluid.
2 800 600.00 us 33
SWING GEARBOX
Fig. 6
Insert the piston into the housing pushing it in as
far as the seals.
Install the disk carrier.
Place the flange (333) on top and force the piston
down to the limit stop by tightening the cylinder-
head screws M 12 x 40.
Loosen the cylinder-head screws and remove the
flange.
Distribute the springs on the piston.
Install new O-ring (341).
Pour liquid screw fixer P/N 73171473 into the
tapped pocket holes.
Refit the flange and pre-tighten with three cyl-
inder-head screws M 12 x 40.
Fig. 7
Screw in the cylinder-head screws (339).
Remove the longer cylinder-head screws and re-
place the shorter ones (339).
Tighten all cylinder-head screws crosswise. The
tightening torques are set out in table 1 in the
Annex.
Installing the multiple-disk brake

See chapter "Assembling the swing gear".
Bleeding the brake

Slacken the screwed connection of the brake line
at the housing port by approximately one turn.
With the Diesel engine running, apply and release
the multiple-disk brake (superstructure holding
brake) two or three times until the oil emerging
from the screwed connection is free from bub-
bles.
Check proper functioning of the brake, see Op-
erating Instructions.
34 2 800 600.00 us
SWING GEARBOX
ANNEX 2796838
2 800 600.00 us 35
SWING GEARBOX
Swing gearbox components

Fig. 1
36 2 800 600.00 us
SWING GEARBOX
Item Quantity Designation
1 1 Swing gearbox
3 1 Swing brake
7 1 Axial-piston motor
10 4 Hex bolt
12 1 O-ring
201 1 Spur-wheel set
202 1 Disk
203 1 Planetary carrier
204 3 Retaining ring
223 1 Ring gear
224 1 Pinion
225 1 Spur wheel
227 2 Cylinder-head screw
252 1 Disk
343 2 Eye bolt
344 1 Connecting piece
345 1 Plug
347 1 O-ring
348 1 Screw plug
349 1 Pipe bend
551 1 Housing
552 1 Pinion
553 1 Nut
554 1 Ring
556 1 Tapered roller bearing
557 1 Tapered roller bearing
558 1 Rotary shaft seal
559 1 Nilos ring
560 1 Plug
561 1 Adjusting shim 0.15 mm
564 1 Toroidal sealing ring
566 1 Sealing ring
573 1 Nilos ring
2 800 600.00 us 37
SWING GEARBOX
Multiple-disk brake S 5, S10
Fig. 2
38 2 800 600.00 us
SWING GEARBOX
3 1 Brake
301 1 Piston
303 1 Pressure disk
305 5 Inner disk
306 6 Outer disk
308 1 Seal
309 1 Seal
310 1 Snap ring
311 30 Compression spring
331 1 Disk carrier
332 1 Housing
2 800 600.00 us 39
SWING GEARBOX
Fig. 3
40 2 800 600.00 us
SWING GEARBOX
1 1 Swing gearbox
3 1 Swing brake
7 1 Axial-piston motor
12 1 O-ring
202 1 Disk
223 1 Ring gear
224 1 Pinion
225 1 Spur wheel
252 1 Disk
331 1 Disk carrier
332 1 Housing
333 1 Flange
341 1 Toroidal sealing ring
343 2 Eye bolt
344 1 Connecting piece
345 1 Screw plug
346 2 Sealing ring
347 1 O-ring
551 1 Housing
552 1 Pinion
553 1 Nut
554 1 Ring
556 1 Tapered toller bearing
557 1 Tapered toller bearing
558 1 Sealing ring (S13)
558 2 Sealing ring (S16)
559 1 Nilos ring
560 1 Screw plug
564 1 O-ring
566 1 Sealing ring
573 1 Nilos ring
2 800 600.00 us 41
SWING GEARBOX
Multiple-disk brake S 13, S 16
Fig. 4
42 2 800 600.00 us
SWING GEARBOX
3 1 Brake
301 1 Piston
303 1 Pressure disk
305 5 Inner disk
306 6 Outer disk
307 1 Disk
308 1 Seal
309 1 Seal
310 1 Snap ring
331 1 Disk carrier
332 1 Housing
333 1 Flange
341 1 O-ring
2 800 600.00 us 43
SWING GEARBOX
Screws, tightening torques and screw fixer
Fig. 5
Fig. 6
44 2 800 600.00 us
SWING GEARBOX
Table 1
Gearbox type: S 5
Screw Thread Quality Tightening torque MA Screw fixer
Item (mm) Nm (lbft) P/N 73171473
10 M 10 10.9 80 (59) X
227 M 10 8.8 55 (40) X
340 M6 10.9 11.2 (8.26) X
345 M 14 x 1,5 - 30 (22) -

1)
553 M 72 x 1.5 - 750 (553)
Gearbox type: S 10
10 M 12 10.9 140 (103) X
227 M 12 8.8 94 (69) X
340 M8 10.9 40 (30) X
345 M 14 x 1.5 - 30 (22) -

2) 1)
553 M 72 x 1.5 -
Gearbox type: S 13, S 16

10 M 12 10.9 130 (96) X
227 M 10 8.8 53 (39) X
339 M 12 10.9 130 (95) X
340 M8 8.8 26 (19) X
345 M 22 x 1.5 - 60 (44) -

2) 1)
553 M 11 x 2 -
1)
Secure nut by staking at five places.
2)
See chapter "Assembling the swing gearbox".
2 800 600.00 us 45
SWING GEARBOX

Bolts with standard thread DIN 13, sheet 33 (e.g. DIN 912, 931, 934)

1)
0.10 0.122) 0.16 (L)3)
M5 8.8 4.9 5.5 6.5

10.9 7.3 8.1 9.5
12.9 8.5 9.5 11.2
M6 8.8 8.5 9.5 11.2

10.9 12.5 14 16.5
12.9 14.5 16.5 19.5
M8 8.8 20.5 23 27
10.9 30 34 40
12.9 35 40 47
M 10 8.8 41 46 55
10.9 60 68 80
12.9 71 79 94
M 12 8.8 71 79 94
10.9 104 117 140
12.9 195 215 260
M 16 8.8 170 195 230

10.9 250 280 340
12.9 300 330 400
M 20 8.8 350 390 470

10.9 490 560 670
12.9 580 650 780
M 24 8.8 600 670 800

10.9 850 960 1140
12.9 1000 1120 1350
M 30 8.8 1190 1350 1600

10.9 1700 1900 2300
12.9 2000 2250 2700
M 36 8.8 2100 2350 2800

10.9 3000 3300 4000
12.9 3500 3900 4700
1)
2)
3)
46 2 800 600.00 us
SWING GEARBOX

0.101) 0.122) 0.16 (L)3)
M 8x1 8.8 22 24.5 30
10.9 32 36 43
12.9 38 43 51
M 10x1 8.8 45 52 62
10.9 67 76 91
12.9 78 89 107
M 10x1.25 8.8 43 49 58
10.9 64 72 86
12.9 74 84 100
M 12x1.25 8.8 77 87 104

10.9 112 125 150
12.9 130 150 180
M 14x1.5 8.8 121 135 165

10.9 175 200 240
12.9 205 235 280
M 16x1.5 8.8 180 205 250
10.9 270 300 370
12.9 310 360 430
M 20x1.5 8.8 380 430 530

10.9 540 620 750
12.9 630 720 880
M 22x1.5 8.8 510 580 700

10.9 720 820 1000
12.9 840 960 1170
M 24x2 8.8 640 730 890

10.9 920 1040 1250
12.9 1070 1220 1500
M 27x2 8.8 940 1070 1300

10.9 1350 1500 1850
12.9 1550 1800 2150
M 30x2 8.8 1370 1490 1740

10.9 1940 2120 2480
12.9 2270 2480 2900
1)
2)
3)
2 800 600.00 us 47
SWING GEARBOX
Special tools and accessories
Table 2
Special tools
No. Fig. Gearbox type Part No. Designation
(item)
S1 2 S5 73176971 Fitting punch

S 10 73176972
S 13 73176973
S 16 73176973
73176974
S2 4 S5 73176726 Fitting cover

5 S 10 73176727
5 S 13 73176728
6 S 16 73176729
S3 20 S5 73176975 Fitting sleeve

S 10 73176976
S 13, S 16 73176976
S4 22 S 5, S 10 73176730 Device
S 13, S 16
S6 21 S5 73176731 Adjusting nut

S 10 73176732
S 13, S 16 73176733
S7 24 S5 73176734 Fitting insert

S 10 73176735
S 13, S16 73176736
S9 S 5, S 10 73176725 Fitting set brake S 5/ S 10

including:
S 9.1 2 fitting plates
S 9.2 2 hex screws M 6 x 12
S 9.3 2 cylinder-head screws M 6 x 25
S 9.4 1 hex bolt M 16 x 120
with hex nut M 16
Table 3
Sealing and securing compounds
Liquid screw fixer : P/N 73171473
- Packing 10 cm3 : P/N 73171475
Sealing compound / Adhesive : P/N 73171476

- Packing 50 g : P/N 73176140
- Packing 250 g : P/N 73176141
48 2 800 600.00 us
SWING GEARBOX
Fig. 1
Cover (S2)
S/N: 73176726
Material: S355J2G3 (St52-3)
2 800 600.00 us 49
SWING GEARBOX
Fig. 2
Cover (S2)
P/N: 73176727
50 2 800 600.00 us
SWING GEARBOX
Fig. 3
Cover (S2)
P/N: 73176728
2 800 600.00 us 51
SWING GEARBOX
Fig. 4
Cover (S2)
P/N: 73176729
52 2 800 600.00 us
SWING GEARBOX
Notes
2 800 600.00 us 53
SWING GEARBOX
54 2 800 600.00 us
HYDRAULIC SYSTEM .............................................................................................................................. 1
Foreword.................................................................................................................................................... 1
Safety Instructions
Danger in the event of non-observance of the safety instructions .......................................................... 1
Depressurizing the hydraulic system .................................................................................................... 5
Venting the hydraulic system

Reasons for venting ................................................................................................................................ 6
Venting .................................................................................................................................................... 6
Hydraulic tank.......................................................................................................................................... 6
Top servo control caps ............................................................................................................................ 6
Hydraulic pumps and hydraulic motors .................................................................................................. 7
Hydraulic cylinder .................................................................................................................................... 8
Flushing the hydraulic system .............................................................................................................. 10
Description of the hydraulic system

Technical data ...................................................................................................................................... 15
Hydraulic circuit diagram P/N 4 530 121.00 - Superstructure................................................................ 15
Hydraulic circuit diagram P/N 4 530 133.00 - Undercarriage ................................................................ 15
Survey of components for the hydraulic circuit diagram ........................................................................ 15
Hydraulic components
Drive engine (item 1) ............................................................................................................................ 21
Twin variable displacement pump (4, Figs. 1,2 and Fig. 3) .................................................................. 21
Proportional demand control ................................................................................................................ 21
Power control ........................................................................................................................................ 23
Load limit regulator ................................................................................................................................ 23
Swing pump (5, Fig. 3) .......................................................................................................................... 25
Filters (6) .............................................................................................................................................. 25
Twin gear pump (7, Fig. 4) .................................................................................................................... 26
Hydraulic reservoir, complete (10, Fig. 5).............................................................................................. 27
Return flow filters (11, Fig. 5) ................................................................................................................ 27
Bypass valve (12, Fig. 5) ...................................................................................................................... 27
Filter contamination switch (13, Fig. 5) .................................................................................................. 27
Temperature sensor (16, Fig. 5) ............................................................................................................ 27
Swinging mode valve (17, Fig. 6) .......................................................................................................... 28
Oil coolers with fan drive ...................................................................................................................... 29
Additional control block (25, Fig. 8) ...................................................................................................... 30
6-way control block (26, Fig. 9) ............................................................................................................ 31
Primary valve with pressure cut-in stage (27, Fig. 10, 11) .................................................................... 32
Mini-rate regulator or shock reducing valve (30, 31 Fig. 11) ................................................................ 33
Valve assembly (35 - 40, Fig. 12) .......................................................................................................... 34
Diaphragm accumulator (36, Fig. 12) .................................................................................................... 34
Sealing plug (37, Fig. 12) ...................................................................................................................... 35
Solenoid valve Y35 (38, Fig. 12) .......................................................................................................... 35
Solenoid valve Y 63 (39, Fig. 12) .......................................................................................................... 35
Solenoid valve Y39.1 (39, Fig. 12) ........................................................................................................ 35
Solenoid valve Y39.5 (39, Fig. 12) ........................................................................................................ 35
Check valve (40, Fig. 12) ...................................................................................................................... 35
Shuttle valve cascade (50 - 54, Fig. 13) ................................................................................................ 36
Switching valve (52, Fig. 13) ................................................................................................................ 36
Switching valve (56, 57, Fig. 14) .......................................................................................................... 37
Right servo control valve (60, Fig. 15) .................................................................................................. 38
Left servo control valve (61, Fig. 15) .................................................................................................... 38
Travel pedals (62, Fig. 15) .................................................................................................................... 38
Pedal (62, Fig. 16) ................................................................................................................................ 39
Solenoid valve (64, Fig. 15 and 16) ...................................................................................................... 39
Swing gearbox (70, Fig. 17) .................................................................................................................. 40
Swing motor (71, Fig. 17) ...................................................................................................................... 40
Speed sensor (72, Fig. 17) .................................................................................................................... 40
Rotor (75, 78, Fig. 18) .......................................................................................................................... 41
Boom cylinders (80, Fig. 19).................................................................................................................. 42
Stick cylinder (82, Fig. 20) .................................................................................................................... 43
Restrictor check valve, adjustable (83, Figs. 20 and 21) ...................................................................... 43
Bucket cylinder (84, Fig. 21) .................................................................................................................. 44
Solenoid valve (91, Fig. 22) .................................................................................................................. 45
Load limit regulator PMS 3 (95) ............................................................................................................ 45
Travel gearbox (100, Fig. 23) ................................................................................................................ 46
Hydraulic travel motor (101, Fig. 23) .................................................................................................... 46
Travel brake valve (101, Fig. 23) .......................................................................................................... 46
Description of system sections

Load limit control system ...................................................................................................................... 47
Unpressurized oil circuit ........................................................................................................................ 47
Servo control system ............................................................................................................................ 48
Servo control valve (60) boom/bucket .................................................................................................. 48
Servo control valve (61) stick/swinging ................................................................................................ 48
Minimum quantity regulator or shock reducer (30, 31) .......................................................................... 48
Servo control valve (62) travel, 1 valve for each track .......................................................................... 49
Servo control valve (62) hammer / scissors .......................................................................................... 49
Working hydraulic system .................................................................................................................... 50
Circuit 1 ................................................................................................................................................ 50
Circuit 2 ................................................................................................................................................ 50
Dual admission ...................................................................................................................................... 50
Single admission .................................................................................................................................. 50
Travel hydraulic system ........................................................................................................................ 50
Additional hydraulics ............................................................................................................................ 50
Parallel bucket connection .................................................................................................................... 51
Swinging system .................................................................................................................................. 51
Neutral position .................................................................................................................................... 52
Counter-clockwise swinging .................................................................................................................. 52
Clockwise swinging .............................................................................................................................. 52
Braking the superstructure .................................................................................................................... 52
Checking and setting pressures

Safety instructions ................................................................................................................................ 53
General.................................................................................................................................................. 54
Pressure settings .................................................................................................................................. 54
Tools
PCS tester (Fig. 1) ................................................................................................................................ 55
Large leather test case with contents .................................................................................................... 55
Pressure gauge (Fig. 2) ........................................................................................................................ 56
Servo control pressure .......................................................................................................................... 57
Working hydraulics with power boost function ...................................................................................... 57
Setting the primary valve to higher pressures ...................................................................................... 57
Secondary valves for cylinders .............................................................................................................. 58
Secondary valves for travel motors ...................................................................................................... 59
Pressure-limiting valves on additional control block .............................................................................. 59
Setting/adjusting primary valves ............................................................................................................ 60
Pump control through proportional demand signals .............................................................................. 61
Output control through proportional demand pressure .......................................................................... 62
Pump 1 .................................................................................................................................................. 62
Pump 2 .................................................................................................................................................. 62
Swinging system .................................................................................................................................. 63
Swing pump adjustments (Fig. 3) : ........................................................................................................ 64
Changing the braking torque ................................................................................................................ 64
Feed pressure and zero point .............................................................................................................. 65
Swinging power (swing mode) .............................................................................................................. 65
High swinging pressure and safety valves ............................................................................................ 65
Safety valve .......................................................................................................................................... 65
Installing the hydraulic pumps

Components .......................................................................................................................................... 66
Removal and installation of the hydraulic pumps .................................................................................. 67
Removing a pump ................................................................................................................................ 67
Installing a pump .................................................................................................................................. 67
Hydraulic cylinders
Safety instructions ................................................................................................................................ 68
General.................................................................................................................................................. 69
Components for boom and bucket cylinders (Fig. 1) ............................................................................ 71
Components for stick cylinder (Fig. 2) .................................................................................................. 73
Assembly .............................................................................................................................................. 74
Boss-type, one-piece (Fig. 3) ................................................................................................................ 74
Pivot bearings........................................................................................................................................ 75
Piston rod guide boom and bucket cylinders ........................................................................................ 76
Piston rod guide stick cylinder .............................................................................................................. 77
Piston rod and piston ............................................................................................................................ 79
TROUBLESHOOTING ............................................................................................................................ 83
Troubleshooting, instructions .............................................................................................................. 83
Layout of the troubleshooting table

Troubleshooting guide .......................................................................................................................... 84
HYDRAULIC SYSTEM 2796736

The "Technical Specifications" manual contains Danger in the event of non-observance

tact with it
immediately when any damage is
The refilling quantities specified for consumables suspected or occurring, to ensure that the
are approximate quantities which are intended as safety of the operator, other persons at
a help for planning consumable requirements. the place of use or other material property
Each unit is equipped with suitable checking de- is not compromised.
vices, e.g. dipstick or checking plugs, permitting
the operator to check proper filling of the units. All components are carefully coordinated.
spare parts.
73179380 08 1
Personnel Personnel
attachments may give rise to life- Metal splinters may cause injury when at-
threatening situations. tachment bolts are being driven in or out.
2 08 73179380

machine and the attachments must be plicable to the product when handling
secured against inadvertent and un- oils, greases and other chemical sub-
authorized starting, e.g. by placing chocks stances.
under the wheels or tracks and by setting Unused but open bores, pipelines and
the working equipment on the ground. hose connections must be closed in a
Set the working equipment on the ground pressure- tight manner.
scalding.
eyes and the skin.
liquids.
ted light.
easily.
73179380 08 3

4 08 73179380
Depressurizing the hydraulic system 2796729
Residual pressure is reduced only gradually. If

work is to be done on the hydraulic system im-
mediately after the excavator has been stopped,
Hydraulic systems must never be opened the system must be depressurized:
unless depressurized. Even when the ma-
chine is parked on a horizontal surface Isolate system section to be opened.
with its working equipment set down on
the ground and its driving motor switched Depressurize system section to be opened, if
off, a substantial amount of residual pres- necessary by combining more than one of the
sure may still be present in parts of the described measures.
hydraulic system: Open depressurized system section carefully.
- Primary pressure from the last hydrau-
lic movements prior to the machine be- System sections are:
ing stopped.
working hydraulic circuit
- Secondary pressure resulting from the
deadweight of the excavator or of in- servo control circuit
dividual components of the working
equipment. Secondary pressure is Depressurizing:
present until the pressure-generating
components have reached their resting a) working hydraulic circuit (Fig. 1)
position, e.g. by being supported me- Immediately after stopping the machine, actu-
chanically so that the supporting func-
ate all control levers in succession in the preci-
tion of the hydraulic system is super- sion control range. Proceed purposefully, as
fluous. the diaphragm-type accumulator which is now
- Precharging pressure in the hydraulic pressurized has a limited capacity and the
system, resulting from structural mea- pressure drops due to loss of leakage oil.
sures.
Fig. 1
b) Servo control circuit
Shift control lever repeatedly to limit stop in all

directions. After ca. 30 shifts - residual pres-
sure down to ca. 2 bars - the servo control
system can be opened.
73179380 08 5
Venting the hydraulic system 2800747
Reasons for venting Top servo control caps
Hydraulic pumps, motors and cylinders must be Loosen the hex-socket screw of servo control
carefully vented after oil changes, before initial caps (arrow, Fig. 2) to be vented.
commissioning, and before recommissioning after With the motor running at low speed, actuate
major repair work. Otherwise their intake and op- the relevant function until bubble-free oil
erating characteristics are severely disturbed. emerges.
Hydraulic oil is simultaneously the lubricant for Close servo control caps.
these units. Allowing them to run dry will result in
a complete breakdown after a short operating
period.
If intake conditions are not in order, a gas-air

mixture is formed. A rise in temperature and pres-
sure results in spontaneous ignition in the gas
bubbles: diesel effect.
Diesel effects damage seals and guide compo-
nents. They also reduce the service life of other
units substantially.
Venting
Hydraulic tank
The hydraulic tank is under slight precharge pres-

sure.
When working on the hydraulic system, measures

must be taken to prevent the entire contents of Fig. 2
the hydraulic tank from running out.
This is done by unscrewing the pressure com-
pensating screw plug (1, Fig. 1) before starting
work.
Fig. 1
6 08 73179380
Hydraulic pumps and hydraulic motors
Dual variable displacement pump: Gear pumps:
Vent dual variable displacement pump after each Vent gear pumps after each installation by slack-
oil change or pump replacement. ening (engine stationary) the threaded union on
the suction side at the fan drive pump. When
Unscrew screw plug (1, Fig. 3) and wait until bubble-free oil emerges, tighten union again.
bubble-free oil emerges at the drilled hole of the
screw plug. Screw the plug back in.
Fig. 4
Fig. 3
Swing pump:
Vent swing pump after each oil change or pump

replacement.
Fill in clean hydraulic oil through the T-connection

(2) after removing the line. Reinstall the line.
Vent feed pump by loosening the suction line

when the engine is stationary. Retighten the suc-
tion line when the oil is free from bubbles.
73179380 08 7
Hydraulic motors: Hydraulic cylinder
After each installation, fill hydraulic motors with oil Before the cylinder is filled with oil for the first
prior to commissioning by unscrewing the top time, the piston must be in one of the two limit
leakage oil connection and filling in oil up to the positions. The piston rod must thus be com-
bottom edge of the drilled hole. pletely retracted or extended.
Driving motor: leakage oil connection (1, Fig. 5) Only then is it ensured that
- the still empty cylinder compartments are
Swing motor: leakage oil connection (1, Fig. 6)
filled almost completely with oil;
- no combustible air-oil mixture can be formed
on a hazardous scale.
Always fill first that cylinder end where the

piston is located, i.e.
the piston surface connection (Fig. 7) when the
piston rod is retracted;
the ring surface connection (Fig. 8) when the
piston rod is extended.
The same applies if the piston rod of the cyl-
inder has to be brought into a central position
for installation purposes.
Fig. 5
Fig. 7
Fig. 6
8 08 73179380
After venting
Start up motor and check hydraulic system under

load. Pay attention to any pump noise. Jerky
movements are an indication of residual air pock-
ets. These can be removed by actuating all hy-
draulic functions.
The system is fully vented when all functions can

be performed smoothly and uniformly and the oil
in the tank is foam-free.
Fig. 8
The first filling must be done with a reduced,

controlled oil flow. So retract or extend piston
rod as slowly as possible.
After installation, the cylinder or group of cyl-

inders must be retracted and extended to the
limit stops at least 5 times.
If the wearing parts of hydraulic cylinders are to

be replaced, all sliding components, guide belts
and sealing elements must be lubricated with
oil from the hydraulic system. Never use
grease for this purpose.
During oil change, repairs or replacement of

units involving the unscrewing of threaded hy-
draulic connections, care must be taken to en-
sure that the quantity of oil in the cylinders is
not reduced.
If this has proved unavoidable, the affected
cylinders must subsequently be vented again.
73179380 08 9
Flushing the hydraulic system 2796732
These instructions summarize the operational se- 1. When to flush the system
quence for cleaning - flushing - the hydraulic
system. The function and layout of the different 1.1 When the quantity, size or appearance of
units are detailed in the individual sections of the foreign bodies exceeds or differs from
Owners Manual. normal abrasion.
It is taken for granted that the machine remains 1.2 When the extent of metal particle deposits
at the deployment location for the flushing opera- in the paper folds of the return flow filter
tion; however, hydraulic units, e.g. hydraulic cyl- is greater than normal.
inders, should be overhauled in a closed, clean
workshop. 1.3 Each time a hydraulic unit has been re-
placed. Flushing can then be confined to
If the hydraulic system is opened at one or more the downstream circuit, providing it can
points, e.g. for replacement of a unit or repair of be unequivocally identified.
a steel component, all resulting openings must
immediately be closed in an appropriate way, e.g.
with plugs or plastic caps. The same applies to
temporarily dismantled lines.
In the event of a hydraulic unit, e.g. pump or

cylinder being damaged, the hydraulic system
must be checked for the presence of metal chips
by removing and inspecting the magnetic bar and
return flow filter element.
10 08 73179380
2. Origin of foreign bodies 4. Response to cylinder damage

2.1 Bright metal platelets and/or fragments: 4.1 Remove and check return flow filter ele-
ment.
Bearing damage at pump or hydraulic
motor. 4.2 Locate. remove, dismantle and clean de-
fective cylinder. Check components care-
2.2 Steel chips with the appearance of chips
fully.
from turning operations:
Internal components of a hydraulic cyl- 4.3 Cylinder(s) working in parallel - if present
inder have corroded. Fragments of guide - must also be removed, dismantled,
belts, O-rings and seals are then often cleaned and checked.
found in the filter.
4.4 When reassembling, all cylinders must be
2.3 Single fragments with the appearance of equipped with new sealing components
a spring or a valve disk: and guide elements.
Valve damage 4.5 Install cylinder, but do not yet connect
hydraulic lines.
These are only rough guides. In cases of ad-
vanced damage, all foreign bodies described 4.6 Flushing is detailed in chapter 7.3 and
above may be found. operations monitoring in chapter 8.
3. Response to pump damage 4.7 If further chips occur during flushing, re-
move, dismantle and clean all hydraulic
3.1 Locate defective pump. Symptoms may cylinders and check all components with
be: care.
- irregular hydraulic hose movement 4.8 Empty and clean hydraulic reservoir.
- marked changes in pressure gauge
readings 4.9 Continue assembly work as detailed in
4.4, 4.5 and chapters 5 ... 8
- abnormal noises
- marked loss of power 5. Response to valve damage
- overheating 5.1 Locate damaged valve.
- reduced drive motor speed
5.2 If all components of the defective valve
3.2 Remove return flow filter element and are found, it is sufficient to install a new
check for foreign bodies. component. No further measures are nec-
essary.
3.3 Empty and clean hydraulic reservoir.
5.3 However, if not all components are found,
3.4 Dismantled defective pump. the search should be continued at the
following places:
3.5 Check bypass valve for perfect seal; re-
place if damaged. - return flow filter of hydraulic reservoir
- units downstream from the defective
3.6 Install new pump.
valve, e.g. cylinders, valves, motors.
3.7 If metal particles have got into the hy-
draulic system from the defective pump,
continue with all work described from 4.7
onwards and in chapters 5 ... 8, even if
no damage is yet visible on a further unit.
73179380 08 11
6. Other measures 7. How to flush the hydraulic system

If the hydraulic system has been severely con- The point at which the contamination has got
taminated by numerous chips, the following into the hydraulic system is decisive for the
additional measures are necessary: scope of the flushing operation. The down-
stream hydraulic system must be flushed as
6.1 Dismantle, clean and reinstall primary far as the filter whose perfect functioning can
pressure-relief valves. be verified.
6.2 Dismantle, clean and reinstall secondary 7.1 After pump damage
pressure-relief valves.
7.1.1 Insert a new return flow filter ele-
6.3 Clean coolant circuit and check hydraulic ment.
reservoir for excessive deposits.
- Dismantle oil cooler, clean externally 7.1.2 Fill in hydraulic oil through return
and flush intensively in both flow direc- flow filter.
tions. The oil cooler must be replaced if 7.1.3 Connect line of individual consum-
the foreign bodies cannot be removed ers direct with each other (short
completely from the fins. circuit) by removing non-detached
- Flush lines or blow through with com- lines from the consumer.
pressed air.
7.1.4 Run drive motor at full speed.
6.4 If units have a hydraulic servo control, Do not switch on control valve until
check the control valves and clean them if filter control lamp has gone out.
necessary.
7.1.5 Switch on each hydraulic function
6.5 If attachments with hydraulic drive are in- fully one after another in each di-
stalled, these systems must also be rection for ca. 1 minute, switching
checked, especially if the cause of the briefly back a few times to 0-posi-
damage cannot be located in the excava- tion.
tor. For repair work, consult the manufac- Total ON time per consumer: at
turer of the attachments if necessary. least 5 minutes.
7.1.6 Replace return flow filter element.
7.1.7 Repeat flushing operation. Switch

on all consumers again successive-
ly, but only briefly.
7.1.8 Check return flow filter again.
7.1.9 Connect and vent all consumers as

prescribed.
7.1.10 Check oil level in hydraulic reser-

voir.
7.1.11 Start up excavator.
12 08 73179380
7.2 After limited cylinder damage acc. to 4.1 - 8. Operations monitoring
4.5
After ca. 1 hour deployment, check return filter
7.2.1 Insert new return flow filter ele- element. If chips are still present, install new filter
ment. element.
7.2.2 Connect connection lines of re-
Repeat checks at increasing intervals.
placed cylinders directly with each
other (short circuit). If there is no clear-cut decrease in the quantity of
7.2.3 Run drive motors at full speed. chips, or if foreign bodies are found in large
quantities, it can be assumed that the defective
Do not switch on control valve of unit has not yet been found, cleaned or replaced.
replaced cylinder until oil filter con- Thorough check and flushing operation must be
trol lamp has gone out. repeated.
7.2.4 Switch working functions of re-
placed cylinders on fully in each
direction for ca. 1 minute, switching
briefly back a few times to 0-posi-
tion.
7.2.5 Replace return flow filter element.
7.2.6 Repeat flushing operation, switch-

ing on all consumers briefly in suc-
cession.
7.2.7 Check return flow filter again.
7.2.8 Connect and vent cylinder(s) as

prescribed.
7.2.9 Check oil level in hydraulic reser-

voir.
7.2.10 Start up excavator.
7.3 After extensive damage acc. to 4.7
7.3.1 Insert new return flow filter ele-

ment.
7.3.2 Fill in hydraulic oil through return
flow filter.
7.3.3 Further procedures are detailed in

7.1.3 - 7.1.11.
7.4 After damage to hydraulic motor (e.g.

travel motor, swing motor)
7.4.1 Install new return flow filter ele-

ment.
7.4.2 Connect connection lines of re-

placed unit directly with each other
(short circuit)..
7.4.3 Further procedures are detailed in

7.2.3 - 7.2.10.
73179380 08 13
14 08 73179380
Description of the hydraulic system 2801893
Technical data
The technical data of the hydraulic system are listed in chapter 2 "Service Data".
Hydraulic circuit diagram P/N 4 530 121.00 - Superstructure
Hydraulic circuit diagram P/N 4 530 133.00 - Undercarriage
Survey of components for the hydraulic circuit diagram

No. Quantity Designation Location
1 1 Motor 4 BT 3.9 C Superstructure

2
3 1 Multicircuit pump unit with: Superstructure
4 (1) Variable displacement pump A8V0 55 Superstructure
5 (1) Swing pump A4VG 40 DWD Superstructure
6 2 Filter Superstructure
7 1 Gear pump (twin) Swing pump
8
9
10 1 Hydraulic reservoir with: Superstructure
11 (1) Filter Hydr. reservoir
12 (1) Bypass valve Hydr. reservoir
13 (1) Oil-pressure switch (S15) Hydr. reservoir
14
15
16 1 Temperature sensor (R14) Hydr. reservoir
17 1 Swing mode valve Superstructure
18
19
20 1 Oil cooler Superstructure
21 1 Fan drive motor Fan drive unit
22
23
24
25 1 Supplementary control block hammer Superstructure
26 1 Control block (6-way) Superstructure
27 2 Primary valve with pressure cut-in stage Control block
28 1 Plug Control block
29
30 1 Mini rate regulator Control block
31 3 Mini-rate regulator Control block
32
33
34
35 1 Valve assembly with: Superstructure
(1) Proportional valve, load limit regulator (Y10) Superstructure
(1) Solenoid valve (high-speed) (Y21.1) Superstructure
(1) Cover plate Superstructure
36 1 Diaphragm-type accumulator Superstructure
37 1 Sealing plug Superstructure
73179380 08 15
38 1 Solenoid valve (Holding brake) swing gear (Y35) Superstructure

39 1 Solenoid valve (Power boost) (Y63) Superstructure
39 1 Solenoid valve (Hammer Y39.1) Superstructure
39 1 Solenoid valve (Pressure increase) Superstructure
40 1 Check valve Superstructure
41
42
43
44
45
46
47
48 6 Shuttle valve cascade Floor-plate
49 6 Shuttle valve cascade Floor-plate
50 1 Switching valve, parallel travel Floor-plate
51 1 Pressure switch, load limit regulator GLR (S10.1) and Floor-plate
swinging mode (S66)
52 1 Pressure switch, superstructure holding brake (S35.1) Floor-plate
53
54 1 Switching valve, parallel travel with pressure pick-up Control block
55 1 Shuttle valve Control block
56
57
58 1 Servo control valve, right, complete Cab
59 1 Servo control valve, left, complete Cab
60 2 Travel pedals with Travel Alarm pressure pick-up Cab
61 1 Hammer pedal Cab
62 1 Solenoid valve, servo control pressure cutoff (Y10.4) Cab
63
64
65
66
67
68 1 Swing gearbox with Superstructure
69 (1) Swing motor F12 - 30 Swing gearbox
70 (1) Speed sensor superstructure holding brake (S35.2) Swing gearbox
71
72
73 1 Rotor Superstructure
74
75
76 1 Rotary union Rotor
77 1 Distributor Superstructure
78 2 Boom cylinder Boom
79
80 1 Stick cylinder Boom
81 2 Restrictor check valve Stick/bucket cyl.
82 1 Bucket cylinder Stick
83 1 Distributor block Bucket cylinder
84
85
86
87
88
89
90
16 08 73179380
91 1 Solenoid valve hammer frequency adjust (Y39.2) Superstructure

92
93 1 Load limit regulator PMS3 Cab
94
95
96
97
98 2 Travel drive complete, with: Undercarriage
99 (1) Travel hydraulic motor A6VE 55 HZ 3/63W Travel gearbox
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
73179380 08 17
18 08 73179380
Hydraulic components 2801894
The following numbers refer to circuit diagram

P/N 4 530 121.00 Superstructure and to circuit
diagram P/N 4 530 133.00 Undercarriage
Some numbers in the circuit diagram are not

listed here, as the components concerned are of
no significance to the functional sequence.
73179380 08 19
Fig. 1
20 08 73179380
Drive engine (item 1)

The water-cooled diesel engine is a water-cooled Proportional demand control
in-line engine with turbocharger.
When the engine is stationary, both pumps are
Twin variable displacement pump (4, held by spring force in the Qmax position. Start-
Figs. 1,2 and Fig. 3) ing up the engine generates circulating pressure
which is applied to the large adjusting piston
Figs 1 and 2: surface via the control piston of the regulator.
The pumps swing against Qmin. When the op-
A - Adjusting piston section erating levers or pedals are actuated, servo con-
P - Pump pressure trol pressure is applied at X1 as proportional
X1 - Load-sensing control pressure demand pressure.
X3 - Load-limit regulator pressure The extent of the proportional demand pressure
depends on the amount by which the lever or
Two variable displacement axial-piston pumps in pedal is moved out of neutral. In the precision
tilted-axis design are installed in one housing. control range, the proportional demand control
Each pump is equipped with a load controller piston is displaced continuously against the
which adjusts the output according to spring char- spring, with the regulator control piston causing
acteristics. the oil to flow from the large adjusting piston
The load controller is influenced by proportional surface into the housing.
demand pressure, by high pressure and by the The pump swings against Qmax.
pressure of the load limit regulator.
73179380 08 21
Fig. 2
22 08 73179380
Power control Load limit regulator
At low operating pressures, e.g. rapid boom The load limit regulator acts on the power intake
lowering, the pumps are in Qmax position and of the twin variable displacement pump, with the
deliver max. outputs for rapid movements. load limit regulator pressure being applied to the
The pump pressure increases with increasing op- power controller at port X3 and influencing, to-
erating resistances and moves the regulator con- gether with the high pressure, the regulation start
trol piston downwards, so that pressure is applied of the pump.
to the large adjusting piston surface.
The control piston is lifted from the Qmax limit
position against the regulating springs, and the
pump reduces the output.
This procedure is referred to as regulation start.
The regulating procedure is complete at that mo-
ment when the hydraulic force at the adjusting
piston is balanced with the force of the regulating
springs. The regulator control piston is then
closed and the pump delivers that quantity of oil
which is dependent on the momentary working
pressure.
The power regulator responds to any change of
working pressure by adapting the output.
73179380 08 23
Fig. 3
24 08 73179380
Swing pump (5, Fig. 3) Filters (6) 2801895
The swing pump is a variable displacement axial- The filters filter the oil flow of the servo control
piston pump in swashplate design for hydrostatic pump and the oil flow of the feed pump for the
drives in a self-contained circuit. self-contained swinging circuit.
The volumetric flow is proportional to the drive

speed and to the displacement volume and is
continuously adjustable.
With increasing inclination of the swashplate, the
flow increases from 0 to its maximum value.
When the swashplate moves through zero posi-
tion, the flow changes its direction smoothly.
To protect the drive system, the pump is

equipped with two pressure relief valves for the
respective high pressure side.
These valves act simultaneously as feed valves.
An integrated booster pump serves as a feed
pump.
The max. feed pressure is limited by the built-in
feed pressure relief valve.
Depending on the preselected control pressure,

the operating pressure and the pressure direction,
and thus the size and direction of the moment at
the hydraulic motor, are continuously adjustable.
This control permits virtually loss-free utilization of

the drive system, both for accelerating and for
braking procedures. No power is converted into
heat via pressure relief valves, and the drive
motor is under less pressure in the braking op-
eration.
There are two means of braking the swinging

operation of the superstructure:
Servo valve in neutral position. The superstruc-
ture is braked by an adjustable braking valve.
Counter-rotation by servo valve. The max.

braking pressure corresponds to max. initial
swinging pressure.
73179380 08 25
Fig. 4
Twin gear pump (7, Fig. 4)

The pump is flange-mounted on the swing pump
connection to the gearbox and supplies the fol-
lowing circuits:
- fan drive unit
- servo control
26 08 73179380
Fig. 5
Hydraulic reservoir, complete (10, Bypass valve (12, Fig. 5)

Fig. 5)
The bypass valve prevents the return flow filter
Reservoir for the hydraulic oil with the following (11) from bursting. It opens at a pressure of more
components: than 1.5 bars. The oil then flows unfiltered into
the reservoir.
- 1 return flow filter (11)
- 1 bypass valve (12) Filter contamination switch (13, Fig. 5)
- 1 filter contamination switch S 15 (13) The switch activates a warning light and an
- 1 temperature sensor R 14 (16) acoustic warning signal in the cab when the re-
turn flow filters are contaminated.
Return flow filters (11, Fig. 5)
Temperature sensor (16, Fig. 5)
The return flow filter filters the oil flowing back
from the consumers. The oil flows through the The temperature sensor senses the temperature
filter element from the inside to the outside. of the hydraulic oil and informs the load limit
regulator.
73179380 08 27
Fig. 6
Swinging mode valve (17, Fig. 6)

The swinging mode valve permits switching the
swinging output in conjunction with the boom lift-
ing funcion. It consists of a solenoid valve with
manual emergency activation and a downstream
pressure relief valve for the control pressure.
28 08 73179380
Fig. 7
Oil coolers with fan drive

(20, 21, Fig. 7)
The return-flow oil from the working- and travel
hydraulics flows through the hydraulic oil cooler
(20). Additionally , the return oil from the fan drive
unit flows through the oil cooler to the filter cham-
ber in the hydraulic reservoir.
The fan is driven by a gear motor with control

valve (21). The fan drive is equipped with a pres-
sure relief and a replenising valve.
73179380 08 29
2801896
Fig. 8
Additional control block (25, Fig. 8)

This control block serves the purpose of control-
ling additional tools such as hammer, scissors,
etc.
The control block is equipped with two pressure

relief valves with integrated replenishing valves
protecting the working lines and the attached
tools. The upper valve is additionally equipped
with a pressure cut-in stage (see also "Primary
valve" 27, Fig. 10). When pilot pressure is applied
to the pressure cut-in stage, the pressure relief
valve opens at an adjustable hig-pressure value.
Without pilot pressure applied, the pressure relief
valve opens at an adjustable medium-pressure
value as , for instance. the hammer operating
pressure prescribed by the manufacturer.
30 08 73179380
Fig. 9
6-way control block (26, Fig. 9)

The control block housing contains 6 control pis- The travel functions are supported by replenish-
tons which are moved by servo control pressure ing valves, by a controlled check valve for parallel
in proportion to the manual control lever or pedal travel and by pressure holding valves.
deflection.
The following travel and working movements are Secondary valves with integrated replenishing
controlled: valves are assigned to the cylinder functions.
There are also paired check valves to maintain
- Control spool for travel right pressure and to separate or combine the oil cir-
- Control spool for travel left cuits.
- Control spool for stick The reservoir channel has two outlets with
- Control spool for bucket precharging valves.
- Control spool for boom

- Control spool for boom-adjusting cylinder (op-
tion)
73179380 08 31
Fig. 10
Primary valve with pressure cut-in

stage (27, Fig. 10, 11)
The primary valves limit the pump pressure for
the travel and working hydraulic systems. When
working with the power boost function, servo con-
trol pressure is applied to the pressure cut-in
stages, so that the primary valves open only at
higher pressure.
32 08 73179380
Fig. 11
Mini-rate regulator or shock reducing

valve (30, 31 Fig. 11)
The control spools for boom and stick are
clamped hydraulically by the mini-rate regulator.
This permits controlled displacement out of the 0
position and controlled retraction of the spool
rods by spring force.
73179380 08 33
Fig. 12
Valve assembly (35 - 40, Fig. 12)

The valve assembly is supplied with servo control The pilot control pressure is also applied to all
oil by the servo control pump (8) through filter (6) solenoids of the valve assembly.
and check valve (40). The assembly consists of
the base unit and flange-mounted solenoid The proportional valve converts the control cur-
valves. rent of the load limit regulator proportionally into
Components: hydraulic pressure.
The high-speed solenoid valve switches the hy-
- Base unit (35) with draulic travel motors to minimum intake volume
- pressure relief for servo control pressure and thus to higher travel speed.
- proportional valve, GLR (load limit regulator)
Y10 Diaphragm accumulator (36, Fig. 12)
- high-speed solenoid valve Y21.2
- Diaphragm accumulator (36) The accumulator is loaded by the servo control
pressure and provides the pressure energy to the
- Solenoid valve (38) for superstructure holding servo control system when the engine has stop-
brake ped for pressure relief of the working hydraulic
- Solenoid valve (39) for power boost function system or for emergency lowering of the equip-
ment.
- Sealing plug (37), internal
Base unit (35)

The adjustable pressure relief valve limits the
pilot pressure which is available at accumulator
(36) and at pilot pressure cut-out solenoid valve
(64). The pressure-measuring port is located on
top of the base unit.
34 08 73179380
Sealing plug (37, Fig. 12) Solenoid valve Y39.1 (39, Fig. 12)
The plug separates the back-pressure-loaded res- The valve is controlled electrically by depressing
ervoir channel of the base unit (35) from the the hammer key on the control panel and the
reservoir channel of the flange-mounted solenoid push-button in the left lever handle. The servo
valve. control pressure flows through the cascade (50 -
54) to the hammer control block (25) and the
Solenoid valve Y35 (38, Fig. 12) regulators of pump 1 and pump 2, port X1, thus
enabling operation of the hammer.
The solenoid valve controls both holding brakes
in the swing gearboxes. With no voltage applied Solenoid valve Y39.5 (39, Fig. 12)
to the valve, the brakes are without pressure and
blocked by spring force. When voltage is applied The solenoid valve is electrically activated by a
to the valve, servo control pressure is admitted to switch for options, e.g. scissors. The servo con-
the holding brakes. The brakes are released and trol pressure flows to the pressure cut-in stage at
the superstructure is free to swing. control block (25), thus enabling high working
The valve is equipped with an emergency unlock pressure for the scissors.
function.
Check valve (40, Fig. 12)
Solenoid valve Y 63 (39, Fig. 12)
The check valve prevents the diaphragm accu-
The valve is operated electrically by the power mulator (36) from losing pressure to the pump
boost key. It switches servo control pressure to after a stop of the Diesel engine.
the pressure cut-in stages of the primary valves,
thus raising the max. pump pressure. At the same time, all solenoid valves of the valve
assembly receive pressure energy from the accu-
mulator.
73179380 08 35
Fig. 13
Shuttle valve cascade (50 - 54, Fig. 13) Switching valve (52, Fig. 13)
The shuttle valve assembly serves to detect one The valve initiates the parallel travel function.
or more servo control pressure signals which
were activated by using the servo control valves It is activated by the servo control pressure of an
or the travel pedals. activated cylinder function. During simultaneous
travel, the servo control pressure of the left travel
The servo control pressure, applied as propor- pedal is switched by the activated switch valve
tional demand pressure pass through line no. 241 (52) to switch valve (56), which is mounted be-
and no. 242 to the regulator of the twin variable hind the 6-way control block.
displacement pump (4).
The pressure switch (53/S10.1) located at the

measuring port opens and informs the load limit
regulator whether the machine is operating. The
load limited regulator now sets the value for the
diesel engine speed and switches off the the auto
idle function.
The pressure switch (54/S35.1) opens only during

swinging, causing solenoid valve (38) to release
the holding brake in the swing gearbox.
The pressure switch (53/S66) in servo control line

no. 120 ensures the Boom Lift function and per-
mits the swinging mode function.
36 08 73179380
Fig. 14
Switching valve (56, 57, Fig. 14)

The switching valve (56) is controlled by switch-
ing valve (52).
It ensures that, during travel, the high pressure

keeps the controlled check valve in the 6-way
control block closed bypassing the switching
valve piston by means of shuttle valve (57).
When a 3rd function is activated, the check valve

in the control block is relieved and the oil flow of
pump 1 is split up into two parallel flows to both
travel motors.
73179380 08 37
Fig. 15
Right servo control valve (60, Fig. 15) Travel pedals (62, Fig. 15)
The boom cylinder and the stick cylinder are The hydraulic travel motors are controlled by
controlled by means of the 4-way servo control means of the 2-way servo control valves.
valve with cross connection.
The servo control pressure ports for forward and
Left servo control valve (61, Fig. 15) reverse travel are equipped with pressure switch-
es ensuring the activation of the Travel Alarm
The stick cylinder and the swinging function are function.
controlled by means of the 4-way servo control
valve with cross connection. All servo control valves (60, 61, 62) are propor-
tional valves. The control valves in the 6-way
control block (26) are adjusted according to the
lever or pedal deflection.
38 08 73179380
Fig. 16
Pedal (62, Fig. 16) Solenoid valve (64, Fig. 15 and 16)
Pedal (62) is used to control a hydraulic hammer The valve blocks the servo control pressure to
or scissors. the servo control valves and to the pedals when
the left control console is raised. When the con-
sole is in its lower, locked position, the solenoid
valve is opened and the servo control pressure is
available to the servo control valves and the ped-
als.
The valve has a manual emergency actuation

system.
73179380 08 39
Fig. 17
Swing gearbox (70, Fig. 17) Speed sensor (72, Fig. 17)
The swing gearbox is a 2-stage planetary gear- The sensor serves as a zero-speed monitor. It
box whose drive pinion engages in the swing controls the holding brake in the swing gearbox
ring. (70) by means of solenoid valve (38). When the
An integrated wet multiple-disk brake serves as a sensor detects zero speed, the holding brake is
holding brake for the superstructure. blocked. The brake remains released as long as
the superstructure is swinging.
Swing motor (71, Fig. 17)
The swing motor is a 40 axial-piston unit with a
constant intake volume. The drive speed is pro-
portional to the incoming oil flow. The torque
supplied grows with the pressure drop between
high-pressure and low-pressure side.
40 08 73179380
Fig. 18
Rotor (75, 78, Fig. 18)

The rotor is the hydraulic connection between
superstructure and undercarriage. It has annular
channels for the functions:
- Travel right, 2 channels
- Travel left, 2 channels
- Leakage oil discharge, 1 channel
A rotary threaded union (78) which lets servo

control pressure through from the high-speed so-
lenoid valve to the hydraulic travel motors (101) is
also mounted below the central channel of the
rotor.
73179380 08 41
Fig. 19
Boom cylinders (80, Fig. 19)

The dual-action hydraulic cylinders are installed
between superstructure and monoblock boom.
They raise or lower the boom and thus the entire
equipment.
42 08 73179380
Fig. 20
Stick cylinder (82, Fig. 20) Restrictor check valve, adjustable (83,
Figs. 20 and 21)
The dual-action hydraulic cylinder is installed be-
tween boom and stick and serves to retract and One valve is provided for the stick lowering func-
extend the stick. tion, and one for bucket filling.
The attenuation at both ends prevents the piston During the stick lowering operation, the valve
from knocking hard against the limit stop. forces the return flow oil out of the rod-side of the
stick cylinder and prevents an excessively rapid
lowering movement and thus cavitation on the
piston side.
During the bucket closing operation, the valve

forces the return flow oil out of the rod-side of the
bucket cylinder and prevents excessively rapid
bucket movements and a shortage of oil on the
piston side.
73179380 08 43
Fig. 21
Bucket cylinder (84, Fig. 21)

The dual-action hydraulic cylinder is installed be-
tween stick and toggle link/toggle lever.
44 08 73179380
Fig. 22
Solenoid valve (91, Fig. 22) Load limit regulator PMS 3 (95)
Solenoid valve (91, Fig. 21) serves to adjust the See Technical Manual "PMS 3".
impact frequency of a hydraulic hammer during
hammer operation.
When solenoid valve (91) is energized, the ham-

mer operating pressure passes from the optional
equipment control block (25) through solenoid
valve (91) and through the control line to the
hydraulic hammer. The chisel stroke of the ham-
mer is shortened with the impact frequency of the
chisel increasing. At the same time, the impact
energy is reduced.
73179380 08 45
Fig. 23
Travel gearbox (100, Fig. 23) Travel brake valve (101, Fig. 23)
The travel gearboxes are 3-stage planetary gear- The travel brake valve protects the hydraulic mo-
boxes with an integrated multiple-disk brake as a tor from overspeeding during downhill travel.
parking brake.
Functioning:
Hydraulic travel motor (101, Fig. 23) During downhill travel, the pump pressure to the
hydraulic motor is reduced and the travel brake
The hydraulic travel motors are variable displace- valve piston restricts the return flow from the
ment axial-piston motors in tilted-axis design. The travel motor, so that the travel speed is con-
hydraulic angle adjustment mechanism is housed trolled.
in the connection plate of the hydraulic motor.
In addition, brake-bleeding valves are provided
A wide angle at the hydraulic motor means high for automatic release of the track brakes. When
take-off torque and traction force on the track at the travel movement is ended, the parking brake
low travel speed. is applied by spring force. For starting up, pump
pressure is used to release the brake by means
A narrow angle at the hydraulic motor means low of shuttle valve, pressure relief valve and brake
take-off torque with high travel speed ("over- release valve.
drive").
Adjustable secondary valves with fixed setting

and replenishing valves are also present as a
protection against excess pressure and lack of oil
in the hydraulic motors.
46 08 73179380
Description of system sections 2801897
For the following functional description of the hy- Unpressurized oil circuit
draulic system, the hydraulic circuit diagram has
been divided into the following system sections: When the engine (1) is running, the drives of the
dual variable displacement pump (4) supply their
Load limit control system minimum oil output past the primary valves (27)
Unpressurized oil circuit through control block (25) and control block (26)
Servo control system into the return flow.
Working hydraulic system The return flow oil flows on the one hand through
Travel hydraulic system a precharging valve in the connection (T2) of the
Parallel bucket connection control block to the filter chamber in the tank, and
Swinging system on the other hand through a precharging valve in
Cooling system port (T1) of the control block to the oil cooler and
on to the filter chamber into the tank.
Load limit control system
The return flow pressure is increased by the cool-
With load limit control (PMS 3), the output of the er flow resistance or precharging valve (T2). This
drive motor is always fully utilized. Any number of precharging serves to supply oil to the cylinders
hydraulic regulating pumps and uncontrolled con- and to the hydraulic travel motors via the replen-
sumers can be driven by one motor, provided the ishing valves
power intake of all uncontrolled consumers is less
than the motor output, as the load limit control The return flow filters (11) in the filter chamber of
can influence only controlled pumps. the hydraulic reservoir are monitored by a pres-
The load limit control uses the load-induced sure switch, which switches on an optic and
speed reduction of the motor as a guide signal. acoustic warning signal in the cab when the filter
This occurs as soon as more power is being is severely contaminated.
taken from the motor than it can supply.
In the event of severe filter contamination, the
The engine drives a multicircuit pump unit via a bypass valves (12) open and the oil flows unfil-
flexible coupling. The multicircuit pump unit com- tered into the tank.
prises a dual variable displacement pump and a
swing pump with connection to gearbox. A dual
gear pump is mounted at the connection to gear-
box. A further gear pump is located at the engine
power take-off.
73179380 08 47
Servo control system

The servo control pump, part of the dual gear Servo control valve (61) stick/swinging
pump (7), draws oil through an intake line from
the hydraulic tank (10) Lowering the stick (PS)
The pumped oil flows through the pressure filter Oil flows through line 117 into the cascade (50,
(6) to the valve assembly (35 - 40). 51) and on through line 217 and through mini-
The servo control oil is available to the servo mum quantity regulators (30) to the servo con-
control valves (60 and 61) and to the travel trol cap on the control block (26) a4.
valves (62) for precise, smooth activation of all Extending the stick (RS)
working and travel movements. Oil flows through line 118 into the cascade (50,
51) and on through line 218 and through mini-
The servo control pressure is moreover available
mum quantity regulators (30) to the servo con-
as control pressure to the PMS.
trol cap at the control block (26) b4.
The solenoid valves of the assembly use the Counter-clockwise swinging
servo control pressure as switching pressure for Oil flows through line 115 into the cascade (50,
the assigned functions. 51) and on through line 216 to the swing pump
(5) connection Y1.
The servo control valves (60 and 61) and pedals
(62) are not supplied with servo control pressure Clockwise swinging
until the excavator operator is seated and has Oil flows through line 116 into the cascade (50,
pushed down and locked the left control console. 51) and on through line 216 to the swing pump
During this operation a switch closes and switch- (5) connection Y1.
es voltage to the solenoid valve (64).
Minimum quantity regulator or shock reducer
The following functions are initiated by actuating (30, 31)
the servo control valves and pedals:
Explanations: The minimum quantity regulators are provided for
boom and stick movements. These attachments
PS = piston side = cylinder is extended with a high dead weight are gradually accelerated
and decelerated by the minimum quantity regula-
RS = rod side = cylinder is retracted tors, resulting in low-vibration machine operation
(shock reduction).
Servo control valve (60) boom/bucket
Raising the boom (PS)

Oil flows through line 120 into the cascade (50,
trol cap on the control block (26) b2.
Lowering the boom (RS)

trol cap on the control block (26) a2.
Filling the bucket (PS)

51) and on through line 221 to the servo con-
trol cap on the control block (26) a3.
Emptying the bucket (RS)

51) and on through line 222 into the servo
control cap on the control block (26) b3.
48 08 73179380
Servo control valve (62) travel, 1 valve for each Servo control valve (62) hammer / scissors
track
Hammer operation / Closing the scissors
Forward travel Depress pedal forwards (increasing pedal de-
Oil flows through lines 111 and 113 into the flection means higher impact frequency of the
cascade (50, 51) and on through lines 211 and hammer). The oil flows through line 154 to the
213 to the servo control caps on the control cascade (50-54) and further through line 254 to
block (26). the top servo control cap at the control block
(25).
Reverse travel
Oil flows through lines 112 and 114 into the Opening the scissors
cascade (50, 51) and on through lines 212 and Depress pedal backwards. The oil flows
214 to the servo control caps on the control through line 153 to the cascade (50-54) and
block (26). further to line 253 to the bottom servo control
cap at optional equipment control block (25).
The servo control pressure in the control spools

for hammer, boom, bucket, stick and travelling is
used via the shuttle valve cascade (50-54) for
controlling the pumps, with the servo control pres-
sure signal being sent through the demand pres-
sure lines 241 and 242 to the regulators of work-
ing pumps P1 and P2.
73179380 08 49
Working hydraulic system Travel hydraulic system

2 hydraulic circuits are provided to execute the On activation of the travel function, the travel
working movements. They are open circuits, i.e. spools are displaced. Pump P1 supplies the hy-
the oil flows from the working points back into the draulic travel motor of the right track, and pump
tank. P2 the hydraulic travel motor of the left track.
The greater travel high pressure is used to close
Circuit 1 the controlled check valve in the 6-way control
block via control lines, shuttle valve (57), switch-
When the control valve is in neutral position, the ing valve (56), behind connection (ST3) in the
minimum oil quantity of pump P1 flows past the 6-way control block (26).
primary valve (27) to the control valves in the
following sequence: The parallel travel function is always initiated if a
hammer, travel right, stick, bucket, boom and on cylinder movement is activated as a 3rd function
into the return flow. during travel.
Circuit 2 The servo control pressure of the 3rd function

opens the switching valve (52) and the servo
When the control valve is in neutral position, the control pressure from the left travel pedal ac-
minimum oil quantity of pump P2 flows past the tuates the switching valve (56) behind the 6-way
primary valve (27) to the control valves in the control block (26) through line 230. This relieves
following sequence: pressure on the controlled check valve in the
boom adjuster, boom, bucket, stick, travel left and 6-way control block connection (ST3), which can
on into the return flow. then open.
Dual admission The oil flow of pump P1 is divided in parallel.
One part continues to supply the hydraulic travel
When work is being done with only one cylinder,
motor of the right track. The second part flows via
the outputs of both pumps are combined in the
the controlled check valve in (ST3) to the control
control block (26) between the paired check
valve Travel left and thus to the left hydraulic
valves, and cylinder admission is thus doubled.
travel motor.
Single admission
If the resistances at the tracks vary, it may not be
If two working movements are activated simulta- possible to travel straight ahead because the oil
neously, the oil flows of the two pumps are sepa- takes the course of least resistance.
rated and each function is activated individually
Pump P2 serves with its output for the 3rd cyl-
by the oil flow of one pump.
inder function.
Additional hydraulics
During activation of the additional hydraulics,

pump 1 primarily supplies oil to the hammer or
scissors function, whereas pump 2 feeds the cyl-
inders for positioning movements.
50 08 73179380
Parallel bucket connection

This connection permits controlled bucket move- The swing pump (5) is equipped with a direct-
ment with simultaneous boom and stick move- controlled swing ring control with pressure cutoff
ment. (SRD). The superstructure can be accelerated or
decelerated with minimum loss with adjustable
The output of pump P2 flows past the primary torque.
valve (27) into the 6-way control block (26). The
oil is applied through a line at the control piston The power obtained from the engine always com-
for bucket cylinders. plies with the power requirement of the hydraulic
swing motor (71) during accelerating and braking.
When boom, bucket and stick are activated, the
output of pump P2 flows mainly back to the boom Machines equipped with SRD swing pump control
cylinders. The rest flows to the bucket cylinder, have a variable and readily changeable power
depending on cross section and pressure. adjustment for the swinging system, the swinging
mode function.
The output of pump P1 supplies the stick cylinder The swinging mode function offers a choice be-
function. tween high lifting power with small swinging an-
gles and increased swinging power for large
When the bucket cylinder is switched off again, swinging angles with a lower lifting power.
the output of pump P2 flows completely to the The swinging mode function influences the swing-
boom cylinders. ing speed and not the swinging moment, i.e.
uphill swinging is not impaired.
Swinging system The swinging mode function is possible only for
swinging with simultaneous boom lifting.
The swinging circuit is a closed circuit, comprising
essentially swing pump (5) and hydraulic swing Swinging mode activated (LED on):
motor (71). To ensure that the closed circuit is
filled, an auxiliary or feed circuit is required. During boom lifting and swinging, the solenoid
valve of swinging mode valve (17) is energized,
The auxiliary or feed pump integrated in the reducing the servo control pressure for swinging
swing pump pumps through the filter (6) to the to the swinging mode pressure. The swash-plate
feed pressure relief valve. The feed pressure is of the variable displacement pump is tilted to a
available to the closed swinging circuit for filling lesser degree and the power consumption of the
purposes via two intake check valves. swing pump limited. The boom can now be lifted
with more power.
The swinging high pressure is limited on both
sides by a pressure cutoff valve. Swinging mode deactivated (LED off):
The closed circuit is protected from pressure The solenoid valve of swinging mode valve (17)
surges by high-pressure safety valves. remains deenergized and the servo control pres-
sure for swinging is not reduced. The swing
The swing pump is an axial-piston pump in
pump can now produce maximum output with
swashplate design. If the swashplate is at right
less power being available to the boom.
angles to the drive axis (zero position), the axial
pistons execute no stroke. Continuous adjustment
of the swashplate adjusts the axial-piston stroke
and thus the output.
In addition, a change of pumping direction from
clockwise swinging to counter-clockwise swinging
is possible.
73179380 08 51
Neutral position
When the servo valve is in neutral position, servo The maximum pressure occurring during initial
control lines nos. 115/215 and 116/216 are un- swinging falls again once the mass inertia of the
pressurized. superstructure has been overcome, and the pres-
The adjusting cylinder of the swashplate is also sure cut-off closes again. In addition, the restor-
unpressurized and is held in neutral position by ing forces of the driving gear are reduced, and
spring force. the swash-plate is adjusted to a greater angle
and the axial piston to a greater stroke. The
Counter-clockwise swinging output of the swing pump increases as the high
pressure is reduced. By the end of the accelera-
When the servo control valve (61) is switched to tion, the pump has reached its maximum output.
the left, servo control pressure gets into the cas-
cade (50/51) and on through hose no. 215 to the The swinging mode function has an influence on
control unit of the swing pump (5) connection Y1. the max. output and thus on the superstructure
The control pressure flows through the intake speed.
nozzle of the control unit via the directional con-
trol valve to the two brake valves and closes During the swinging movement, the high pressure
them. The pressure is also applied at the pres- keeps the check valve closed for intake, while the
sure cut-off and via connection Y 3 at the swing- feed pump pumps in on the low-pressure side
ing mode valve (17). At the same time, the con- and compensates for leakages.
trol pressure opens the servo valve and has
direct access to the control chamber of the ad- Clockwise swinging
justing cylinder.
Clockwise swinging is done analogously to coun-
The swash-plate is moved out of zero position, ter-clockwise swinging.
the axial pistons execute a stroke, and the swing
pump pumps oil to the hydraulic swing motor Braking the superstructure
(71). The pressure being built up depends on the
The superstructure is braked by moving the servo
resistance, i.e. on the torque of the hydraulic
valve (61) to zero position. The control pressure
swing motor (71).
in the servo unit is reduced. The control valve is
The pressure cut-off limits the torque and thus closed by spring force and the pressure is re-
the acceleration of the superstructure. As long as lieved on both brake valves, activating one brake
the pressure cut-off is open, the control pressure valve. The control pressure from the control
into the pump housing is reduced and the swash- chamber of the adjusting cylinder flows via the
plate moved towards zero position. The output is activated brake valve into the pump housing. The
then equivalent only to the leakage losses, and speed at which the control pressure is reduced is
the torque at the hydraulic swing motor is main- determined by the braking action.
tained.
The high swinging pressure generates restoring

forces against the swash-plate which is moved by
control pressure. As a result, the swing pump
pumps that quantity of oil which the hydraulic
swing motor can take in.
52 08 73179380
Checking and setting pressures 2796747
Safety instructions
Observe accident prevention and The hydraulic cylinders must be brought

safety regulations at all times. into their limit positions before pressures
are checked or set, to ensure that the
The pressure checking and setting may working equipment does not move when
be done only by specially trained and au- pressure is applied.
thorized personnel with the proven tech-
nical know-how. The excavator operator must operate the
The opening pressure of pressure relief relevant function gently (gradual pressure
valves must not be changed. application) and then shift the control le-
ver / pedal to its limit position.
All personnel involved in commissioning,
operating, inspecting and servicing the All pressure test points on the excavator
hydraulic excavator must have read and have Minimess measuring ports. Pressure
understood the operating instructions and gauges used for checking must therefore
in particular the chapter "SAFETY" before have corresponding fittings.
starting any work. Always connect the measuring hose first
Unauthorized conversions or modifica- to the pressure gauge and then to the test
tions of the hydraulic excavator are for- point of the hydraulic system to prevent
bidden for safety reasons. hazardous pressurized-oil spillage.
Before starting any servicing or inspec- The springs of pressure relief valves must
tion work, secure the machine and never be tightened fully to "block". The
equipment against inadvertent and un- windings of the springs are then jammed
authorized starting and set the working so that the valve cannot open.
equipment down on the ground. Therefore, before initial valve setting (pri-
Tools, hoists, slings, trestles, working mary and secondary), loosen the valve in-
platforms and other devices must be in a serts by ca. 1 turn:
reliable, safe state. Turning counter-clockwise (loosening) =
Line systems on which work is to be lower pressure setting
done must first be properly depressuriz- Turning clockwise (tightening) = higher
ed. pressure setting
Protective devices on moving machine To set/adjust a pressure relief valve, loos-
parts may be opened or removed only en the counter nut on the valve insert, set
when the drive unit is stationary and se- the opening pressure using the setscrew,
cured against inadvertent starting. Before then tighten the counter nut again.
recommissioning, all protective devices
must be closed or refitted.
73179380 08 53
General 2800756 Pressure settings 2796823
Pressure checking must be done with calibrated Designation Unit

pressure sensors in conjunction with EDS tester bars
or with calibrated pressure gauges connected to
the respective measuring points. Servo control pressure 45
The two main pumps are designated P1 and P2 Primary pressure for main pumps 320 / 360
(Fig. 1). with / without power boost function
Secondary pressure for

- boom cylinder
- stick cylinder 380
- bucket cylinder
- hydraulic travel motor
Feed pressure for swing pump 20
Pressure cutoff for swing pump 390
Safety valve for swing pump 420
Control pressure for swinging mode 18.5
Fig. 1
When adjusting pressure relief valves, the tem-

perature of the hydraulic oil must be at least
50C.
54 08 73179380
Tools 2801088
For checking and setting of pressures, the tools listed below are needed:
PCS tester (Fig. 1)
Fig. 1
Large leather test case with contents

Individual parts
PCS - tester with leather case: 73175280 Pressure gauge connection: 4 x 73175287
Printer: 73177879 Couplings: 4 x 73175288
Adapter for printer: 73177880 Mains adapter: 73180157
Printer with power supply: 73180160 RAM-Card, multi-lingual 73175292
Battery - printer: 73180161 Case, large: 73175291
Cable - printer: 73175285 Case, small (only for tester): 73176679
Cable - OOC: 73175281 Leather case: 73176680
Cable - sensors: 4 x 73175284
Measuring hose: 4 x 73175289
73179380 08 55
Pressure gauge (Fig. 2)
Pressure gauges can be used as an alternative

to the PCS tester.
For:
Checking and adjusting operations on the hydrau-
lic system.
Fig. 2
Part Nos.
Measuring hose, 2000 mm 73176714
Measuring hose adapter 73176715
56 08 73179380
Servo control pressure 2796825 Working hydraulics with power boost

Connect 90-bar pressure sensor to Minimess
function 2800757
measuring point (arrow, Fig. 1). To check the secondary valves, the primary pres-
Engine speed = idling speed sures must be increased beforehand.
Setpoint value = 45 bars, correction at valve Setting the primary valve to higher pressures
(1).
Switch off engine.
Connect 600-bar pressure sensors to Minimess

measuring points of both primary valves.
For checking the secondary valves, the pres-

sure settings of the pressure cut-in stages in
both primary valves (2, Fig. 2) must be raised
as follows:
- Disconnect hoses from both pressure cut-in
stages and plug.
- Unscrew lock nut (2.2) and turn in setscrew
(2.1) down to the limit stop.
- Tighten lock nut (2.2), holding against set-
Fig. 1 screw (2.1).
- Loosen lock nut (2.3) and turn in setscrew
(2.1) by 1/3 turn.
Start engine and run at moderate speed.
Fig. 2
73179380 08 57
2801899
Fig. 3
Secondary valves for cylinders
Move all cylinders successively against limit

stop and check secondary pressure; correct if
necessary.
Setpoint value of secondary valves (3, Fig. 3):

380 bars
Attention:
Boom lowering function individually activated by

pump P2
Legend:
Na - Controlspool boom adjusting cylinder

A - Controlspool boom cylinder
L - Controlspool bucket cylinder
St - Controlspool stick cylinder
K - piston side (extend cylinder)
R - rod side (retract cylinder)
58 08 73179380
Secondary valves for travel motors 2800758 Pressure-limiting valves on additional control
block 2801901
Unscrew control lines of track brakes and plug.
That blocks the track brakes. Excavators with additional control block have the
primary valve (2, Fig. 5) for pump 1 and the
Move travel motor forward and back against
pertaining measuring point on the the additional
the blocked brakes and check secondary
control block.
valves (4) for 380 bars.
Reconnect control lines of track brakes. Machines with a hydraulic system for hammers
have a single-stage pressure-limiting valve (5,
Fig. 5) limiting the hammer operating pressure.
Valve (6, Fig. 5) would not be installed and re-
placed by a closing plug.
Pressure setting: Close the express couplings

on the stick and switch on the hammer.
Set pressure: see the instructions of the ham-
mer manufacturer
Excavators with a hydraulic system for hammer

and scissors have two pressure- limiting valves (5
and 6, Fig. 6) installed in the control block. The
upper valve (5) has a switchable pressure cut-in
stage limiting the scissors high pressure (for clos-
ing of the scissors) on the one hand and the
hammer operating pressure on the other. The
lower valve (6) limits the scissors high pressure
(for opening of the scissors).
Pressure checking: close and open scissors

Fig. 4
fully to the respective limit stops and adjust the
valves (5 and 6) in compliance with the instruc-
tions of the scissors manufacturer.
Fig. 5
73179380 08 59
2796829
Fig. 1
Setting/adjusting primary valves Pressure stage 1 (320 bars)
Unscrew nut (25).
Set pressure stage 1 by turning setscrew (24)

Observe setting/adjusting instructions counter-clockwise.
strictly; this is the only means of ensuring
Tighten lock nut (25) again, holding against
a correct setting.
setscrew (24).
Connect hoses to pressure cut-in stages again,

Basic setting holding against setscrew (24).
Unscrew lock nut (19, Fig. 1).
Turn adjusting spindle (26) fully out.
Block switching piston (23) by turning in set-

screw (24).
Tighten lock nut (25), holding against setscrew

(24).
Screw adjusting spindle (26) back into housing

(16).
Pressure stage 2 (360 bars)
Set pressure stage 2 with adjusting spindle

(26).
Tighten lock nut (19) again, holding against

setscrew (24).
60 08 73179380
2801902
Fig. 1
Pump control through proportional demand signals

This is necessary in cases of insufficient power at
one or at both pumps. Function Pressure demand
at pump
Connect 60 bar pressure gauge to measuring
ports of proportional demand control lines no. Swinging CW / CCW 1
241 (Fig. 1) and no. 242.
Right travel forward / 1
Activate functions fully in sequence shown in reverse
adjacent table and compare demand signals
with those given in the table, executing travel Boom adjusting cylinder 1+2
functions with tracks raised. PS* / RS* (option)
Boom cylinder PS* / RS* 1+2
Stick cylinder PS* / RS* 1+2
Bucket cylinder PS* 1+2
Bucket cylinder RS* 2
Left travel forward / 2

reverse
Hammer 1+2
Scissors 1+2
73179380 08 61
Output control through proportional demand pressure

The proportional demand pressure has to be Pump 1
checked or corrected when boom or stick func-
tions are subject to jerky movements in the preci- Extend boom cylinder to limit stop.
sion control range. The resulting lack of oil in the Servo control pressure of 7 to 8 bars produces
cylinders can be avoided by adjusting the propor- a high pressure of 150 to 180 bars.
tional demand pressure.
Pump 2
Connect 600 bar pressure gauge at measuring
ports of primary valves (Fig. 1). Extend stick cylinder to limit stop.
Connect 60 bar pressure gauge at cascade Servo control pressure of 7 to 8 bars produces
measuring port or at measuring ports for pro- a high pressure of ca. 200 bars.
portional demand pressure at pump regulators.
Make the necessary corrections at setscrews (6,
Set specified servo control pressure at max. Fig. 2).
engine speed; this results in high pressure at
the control block. Slacken setscrew: increased pressure
The servo control pressure : high pressure ratio Tighten setscrew: reduced pressure.
allows the proportional demand control to be
assessed.
Fig. 2
Fig. 1
62 08 73179380
Swinging system 2801903
Pressure-testing of the swinging system must be Location of measuring ports and adjusting
done only when the superstructure holding brake screws (Figs. 2 + 3).
is applied.
No. Function
The pressure-relief valves and measuring ports
for the self-contained circuit of the swing drive are 1 Pressure-limiting valve for feed
located at the swing pump (arrow, Fig. 1) and at pressure, fixed setting
the swing-mode valve located below it.
2 Pressure cut-off valve
3 Shifting
MA Measuring port for feed pressure and

maximum swing pressure
MB Measuring port for feed pressure and

maximum swing pressure
6 Adjusting screw for swing pump

mechanical zero point
7+8 Safety valves for counter-clockwise and

clockwise swinging, fixed setting
Fig. 1
9 Measuring port for swing mode
pressure
10 Adjusting screw for swing mode

pressure
11 Brake valve
12 Regulating valve with lead seal
13 Swing mode connection
G Servo control
Fig. 2
Note:
Fig. 3 does not correspond to the pump installa-
tion position.
73179380 08 63
Fig. 1
Swing pump adjustments (Fig. 3) : Changing the braking torque

1 - Feed pressure valve The braking action can be continuously influ-
enced by means of a setscrew.
2 - Pressure cut-off
Setscrew slackened = stronger braking.
3 - shifting
Maximum braking is attained when the clearance
MB - Measuring connection for feed pressure and between the setscrew and the lock nut is 11 mm.
swinging pressure maximum
Setscrew tightened = more gentle braking.
MA - Measuring connection for feed pressure and
swinging pressure maximum
6 - Mechanical 0-position adjustment
7 - Secondary valve (emergency valve for swing

function)
8 - Secondary valve (emergency valve for swing

function)
11 - Brake valve
12 - Regulating valve with lead seal
13 - Swing mode connection
G - Servo pressure
64 08 73179380
Feed pressure and zero point High swinging pressure and safety valves
Connect first 600 bar, then 60 bar pressure Activate CW/CCW swinging and check pres-
gauge to both high-pressure measuring ports (4 sure cutoff (2) for 390 bars; adjust if necessary.
and 5, Fig. 2) and check 20 bar feed pressure
with the engine running. Check opening pressure of safety valves (7
and 8, Fig. 2) for 420 bars by turning up pres-
Correction of non-uniform pressures: sure cutoff (2). For setting, see safety valve
Turn set screw for mechanical zero point (6) (Fig. 4).
until both pressures are the same.
Correction of incorrect feed pressure:

Influence permanently set feed pressure valve
with spacers.
Replace the 60 bar pressure gauges again by

the 600 bar pressure gauges
Swinging power (swing mode)
Connect 60 bar pressure gauge to control pres-

sure measuring port (9, Fig. 3).
Turn in setscrew of pressure cutoff (2, Fig. 2)

by two turns.
Fig. 2
Set swing mode key to normal swinging power
- LED on.
Raise boom sensitively and connect full swing- Max. checking time: 5 seconds.
ing power.
Risk of overheating.
Set pressure cutoff (2) back to 390 bars.

Max. checking time: 5 seconds.
Risk of overheating. Safety valve
For pressure changes, the safety valve must be

Check control pressure at measuring port (9); if removed.
necessary, set to 18.5 bars at swing mode
valve, pressure relief (10). Fig. 4
Then adjust pressure cutoff (2). 1 - Housing; tightening torque = 90 Nm
3 - Spindle for changing the pressure setting; 1

turn of spindle = 44 bars; change of set
value possible only after loosening lock-
screw (7).
4 - Valve disk; the set differential pressure is

stamped into the valve disk, e.g. 400 bars.
7 - Lock-screw
73179380 08 65
2800761
Fig. 1
Installing the hydraulic pumps

Components
size grade size Nm lbft
mm
1 1 Multi-circuit pump unit 135 / 315
2 1 Gear pump (twin) 6 / 14
4 1 Coupling, compl.
5 12 Hex screw M 10 x 35 10.9 17 60 44
6 8 Hex socket-head screw 3/8" x 7/8 8 grade 55 41
7 2 Hex socket-head screw M 10 x 25 8.8 17 46 34
66 08 73179380
2800761
Fig. 1
Removal and installation of the hydraulic pumps

Removing a pump Installing a pump
Drain hydraulic oil from reservoir into clean Coat toothed connection of pump and coupling
container. Note quantity. with lubricant paste P/N 73171484.
Disconnect hydraulic lines carefully at pump. Attach pump to lifting tackle and install. Turn in
Collect escaping oil in a suitable container. fastening screws and tighten with tightening
torque shown in table.
Remove hydraulic lines. Close open connec-
tions to prevent dirt from penetrating. Reconnect all hydraulic lines.
Fill hydraulic oil reservoir again.
Attach pump to lifting tackle, unscrew fastening
screws and remove pump. Vent pump.
The working pumps are vented through the
When removing gear pumps and swing pump,
venting plug (T, Fig. 1). The working pump
there is no need to drain the oil out of the
housing can be filled in addition through this
reservoir (use vacuum pump if necessary).
connection if necessary.
The swing pump housing must be filled
through the connection (T1), as venting cannot
be done through the intake line.
73179380 08 67
Hydraulic cylinders 2801898
Safety instructions
Observe the accident prevention regula- Close any hose and pipe connections that
tions. have been opened during dismantling and
Any person involved in activities in con- any open bores and housings to prevent
junction with commissioning, operation, dirt from getting into the system.
inspection and servicing or repair of the Work on hydraulic cylinders, especially in
hydraulic excavator must have read and conjunction with the removal and the as-
understood the Operating Instructions, sembly of piston rods, should be per-
and, in particular the chapter on SAFETY, formed as far as possible with the cyl-
before beginning to work on the machine. inder in vertical position. Long cylinders
The personnel working on the machine should be lowered into inspection pits.
must have the required technical know- Cleanliness at the place of work is of
how. prime importance. Use lint-free cleaning
Tools, lifting tackle, slings and fasteners, rags only (do not use cotton waste).
trestles, working platforms and other Always use the recommended tools.
working aids must be in a safe and reli- The removal and the installation of seal-
able state of operation. ing elements and wear parts must be per-
Line systems to be opened for working formed with suitable tools such as, for
purposes must be depressurized before- instance, snub-nosed screwdrivers to pre-
hand by suitable means. vent damage to the sealing surfaces.
Park the excavator on level ground, se-
cure it against inadvertent movements,
stand the working equipment on the
ground, shut off the engines and protect
them by reliable means against inadver-
tent starting.
Slacken screwed pipe connections and
hydraulic hoses only if you are absolutely
certain that the hydraulic system is safely
depressurized.
Be careful in the presence of hot hydrau-
lic oil.
The piston rods of hydraulic cylinders to
be removed must be retracted completely.
Secure the piston rod in this position at
the cylinder to prevent it from extending
inadvertently before slackening any hy-
draulic line connections.
Collect escaping hydraulic fluid in suit-
able recipients.
Use lifting tackle to remove and to refit
the piston rod and the guide bushing.
68 08 73179380
General
All cylinder components are perfectly matched. Hydraulic cylinders must be vented after repairs
Long-term and trouble-free operation can there- prior to recommissioning. In certain operating
fore only be ensured when original spare parts conditions, entrapped air together with hydraulic
are used. fluid can burn away due to self-ignition (diesel
effect) and cause serious damage to the cylinder
The wear and spare parts required for reparing already after a short time.
hydraulic cylinders can be inferred from the
spare-parts list belonging to your machine. The whole hydraulic system must be flushed
when impurities or even metal particles are found
This chapter does not contain any information on in a defective cylinder, at the magnetic rod or in
how to rework damaged components of hydraulic the filters.
cylinders.
Only specialized workshops can say whether a
damaged component can be reworked and what
procedures are required to do so.
Work carried out in your own workshop should
therefore be limited to the installation of new wear
and spare parts.
All activities involved must be performed carefully
and in a clean environment.
Negligence can cause severe consequential dam-
age to the whole hydraulic system.
73179380 08 69
Fig. 1
70 08 73179380
Components for boom and bucket cylinders (Fig. 1)

Item Quantity Designation Item Quantity Designation
1 1 Bearing eye 14 1 Lip seal
2 - 15 Fitting paste P/N 73171461

for items 12, 13, 14, 16
3 -
16 1 Lip seal
4 -
17 1 Guide ring
5 2 Fastening screw for bearing eye
18 1 Backing ring
6 see Fastening screw for bushing
spare- 19 1 O-ring
parts list
20 3 Guide ring
7 1 Rod guide
21 1 OK piston seal
8 1 Piston rod with piston
A Pivot bearing gap
9 1 Dampener at piston (gap perpendicular to the
direction of forces)
10 4 Circlip for pivot bearing
11 2 Pivot bearing
12 1 Wiper
13 1 Wiper
73179380 08 71
Fig. 2
72 08 73179380
Components for stick cylinder (Fig. 2)

Item Quantity Designation Item Quantity Designation
1 1 Bearing eye 14 1 Lip seal
2 1 15 Fitting paste P/N 73171461

for items 12, 13, 14, 16
3 1
16 1 Lip seal
4 1
17 1 Guide ring
5 6 Fastening screw for bearing eye
18 1 Backing ring
6 8 Fastening screw for bushing
19 1 O-ring
7 1 Rod guide
20 1 Guide ring
8 1 Piston rod with piston
21 1 OK piston seal
9 1 Dampener at piston
22 1 Guide ring (metal)
10 4 Circlip for pivot bearing
23 1 Dampener bush
11 2 Pivot bearing
24 1 OK piston seal
12 1 Wiper
25 1 Threaded pin secured with
13 1 Wiper Loctite 242
26 1 Ball dia. 6 mm
27 1 Dampener bush
28 1 Pin
A Pivot bearing gap

(gap perpendicular to the
direction of forces)
73179380 08 73
Assembly
The following chapters describe dismantling and If the pivot bearing (11) needs replacing, re-
assembly of hydraulic cylinders move circlip (10, Fig. 4) by means of special
pliers before knocking out the pivot bearing
Boss-type, one-piece (Fig. 3) (11) with a suitable mandrel.
Fig. 3 Fig. 5
Dismantling and checking: Assembly:
Slacken the screws (5, Fig. 4) and screw the If the pivot bearing (11, Fig. 3 + 4) has been
bearing eye slotted on one side (1) off the removed: refit new bearing as described under
piston rod (8). To facilitate dismantling, spread "Pivot bearings".
the bearing eye halves apart using a wedge.
Apply anti-corrosive P/N 73171467 on the
thread and the thread run-out of piston rod (8)
Fit bearing eye (1) to piston rod (8) and screw

down to the limit stop. The loosen by ca. 15 -
30.
Insert and tighten bolts (5). Tightening torque

for hex bolts (see table 1)
Apply anti-corrosive equally to the exposed

threaded ends of the bolts (5) and to the
clamping slot of the bearing eye.
Close gap between rod and eye threads (B,

Fig. 3) and the slot in bearing eye near (C) with
Fig. 4 sealing compound P/N 72183648.
Swing out the internal race of pivot bearing (11,
Fig. 4 + 5) and turn slowly checking the bear-
ing for play and condition and examining the
greasing channels.
Table 1: Bearing tightening torques
Type of cylinder Type of bolt Quality Size Wrench MA Torque

(mm) (Nm) lbft
Boom Hexagonal 10.9 M 16 x 90 24 250 185
Stick Hexagonal 10.9 M 16 x 90 24 250 185
Bucket Hexagonal 10.9 M 16 x 90 24 250 185
74 08 73179380
Pivot bearings
Some of the cylinders have pivot bearings (11,

Figs. 6 + 7) installed in their barrel and rod eyes.
The pivot bearings are held in place by means of
circlips (10).
Fig. 6 Fig. 8
Assembly:
Insert the lower circlip (10, Fig. 8).
Install the pivot bearing (11) using a suitable

tool (e.g Fig. 8).
Observe the correct position of the pivot

bearing gap in the outer race (A, Fig. 1 +
2). The gap must be perpendicular to the
main direction of loading.
Pivot bearings are fully hardened. Local
Fig. 7 impact stresses involve the risk of har-
dening cracks. Pivot bearings must ther-
Dismantling and checking: fore not be driven in with a hammer.
Swing out the internal race of pivot bearing (11)
and turn slowly, checking the bearing for play Install the upper circlip (10).
and condition and examining the greasing
channels.
If the pivot bearing (10) needs replacing, re-

move circlip(s) by means of special pliers be-
fore knocking out the pivot bearing (11) with a
suitable mandrel.
73179380 08 75
Piston rod guide boom and bucket cylinders
Dismantling and checking:
Fig. 9
Drain hydraulic oil from the cylinder. Collect Withdraw the guide (7).
escaping oil in a suitable recipient. Remove all sealing elements and wear parts
using suitable tools such as, for instance, snub-
Remove the bearing eye (1, Fig. 9). nosed screwdrivers to prevent the sealing sur-
Loosen the fastening screws (6). faces from being damaged.
Dislodge guide (7) from the barrel by means of Check the guide (7). Replace if damaged. The
two M 12 x 150 jack screws or M 10 x 150. other sealing elements and wear parts will oth-
erwise be irreparably damaged in a very short
time. Always replace all wear parts (wipers, lip
seal, etc.).
76 08 73179380
Piston rod guide stick cylinder
Fig. 10
Drain hydraulic oil from the cylinder. Collect Withdraw the guide (7) and dampener (23).
escaping oil in a suitable recipient. Remove all sealing elements and wear parts
using suitable tools such as, for instance, snub-
Remove the bearing eye (1, Fig. 10). nosed screwdrivers to prevent the sealing sur-
Loosen the fastening screws (6). faces from being damaged.
Dislodge guide (7) from the barrel by means of Check the guide (7) and dampener (23). Re-
two M 12 x 150 jack screws or M 10 x 150. place if damaged. The other sealing elements
and wear parts will otherwise be irreparably
damaged in a very short time. Always replace
all wear parts (wipers, lip seal, etc.).
73179380 08 77
Assembly: Slide assembly sleeve (C, Fig. 12) over the

thread of the piston rod.
Stick cylinder only:
Insert dampener with OK piston seal (24). For The sleeve protects the sealing and guide rings
OK piston seal fitting, see section "Piston rod against being damaged by the rod thread when
and piston". the guide is installed.
If no sleeve is available, cover up the thread
Fit O-ring (19) and backing ring (18). Make with adhesive tape.
sure the backing ring is on the side of the
O-ring away from pressure.
Insert the slotted guide ring (17).
Apply assembly paste P/N 73171461 to groove

(15) of the guide.
Insert the lip seals (14 + 16). Lip seal (16)

consists of the lip seal itself and a loose back-
ing ring.
Press lip seal into kidney shape and install in
the groove (Fig. 11) before inserting the slotted
backing ring.
Install wipers (12 + 13). Fig. 12

Before fitting the guide, apply hydraulic oil on Install the guide (7, Fig. 13) in the cylinder
wipers, sealing rings guide rings. barrel.
Insert the fastening screws (6, Fig. 13) and

tighten (torques see Table 2).
Install the bearing eye (see chapters "Boss-

type bearing eye, one-piece" and "Pivot bear-
ings").
Fig. 11
Fig. 13
Table 2: Tightening torques for guide bolts
Type of cylinder Type of bolt Quality Size Wrench MA Torque

(mm) (Nm) lbft
Boom Cylinder 10.9 M 20 x 100 17 490 362
Stick Cylinder 10.9 M 12 x 120 10 104 77
Bucket Cylinder 10.9 M 20 x 100 17 490 362
78 08 73179380
Piston rod and piston
Drain hydraulic oil from the cylinder. Collect Remove the plastic guide rings (20, Fig. 16)
escaping oil in a suitable recipient. and the OK piston seal (21).
Remove bearing eye (1, Fig. 14) and guide (7).
Fig. 16
Fig. 14 Check the piston with piston rod and dampen-

ers and the the cylinder barrel carefully for
Attach piston rod (8, Fig. 15) with fitting ring damage and wear. Check the cylinder barrel
(D) to lifting tackle, withdraw carefully from cyl- also for signs of widening. Replace all defective
inder barrel and place on a suitable working parts. The plastic guide rings, the protective
surface. elements and the OK piston seal must always
be replaced.
Fig. 15
73179380 08 79
Assembly:
The element used to seal off the piston is the OK Install the guide rings (20, Fig. 19).
piston seal (21, Fig. 16). The joints of the guide rings must be offset by
180 with respect to one another.
The OK piston seal comprises:
- the stepped plastic sealing ring (21.1) and
- the square-shaped tensioning ring (21.2, Fig.
17).
Insert the tensioning ring (21.2) in the groove

provided for this purpose:
- Place the tensioning ring over ca. 1/5 of its
length into the groove.
- Slide a smooth, round rod under the ten-
sioning ring (Fig. 17) and guide the tension-
ing ring towards the groove by running the
rod round the piston in the direction of the
arrow. Fig. 19
Insert the sealing element (21.1, Fig. 20) of the

OK piston seal.
Fig. 17
- Withdraw the rod only after the tensioning
ring lies torsion-free and straight in the
Fig. 20
groove (Fig. 18).
Fig. 18
80 08 73179380
Apply hydraulic oil on the sealing and guide Attach the piston rod (8) with the fitting ring (D,
rings and on the protective elements. Slide the Fig. 22) to a lifting tackle and let down carefully
assembly sleeve (E, Fig. 21) over the piston to to the bottom of the cylinder barrel.
keep the sealing and guide rings in place.
Install the bearing eye and the guide (see
chapter "Piston rods and pistons").
OK piston seals are installed with pre-ten-

sion of 0.65 - 1 mm depending on diam-
eter.
Fig. 22
Fig. 21
Installing the piston without using the assembly

sleeve involves the risk of the sealing and guide
rings jamming in the cylinder.
73179380 08 81
Fig. 23
Limit stop dampening at stick cylinder:
The stick cylinder piston is equipped with a limit-

stop dampening bush (Fig. 23). Proceed as fol-
lows if the dampening bush (27) is to be re-
placed.
Screw out headless screw (25) and collect the

balls (26).
Remove bolt (28) and dampening bush (27).
Install new dampening bush (27) and insert bolt

(28).
Insert the balls (26) into the borehole.
Apply Loctite 242 on headless screw (25), turn

into bore and tighten.
82 08 73179380
TROUBLESHOOTING 2732227
Troubleshooting, instructions Layout of the troubleshooting

Faults are often due to the machine not having
table
been correctly operated or serviced.
Fault
It is therefore essential to read the corresponding
This column describes the fault as determined by
section of the Owners Manual again each time a
an observation or during a preceding activity.
fault occurs.
Therefore keep a careful watch on the machine.
If the cause of the fault cannot be detected or the
fault cannot be eliminated, contact the Service Study the problem with care. Think before acting.
Dept.
Ask yourself the following questions:
Describe the fault and all symptoms as exactly as
possible if you call on the Service Dept. Exact - What warning signs preceded the fault?
data make for rapid trouble shooting. - What repair and servicing work was done be-
fore the fault was detected?
Never do any work for which you are not quali-
fied. - Has the same fault occurred before?
This troubleshooting table lists faults which have - Is this one single fault or a number of simulta-
previously occurred, together with their possible neous faults?
causes and their remedies. In exceptional cases,
a described fault may have a different cause. Possible cause
This column describes possible causes of the
respective fault. They are listed in the order of
their probability, i.e. the most likely cause is listed
first.
Remedy
This column describes the troubleshooting opera-
tion.
73179380 08 83
Troubleshooting guide 2800762
The troubleshooting guide covers the detection It is possible that a malfunction may have other
and elimination of faults in the event of a mal- causes not listed here.
function. In such a case where a fault cannot be located,
contact your Service Dept.
Fault Possible cause Remedy
1. No working, travel and No servo control pressure

swinging functions possible PRV servo control pressure Check; repair and adjust if nec-
defective essary.
Servo control circuit filter Replace filter cartridge.
contaminated
Servo control pump not Check drive; repair if neces-
pumping oil sary.
Check pump; replace if neces-
sary.
Servo control oil escaping to Check which valve is leaking.
tank through defective servo Repair or replace defective
control valve or pedal valve.
Servo control pressure o.k.
Servo control pressure cutout Check whether LED in plug is
solenoid defective illuminated; if not, repair elec-
trical system or work with man-
ual standby activation.
2. Working, travel and swinging Diesel engine speed Check speed adjustment or
functions slow control PMS programming.
Output stage Switch over output stage.
Servo control pressure too low Check and correct.
3. Working and travel function Insufficient diesel engine out-

slow. Swinging function o.k. put, speed o.k.
PMS reducing output of Check air filter, fuel filter etc.;
working pumps. replace/change if necessary.
No fault display
PMS reducing output of Locate fault from fault code ta-
working pumps. ble and eliminate problem.
Fault code display
Regulators of working pumps Check pressure demand con-
receiving incorrect pressure trol, determine and eliminate
demand signals fault.
84 08 73179380
4. Individual working or travel Primary valve opening prema- Check and adjust.
functions not o.k. turely
Control piston in control block Check control piston for easy
not moving full stroke movement and correct stroke;
repair/clean if necessary.
Secondary valve opening pre- Check pressure and adjust.
maturely
5. One attachment function with Defective piston seal in one Locate defective cylinder (heat
no power in both directions cylinder build-up or escaping oil). Re-
place seal and guide belts.
6. One attachment function with Secondary pressure reducing Check setting; correct if neces-
no power in one direction valve incorrectly set or defec- sary, or replace seals or valve
tive complete.
7. Neither track can be moved Brakes are applied Check brake control function.
Release brakes mechanically.
8. One track slow; low traction in Servo control pedals cannot be Check for foreign matter under
both directions uniformly depressed pedal; remove if necessary.
Servo control pedal signalling Check servo control valve; re-
incorrect pressure demand to pair or replace if necessary.
one pump regulator, so pump
outputs different.
Primary pressure reducing Check; reset or replace valve if
valve set too low. necessary.
Travel motor worn or defective. Replace travel motor.
Valve piston of travel brake not Repair or replace valve.
opening completely, piston jam-
ming.
Spool in travel control block not Check spool for free move-
moving full stroke. ment; repair or replace control
block if necessary.
Rotor seal defective Check; repair if necessary.
73179380 08 85
9. One track slow; low traction in Replenishing valve defective Replace replenishing valve.
one direction (no pressure build-up).
Secondary valve opening pre- Check; adjust if necessary.
maturely
10. Excavator circles on cylinder Parallel travel function out of Check switching valve at cas-
activation order. cade and distributor at control
block; repair if necessary.
11. Swinging not possible in either Holding brake blocking Release brake or use standby
direction control system.
Pressure cut-off permanently Repair and reset.
open
No charge pressure Check; adjust if necessary.
Charge pump defective Replace.
Charge circuit filter contaminat- Replace filter cartridge.
ed
12. No swinging power in either Pressure cut-off opening pre- Check; adjust if necessary.
direction maturely
13. No swinging power in one di- Safety valve opening prema- Check; adjust or replace if
rection turely necessary.
14. Superstructure speed too low Pressure cut-off opening pre- Check, adjust if necessary.
maturely
Hydraulic swing motor worn Replace hydraulic motor.
Swinging mode valve perma- Check/repair valve.
nently open Close control line to valve.
Swash-plate adjustment cylin- Replace pump.
der worn
Control valve in the control unit Replace control unit.
is blocked
Brake valve blocked in open Check valve and repair if nes-
position secary.
86 08 73179380
15. Superstructure tries to swing Swing pump regulator not in Reset mechanical "0" position
in one direction as soon as mechanical "0" position until charge pressure is equal
engine is started on both sides.
16. Hydraulic oil temperature too Cooler contaminated Clean.

high, PMS reporting overheat-
ing
Precharging valve for return Check valve and measure re-
flow defective. Oil flowing t u r n f l o w p r e s s u r e . R e -
straight back to tank pair/replace valve.
Fan speed to low:
Fan pump worn Replace.
Fan motor worn Replace.
Pressure relief valve defec- Replace.
tive
Replenshing valve defective Replace.
73179380 08 87
F
6 Feed pressure and zero point ............................ 65
6-way control block (26, Fig. 9) .......................... 31 Filter contamination switch (13, Fig. 5) .............. 27
Filters (6) ............................................................ 25

A Flushing the hydraulic system ............................ 10
Additional control block (25, Fig. 8) .................... 30
Foreword .............................................................. 1
Additional hydraulics .......................................... 50
Assembly ............................................................ 74 G
General ........................................................ 54, 69
B
Boom cylinders (80, Fig. 19) .............................. 42 H
Boss-type, one-piece (Fig. 3) ............................ 74 High swinging pressure and safety valves.......... 65
Braking the superstructure ................................ 52 Hydraulic circuit diagram P/N 4 530 121.00 -
Superstructure .................................................... 15
Bucket cylinder (84, Fig. 21) .............................. 44
Hydraulic circuit diagram P/N 4 530 133.00 -
Bypass valve (12, Fig. 5) .................................... 27 Undercarriage .................................................... 15
Hydraulic components ........................................ 19

C
Hydraulic cylinder ................................................ 8
Changing the braking torque .............................. 64
Hydraulic cylinders ............................................ 68
Check valve (40, Fig. 12) .................................... 35
Hydraulic pumps and hydraulic motors ................ 7
Checking and setting pressures ........................ 53
Hydraulic reservoir, complete (10, Fig. 5) .......... 27
Circuit 1 .............................................................. 50
HYDRAULIC SYSTEM ........................................ 1
Circuit 2 .............................................................. 50
Hydraulic tank ...................................................... 6
Clockwise swinging ............................................ 52
Hydraulic travel motor (101, Fig. 23) .................. 46
Components ...................................................... 66
Components for boom and bucket cylinders I

(Fig. 1) ................................................................ 71
Installing a pump ................................................ 67
Components for stick cylinder (Fig. 2) ................ 73
Installing the hydraulic pumps ............................ 66
Counter-clockwise swinging .............................. 52
L
D
Large leather test case with contents ................ 55
Danger in the event of non-observance of the
safety instructions ................................................ 1 Layout of the troubleshooting table .................... 83
Depressurizing the hydraulic system .................... 5 Left servo control valve (61, Fig. 15) .................. 38
Description of system sections .......................... 47 Load limit control system .................................... 47
Description of the hydraulic system .................... 15 Load limit regulator ............................................ 23
Diaphragm accumulator (36, Fig. 12) ................ 34 Load limit regulator PMS 3 (95) .......................... 45
Drive engine (item 1) .......................................... 21
Dual admission .................................................. 50

M Restrictor check valve, adjustable (83, Figs.
20 and 21) .......................................................... 43
Mini-rate regulator or shock reducing valve
(30, 31 Fig. 11) .................................................. 33 Return flow filters (11, Fig. 5).............................. 27
Minimum quantity regulator or shock reducer Right servo control valve (60, Fig. 15) ................ 38
(30, 31) .............................................................. 48
Rotor (75, 78, Fig. 18) ........................................ 41

N
Neutral position .................................................. 52
S
O
Safety instructions ........................................ 53, 68
Oil coolers with fan drive .................................... 29
Safety valve ........................................................ 65
Output control through proportional demand
pressure.............................................................. 62 Sealing plug (37, Fig. 12) .................................. 35
Secondary valves for cylinders .......................... 58

P Secondary valves for travel motors .................... 59
Parallel bucket connection.................................. 51
Servo control pressure ...................................... 57
PCS tester (Fig. 1) .............................................. 55
Servo control system .......................................... 48
Pedal (62, Fig. 16) .............................................. 39
Servo control valve (60) boom/bucket ................ 48
Piston rod and piston .......................................... 79
Servo control valve (61) stick/swinging .............. 48
Piston rod guide boom and bucket cylinders ...... 76
Servo control valve (62) hammer / scissors........ 49
Piston rod guide stick cylinder ............................ 77
Servo control valve (62) travel, 1 valve for
Pivot bearings .................................................... 75 each track .......................................................... 49
Power control...................................................... 23 Setting the primary valve to higher pressures .... 57
Pressure gauge (Fig. 2) ...................................... 56 Setting/adjusting primary valves ........................ 60
Pressure settings ................................................ 54 Shuttle valve cascade (50 - 54, Fig. 13) ............ 36
Pressure-limiting valves on additional control Single admission ................................................ 50

block .................................................................. 59
Solenoid valve (64, Fig. 15 and 16) .................... 39
Primary valve with pressure cut-in stage (27,
Solenoid valve (91, Fig. 22) ................................ 45
Fig. 10, 11) ........................................................ 32
Solenoid valve Y 63 (39, Fig. 12)........................ 35
Proportional demand control .............................. 21
Solenoid valve Y35 (38, Fig. 12) ........................ 35
Pump 1 .............................................................. 62
Solenoid valve Y39.1 (39, Fig. 12)...................... 35
Pump 2 .............................................................. 62
Solenoid valve Y39.5 (39, Fig. 12)...................... 35
Pump control through proportional demand
signals ................................................................ 61 Speed sensor (72, Fig. 17) ................................ 40
Stick cylinder (82, Fig. 20) .................................. 43

R
Survey of components for the hydraulic circuit
Reasons for venting.............................................. 6 diagram .............................................................. 15
Removal and installation of the hydraulic Swing gearbox (70, Fig. 17) .............................. 40
pumps ................................................................ 67
Swing motor (71, Fig. 17) .................................. 40
Removing a pump .............................................. 67
Swing pump (5, Fig. 3) ...................................... 25
Swing pump adjustments (Fig. 3) : .................... 64
Swinging mode valve (17, Fig. 6) ...................... 28
Swinging power (swing mode) ............................ 65
Swinging system .......................................... 51, 63
Switching valve (52, Fig. 13) .............................. 36
Switching valve (56, 57, Fig. 14) ........................ 37
T
Technical data .................................................... 15
Temperature sensor (16, Fig. 5) ........................ 27
Tools .................................................................. 55
Top servo control caps ........................................ 6
Travel brake valve (101, Fig. 23) ........................ 46
Travel gearbox (100, Fig. 23) ............................ 46
Travel hydraulic system ...................................... 50
Travel pedals (62, Fig. 15) .................................. 38
TROUBLESHOOTING ...................................... 83
Troubleshooting guide ........................................ 84
Troubleshooting, instructions.............................. 83
Twin gear pump (7, Fig. 4).................................. 26
Twin variable displacement pump (4, Figs. 1,2

and Fig. 3) .......................................................... 21
U
Unpressurized oil circuit .................................... 47
V
Valve assembly (35 - 40, Fig. 12) ...................... 34
Venting ................................................................ 6
Venting the hydraulic system ................................ 6
W
Working hydraulic system .................................. 50
Working hydraulics with power boost function .... 57

Technical handbook "Fundamentals of electrical engineering"
Technical handbook "Interpretation of wiring diagrams"
Technical handbook "PCS III"
Electrical components in circuit diagram, P/No. 1 287 787
Electrical components in circuit diagram, P/No. 1 287 788
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2 09 73179380
Fundamentals of electrical engineering
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PREFACE .................................................................................................................................................. 1
IMPORTANT INSTRUCTIONS .................................................................................................................. 1
ELECTRICAL SYSTEMS IN GENERAL .................................................................................................... 2
The atom .................................................................................................................................................... 2
Structure of atoms
Free electron .......................................................................................................................................... 3
Electromagnetic field .............................................................................................................................. 4
Alternating current diagram .................................................................................................................... 5
POWER GENERATION ............................................................................................................................ 6
Power generation in motor vehicles ...................................................................................................... 6
Battery charging
Claw-pole alternator ................................................................................................................................ 8
Circuit with fault indication on interruption in the exciter circuit .............................................................. 8
Testing the charging system .................................................................................................................. 9
MAIN COMPONENTS OF AUTOMOTIVE ELECTRICAL SYSTEM ........................................................ 10
Battery
Types of batteries .................................................................................................................................. 11
Maintenance-free starter battery .......................................................................................................... 11
Low-maintenance batteries .................................................................................................................. 12
Checking the battery ............................................................................................................................ 12
Density values of diluted sulphuric acid ................................................................................................ 12
Mixing fresh battery acid ...................................................................................................................... 13
Mixing instructions ................................................................................................................................ 13
Maintenance .......................................................................................................................................... 13
Troubleshooting .................................................................................................................................... 14
Function of the alternator

Alternator .............................................................................................................................................. 16
Type designation .................................................................................................................................. 16
Alternator .............................................................................................................................................. 17
Claw-pole alternator .............................................................................................................................. 17
Maintenance .......................................................................................................................................... 17
Electric motors
Principle of the electric motor ................................................................................................................ 18
Starting motor (starter)

Function of the starter .......................................................................................................................... 20
Checking the vehicle starter system ...................................................................................................... 21
Starter.................................................................................................................................................... 21
Maintenance .......................................................................................................................................... 22
Lubrication ............................................................................................................................................ 22
FUNDAMENTALES OF AUTOMOTIVE ELECTRICAL SYSTEMS ........................................................ 23
Current, voltage, resistance and power ................................................................................................ 23
MEASUREMENTS WITH THE MULTIMETER

Adjustment of the multimeter ................................................................................................................ 24
Measuring voltage .................................................................................................................................. 24
Measuring current .................................................................................................................................. 24
Measuring resistance
Ohmmeter ............................................................................................................................................ 24
SERIES AND PARALLEL CONNECTION OF ELECTRICAL COMPONENTS ...................................... 25
Batteries .................................................................................................................................................. 25
Resistors
Series connection .................................................................................................................................. 25
Parallel connection ................................................................................................................................ 25
Capacitors
Series connection .................................................................................................................................. 25
Parallel connection ................................................................................................................................ 25
Electrolytic capacitors............................................................................................................................ 25
VOLTAGE LOSSES AND CABLES ........................................................................................................ 27
Calculation of lines
Computation .......................................................................................................................................... 28
Lines and wires in automotive electrical systems .............................................................................. 29
Design example ...................................................................................................................................... 29
LIGHTING ................................................................................................................................................ 30
Headlamps adjustment hints ................................................................................................................ 30
Floodlamps .............................................................................................................................................. 30
Bulbs ........................................................................................................................................................ 30
Malfunctions of the lighting system and their causes ........................................................................ 30
Transition resistance in electrical circuits .......................................................................................... 30
SPECIAL CIRCUITS IN AUTOMOTIVE ELECTRICAL SYSTEMS ........................................................ 31
The diode
The "free-wheeling" diode .................................................................................................................... 31
Varistors ................................................................................................................................................ 32
Voltage rectification in three-phase bridge circuits ................................................................................ 32
Alternator regulator................................................................................................................................ 34
FUSES IN MOTOR VEHICLES ................................................................................................................ 35
DESIGNATION OF INDIVIDUAL COMPONENTS .................................................................................. 36
STANDARDIZED DESIGNATIONS OF TERMINALS

Terminal designation ............................................................................................................................ 37
Generator and generator regulator ........................................................................................................ 39
Turn-signal indicator (flasher relay) ...................................................................................................... 39
Symbols used in electrical engineering

Symbols for directions of motion .......................................................................................................... 47
TECHNICAL HANDBOOK
PREFACE 2440033 IMPORTANT INSTRUCTIONS

Electrical systems for construction machinery Observe the accident prevention regulations.
have developed far beyond their original applica-
The personnel executing work must have the
tions as starting and lighting devices. The new
necessary expertise.
tasks are essentially monitoring and control func-
tions. This has entailed an inevitable increase in Tools, lifting gear and other equipment must be
the number of circuits, so that the overall system in a secure, safe state.
appears complex and unclear to the non electri-
cian. Prior to servicing or inspection work, secure the
machine and equipment against unauthorized
This technical handbook applies to electrical sys- starting, e.g. chock the vehicle wheels and low-
tems for motor vehicles as well as to low-voltage er the working equipment to the ground.
and medium-voltage systems on construction ma-
chines. Attention must be paid in all events to the Protective devices of moving machine compo-
relevant accident prevention regulations, whose nents must not be opened or removed except
requirements vary with the different service vol- when the machine is stationary and secured
tages. against inadvertent starting.
Metal objects such as rings, watches etc. must

be removed prior to any work on automotive
electrical systems.
Direct current (d.c.) must be prevented from

flowing through the human body.
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ELECTRICAL SYSTEMS IN Structure of atoms

GENERAL The number of protons corresponds to the num-
To make electrical systems comprehensible, we ber of electrons, i.e. it is electrically neutral.
need a slight grasp of the physics of electrotech-
nology.
The atom
All substances are composed of atoms.
An atom consists of a positively charged nucleus.

Negatively charged electrons orbit the nucleus at
vast speed.
The nucleus itself is composed of positively

charged protons and of neutrons with neutral
charge.
The number of protons and neutrons depends on Fig. 1

the structure of the atom.
The large quantity of atoms in the substances
If an atom possesses the same number of elec- may well result in an electron being the same
trons and protons, the atom is electrically neutral. distance from another nucleus as from its own.
All atoms are bound to their nucleus by magnetic If this is the case, the magnetic force of attraction
forces. If an electron is missing for some reason, of the electrons own nucleus is eliminated. Such
i.e. the nucleus has one proton too many in an electron is no longer bound to its own nu-
numerical terms, the atom is positive. cleus, i.e. it is free. We refer to such electrons as
"free electrons".
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Free electron
If an electron has left its path and is equally far A relatively large number of free electrons are
from another nucleus as from its own, it is no present in noble metals and non-ferrous metals. If
longer bound to its nucleus - it is free. a conductor (e.g. a copper wire) is moved in a
magnetic field, the free electrons are forced into
one direction or another.
Fig. 2
The electron of nucleus A has entered a neutral

path. As atom B is electrically neutral and atom C
electrically non neutral (one electron is missing),
the electron is attracted by nucleus C, and nu-
cleus A thus becomes non-neutral.
It attracts another electron which has entered a

neutral path. If an electron from nucleus C, which
is now neutral, returns to a neutral path, it is also
attracted by a non-neutral nucleus (etc.).
Fig. 3
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TECHNICAL HANDBOOK
Electromagnetic field
When current is flowing in a conductor, a mag- The outcome is that an electric potential is built
netic field is formed round the conductor as up alternately at the ends of the conductor. This
shown in the diagram below. is known as electric voltage and is measured in
volts (V). If this conductor is now formed as a
closed circuit, the electron flow moving through
the conductor can be measured. This electron
flow, known as electric current, is measured in
amperes (A).
Fig. 4
Resistor "R" in the above diagram serves only to

prevent a short circuit in the system.
If a conductor is shaped into a coil with several Fig. 6

turns, a magnetic field will spread round the coil
as shown in the diagram below. The strength of N.B.: The build-up of a constantly changing po-
the magnetic field depends on the current flowing tential in a conductor is known as alternat-
through the coil and on the number of turns. ing voltage, and the current flowing in the
process as alternating current (a.c.), i.e.
the current is continuously changing its di-
rection and strength.
The alternating current or alternating voltage can

be visualized by means of a visual display unit.
Current and voltage are normally isochronous.
The term used when current is not isochronous
with voltage is phase shift.
Fig. 5
To strengthen the magnetic field, an iron core

with a preferred direction of magnetization is nor-
mally used as a winding support. The electromag-
netic force is thus sufficient to attract a hydraulic
switching piston, for example.
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Alternating current diagram
T = Duration of one full cycle (period) in s The type of curve characterising alternating or
direct current is known as a sine curve. If current
= frequency in Hz ( = 1/T) and voltage are in phase, both reach their peak
value at the same time. The oscillations in one
= Peak value (amplitude) of the current, second are referred to as frequency (). The
number of oscillations per second are stated in
u = Peak value (amplitude) of the voltage, Hertz (Hz).
omega = Radian frequency in 1/s

(omega = 2pi )
phi = Phase shift angle (phase shift means:

current and voltage attain their peak
value or their zero crossing at different
times) between current and voltage.
Fig. 7
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POWER GENERATION Power generation in motor

If the fact is exploited that a magnetic field is
vehicles
formed round a conductor when a current flows Some years ago, so-called d.c. generators were
through it, it is relatively easy to build an electric installed in motor vehicles. Because of their size
generator. The principle is shown in the diagram and output, they were replaced by a.c. gener-
below. Windings (2) supplied with direct current ators.
(3) are mounted on a rotor (1), resulting in a
magnetic field (4). The windings (6) mounted on In an a.c. generator, three alternating currents,
the stator (5) of our theoretical generator are cut each phase-shifted by 120, are generated. This
by the magnetic field (4) of the rotor as the rotor alternating current is rectified in the vehicle by
is turned. This generates electric voltage in the means of diodes, and we have direct current. The
stator winding. direct current is regulated to the required charg-
ing current with a regulator. The resulting direct
current is needed to recharge the battery, i.e. the
battery is recharged while the engine is running.
Fig. 1
Fig. 2
Fig. 3
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Battery charging
If voltage is applied to the field winding mounted As the generator is used in the motor vehicle to
on the rotor, the current flows. This current in- recharge the battery, the alternating current must
duces a magnetic field large enough to cut the be converted into direct current. This is done with
stator windings as the rotor turns. rectifier diodes as shown in the circuit diagram
below.
As the rotor turns, alternating current is generated 1 Field diodes
in each coil. Three equally large voltages are 2 Main diodes
formed in the three coils. These voltages are, 3 Regulator
however, out of phase by 1/3 period, i.e. the
phase shift is 120. If the coils are uniformly
loaded, the phase angle between the currents is
also 120.
Three alternating currents, each phase-shifted

by 120 are known as three-phase alternating
current or rotary current.
Fig. 4
The field diodes have the task of converting the

alternating current into direct current. This direct
current is then conducted via the regulator to the
field winding, which ensures that the field current
is limited or cut out when the charging voltage is
reached. The main diodes are interconnected to
form a so-called bridge. The output terminal (B+)
of this diode bridge is firmly connected with the
battery pole (+).
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Claw-pole alternator Circuit with fault indication on

interruption in the exciter circuit
1 - Slip-ring end shield
2 - Rectifier heat-sink 1 = Alternator
3 - Power diode 2 = Charge monitoring lamp
4 - Exciter diode 3 = Resistor R
5 - Transistorized regulator in hybrid technique 4 = Ignition switch
6 - Stator with three-phase winding 5 = Battery
7 - Stator with claw poles
8 - Fan
9 - Pulley
10 - Drive end shield with mounting flanges
Fig. 6
The sole functions of the charging control lamp

are to ensure that the alternator is pre-magne-
tized and to monitor the exciter circuit. If the
charging control lamp lights up while the alterna-
tor is running, it means that no exciter current is
present and thus that no battery charging is being
executed.
Fig. 5 Important:
Important: The charging control lamp must not be re-
placed except with an equivalent one, in gen-
The battery must not be disconnected from the eral 1.2 W with 12 V systems and 2 W with
alternator when the alternator is running. 24 V systems.
The functions of the charging control are based

on the system shown in Fig. 6. If the ignition
switch (4) is closed, current flows from the battery
(5) through the lamp (2) via a resistor to ground.
The resistor (3) has such a resistance value that
the lamp lights up. If the diesel engine is then
started and the alternator thus driven, a positive
voltage will result at terminal (D +) of the alterna-
tor. When there is a positive voltage on both
sides of the lamp, the charging control lamp will
be extinguished. The resistor must be mounted
immediately adjacent to the lamp.
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Testing the charging system

To test the charging system, the voltmeter must
be connected direct to the battery. The engine
must then be run up to top speed. After ca. 2
minutes, the required charging voltage must be
attained. This is between 13 and 14.5 V for a
12 V system, and 26 to 29 V for a 24 V system.
If the voltmeter indicates a higher value, the regu-

lator is defective. If the measured value is lower,
however, the fault is in the charging system.
Important: The voltmeter must be switched to

the d.c. voltage measuring range.
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MAIN COMPONENTS OF AUTOMOTIVE ELECTRICAL SYSTEM

Battery
The battery is basically needed only for starting
and lighting of the parked machine.
In operation, power is supplied by the alternator

which charges at the same time the battery.
The most commonly used batteries in motor ve-

hicles are 12-volt batteries. By connecting 6 cells
(with 2 volts each) in series, we obtain the nomi-
nal voltage of 12 volts.
Fig. 2
Basic design of a lead-acid cell.
Fig. 1
The battery nominal voltage depends on the num-

ber of cells connected in series.
UB = n UZ
n = number of cells
UB = nominal voltage of battery
UZ = nominal voltage of cell
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Types of batteries
Batteries used today are mostly maintenance- Important:
free. On account of metallurgical improvements,
The designation "maintenance-free in accordance
the water decomposition under normal operating
with DIN" only means that a battery does not
conditions of the vehicle electrical system (U =
exceed certain limits concerning water consump-
constant) has been reduced to such an extent
tion. It is by no means a guarantee that refilling
that the electrolyte reserve above the plates
with water can be dispensed with during the ser-
should be sufficient for the whole service life of
vice life of the battery. Moreover, this definition
the battery.
does not concern other aspects of maintenance.
If such a battery is to be recharged after it has For these reasons, both the DIN designation and
been disconnected from the electrical system, it also certain publicity statements with regard to
must be ensured that the charging voltage per freedom from maintenance are misleading.
cell is limited to 2.4 volts max. (2.3 to 2.4 volts).
Maintenance-free starter battery
1 - One-piece cover
2 - Terminal post cover
3 - Direct cell strap
4 - Terminal post
5 - Frit
6 - Plate strap
7 - Battery case
8 - Base frame
9 - Positive electrodes in separating foils
10 - Negatives electrodes
Fig. 3
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TECHNICAL HANDBOOK
Low-maintenance batteries Checking the battery

The electrolyte level of low-maintenance batteries 1) Acid density is the most important indicator of
should be checked at least once a year. If the battery charge. The degree to which a battery
electrolyte level drops below the "min" mark, the is charged can therefore be determined by
cells must be topped up with distilled water. measuring the acid density. The acid density
is measured with a hydrometer. The density
If the battery is disconnected from the vehicle can be read on the scale of this hydrometer.
electrical system for recharging, it must be
charged with a current corresponding to 1/10 of Density values of diluted sulphuric acid
the nominal capacity of the battery.
Charge Type of Acid density Freezing point
Important: condition battery kg/l1) C
During the charging process, batteries give off
charged normal type 1.28 - 68
highly explosive gases. Batteries must only be
charged in well ventilated rooms provided for tropicalized 1.23 - 40
type
this purpose. Fire, unshielded light and smok-
ing are prohibited. half charged normal type 1.16 / 1.20 - 17 ... - 27
The safety regulations pertaining to battery tropicalized 1.13 / 1.16 - 13 ... - 17
handling must always be observed. type
discharged normal type 1.04 / 1.12 - 3 ... - 11
tropicalized 1.03 / 1.08 - 2 ... - 8
type
2) Starting test
Starting tests are carried out by measuring the
battery voltage under load conditions with a
battery tester.
For batteries of the one-piece cover type, bat-
tery testers for 12 volts are used. The battery
tester measures the voltage by applying a
load resistor across the battery terminals, so
that a current of 300 A flows for abt. 5 sec-
onds through this resistor. The voltage is an
approximate measure of the batterys starting
capability. The admissible minimum voltage
limit is fixed at 8 V = 1.33 V/cell. When the
voltage is measured with the battery tester, it
is important that the measuring probes and
the terminal posts are in good contact.
3) Measuring results
If the acid density is insufficient, but if the
starting test is satisfactory, the battery will in
most cases only need recharging.
If the acid density and the starting test are
unsatisfactory, the battery must only be
charged with a low current of 6 A.
If the acid density is sufficient (e.g. after suc-
cessful charging), but if the starting test is
unsatisfactory, the battery is in most cases no
longer useful.
If the acid densities of the cells or the battery
voltages during the starting test differ consi-
derably when the batteries are charged, or if
they are even unsatisfactory, it is recommen-
ded to discard the battery.
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Mixing fresh battery acid Maintenance

Important: The term "maintenance" encompasses all mea-
When mixing new battery acid, care must be sures of battery care required for an optimal func-
taken that concentrated sulphuric acid is al- tion of the battery over its whole lifetime.
ways poured into the distilled water and never
the other way round to avoid back-splashing Topping up the electrolyte level
of sulphuric acid. Wear goggles and protec- Periodic recharging during storage
tive clothes and observe the accident preven-
tion rules. Immediate recharging after discharges
The volumetric ratio of concentrated sulphuric Avoiding overcharging

acid (96 %) to distilled water is set out in the
Avoiding exhaustive discharging
table below.
Mixing instructions
Desired Volumetric ratio of concentrated

acid density sulphuric acid (96 %) to
kg/l distilled water
1.23 1 : 3,8
1.26 1 : 3,2
1.28 1 : 2,8
1.30 1 : 2,6
1.34 1 : 2,3
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Troubleshooting
Trouble Cause Remedy
1. Acid level too low Overcharging, evaporation Top up with distilled or

(particularly during the summer demineralized water
months) (when the battery is charged)
2. Acid leaks out of the vent plug 1. Charging voltage too high Check and adjust voltage
regulator or have it replaced
2. Acid level too high Draw off excessive acid with
the hydrometer
3. Acid density too low 1. Battery discharged Charge the battery

2. Alternator malfunction Have alternator checked
3. Short-circuit in wiring Have electrical system checked
4. Too much water in acid Have acid density re-adjusted

due to incorrect servicing
4. Acid density too high Too much acid Have acid density adjusted
5. Battery output power insufficient. 1. Battery discharged Recharge battery

Heavy voltage drop
2. Charging voltage too low Re-adjust or replace voltage
regulator
3. Connection terminals Clean terminals and apply a
loose or corroded thin layer of acid-protection
grease Ft 40 v 1 on the
underside; tighten terminal
screws
4. Battery capacity Use greater battery. If required,
insufficient (too many install also stronger alternator;
consumers) consult specialized workshops
5. Excessive self-discharge Replace the battery
of the batteries due to
impurities in the battery
acid
6. Battery "sulphated" Charge battery with low current
(grey-white layer on the to induce decomposition of the
positive and negative layer. If the output is still
plates) insufficient after repeated
charging and discharging,
replace the battery
7. Battery used up, plate Replace the battery
substance no longer active
8. Acid level below upper Top up with distilled or de-
edge of plates mineralized water to the
prescribed level
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Trouble Cause Remedy
6. Insufficient service life of the 1. Battery too often and Use battery with greater
battery exhaustively discharged capacity considering using
special "S" type batteries
2. Battery gets too warm Install at a better suited

loacation
3. Battery vibrations too Install at a better suited location

heavy
4. Battery possibly cf. 5.6

"sulphated"
5. Battery acid containing Replace the battery

impurities
7. Battery charge permanently 1. Defective alternator, Increase alternator capacity or

insufficient voltage regulator or line repair resp. replace alternator
connections and voltage regulator; fasten
connections properly
2. V-belt loose Retension the belt or replace
3. Too many consumers Install bigger battery. Consider

connected to the battery using a stronger alternator;
consult specialized workshops
8. Permanent overcharge Voltage regulator and possibly Replace voltage regulator or
alternator defective change regulator setting; check
alternator
9. Switch contacts in voltage Battery incorrectly connected Connect battery with correct
regulator burnt (in case of d.c. (wrong polarity) polarity. Replace voltage
generators) regulator
10. Rectifier diodes destroyed (in Battery incorrectly connected Connect battery with correct
case of alternators) (wrong polarity) polarity. Replace rectifier
diodes
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Function of the alternator

The alternator has the function to meet the en- Type designation
ergy demands of the electrical consumers. More-
over, it has to ensure that the batteries are being N1 14 V 36 / 80 A
charged when power is at the same time supplied
max. current in A
to permanent consumers, and even when the
engine is running at low speed (idling). The al- at 1500 1/min
ternator has to supply a constant voltage under Voltage
all operating and loading conditions.
Claw-pole alternator
In doing so, the alternator is assisted by the
regulator which maintains the voltage between 13
and 14.5 volts independent of alternator load and
alternator speed. Important:
Depending on type, our machines are equipped
Alternator with alternators for 12 volts resp. 28 volts.
1 - Housing
2 - Diode carrier
3 - Power diode
4 - Excitation winding (rotor)
5 - Regulator
6 - Stator winding (stator)
7 - Rotor
Fig. 4
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Alternator Claw-pole alternator
The alternator is a self-excited 12-pole synchro-

nous claw-pole alternator with incorporated silicon 1 - Slip ring end shield
rectifier diodes. The three-phase winding is in the 2 - Rectifier heat-sink
stator and the exciter winding in the rotor. 3 - Power diode
4 - Excitation winding (rotor)
The exciter current is supplied from the rectifier 5 - Transistor regulator with incorporated
via D+, the regulator, two brushes and the slip carbon brushes
rings to the exciter winding in the rotor. The 6 Stator with three-phase winding
stator winding is connected to the silicon rectifier 7 - Rotor with claw poles
diodes by means of a three-phase bridge circuit. 8 - Fan
9 - Pulley
The rectified current is supplied to the consumers 10 - Drive end shield with mounting flanges
and the battery via the B+ terminal. The D+
terminal must only be loaded with the regulator
current, the charging monitor and an additional
current of 0.5 A (e.g. start inhibit relay).
In 24 V systems the charge monitoring lamp must
be a 2 W type to ensure the appropriate excita-
tion of the alternator. The voltage is regulated by
the incorporated electronic field rheostat.
Fig. 5
Maintenance
Alternators installed in modern vehicles are large-
ly maintenance-free. The V-belt tension should be
checked once every month depending on the use
of the machine.
The carbon brushes should be checked once

every year. The slip-rings must also be visually
inspected and polished with ultra-fine polishing
cloth.
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Electric motors
In motor vehicles, d.c. motors (starter motors,
windscreen-wiper motors, fan motors, etc.) are
used almost exclusively. The principle of these
motors will therefore be discussed in greater de-
tail.
Principle of the electric motor

An electric motor is a device that converts elec-
trical energy (voltage times current) into mechani-
cal energy (speed times torque). This is based on
the fact that a current-carrying conductor in a
magnetic field experiences a force. The force is
proportional to the strength of the magnetic field
and the magnitude of the current, and is greatest Fig. 7
when the magnetic field and the conductor plane
are in alignment. Fig. 7 = Torque imparted to a loop of wire
For practical purposes, the conductor has the If it can be ensured that the flow of current is
form of a rotating loop of wire (Fig. 6). The reversed in the loop of wire after every half turn,
magnetic field lines extend from pole to pole the torque has always the same sense of rotation
(pole-shoe to pole-shoe). and can therefore cause the loop to turn continu-
ously.
If the conductors are under the pole-shoes, i.e.
inside the magnetic field, the torque imparted to The current is reversed by means of a commuta-
the loop of wire is constant and has a certain tor consisting of two separate halves of a split-
direction. After a half turn, when each conductor ring to which two ends of the wire loop are
comes under the influence of the opposite mag- connected. Two collectors, called carbon brushes,
netic field, the torque remains the same but its are connected to the current source and slide on
direction is reversed. If the loop is perpendicular the split-ring segments (Figs. 6 and 8).
to the pole shoe, the torque becomes zero (Fig.
7). In order to obtain a uniform torque, an electric
motor makes use of many wire loops (Fig. 8).
Fig. 9 shows the individual torques for three sym-
metrically arranged loops and the resulting overall
torque. In this case, the commutator has six in-
dividual segments, which are also called lamina-
tions. In reality, the number of loops is even
higher since the torque increases with the num-
ber of wire loops installed.
Fig. 6
Fig. 6 = Schematic diagram of an electric motor

with a loop of wire
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Fig. 8 Fig. 9
Fig. 8 = Schematic diagram of an electric motor Fig. 9 = Torque of three wire loops
with three wire loops
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Starting motor (starter)

Function of the starter Engaging
When the starter switch is operated, the starting

motor solenoid and the engaging lever push the
pinion along the spiral spline into the ring gear
(Fig. 10).
When the starting motor solenoid reaches its end

position, the main current contact is closed
(Fig. 11).
The pull-in winding is now without current and the

pinion kept in engagement by the hold-in winding.
When the motor starts, the pinion is pushed back

into its original position by the armature-return
spring when the starting switch is released. Fig. 10
Engaged
Fig. 11
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Checking the vehicle starter system
Checking the battery (cf. under "Battery").

Checking the battery cables and connections for proper contact.
Measuring the voltage drop (0.5 V).
Measuring the minimum pull-in voltage at solenoid switch terminal 50 (8.0 V).
Starter
1 - Armature-return spring 14 - Armature

2 - Hold-in winding 15 - Exciter winding
3 - Pull-in winding 16 - Armature winding
4 - Starting motor solenoid 17 - Guide ring
5 - Contact 18 - Stop
6 - Mounting stud 19 - Roller-type overrunning clutch
7 - Contact bridge 20 - Armature shaft
8 - Collector bearing 21 - Pinion
9 - Brush spring 22 - Driver
10 - Collector 23 - Brake disk
11 - Carbon brush 24 - Engaging spring
12 - Pole housing 25 - Engaging lever
13 - Pole shoe
Fig. 12
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Maintenance Lubrication
1) Basic rules Both bearings of pre-engaged-drive starting mo-
tors are self-lubricating. This means that they
Working on the electrical part of the starting
must not be lubricated. This type of bearing must
motor involves the risk of short-circuits. It is
not be treated with fat-dissolving detergents.
therefore recommended to disconnect the
ground terminal from the battery before un- Carbon brushes and brush holders must be free
dertaking such work. Do not place tools on from oil and grease. If these parts are contami-
the battery. nated or jamming, they must be cleaned with a
clean and petrol-stained cloth (do not use clean-
2) Carbon brushes
ing wool because it is not lint-free) and well dried.
The carbon brushes must be checked from Do not treat the bright metal sliding surface of the
time to time for condition (cf. figure). After carbon brushes with emery-paper, files or knives.
removing the end cover, the spring pressing Brush holders must be blown clean. If a carbon
the carbon brush against the collector is lifted brush is broken, unsoldered or worn out to such
with a hook. Do not bend spring sideways an extent that the spring or the stranded wire
and do not lift more than necessary before soldered into the brush threatens to contact the
checking whether the carbon brushes move brush holder, the carbon brush must be replaced.
easily in the brush-holder guide. When inserting the carbon brush, care must be
taken that the spring does not tap on the brush
3) Collector
The collector should present a uniform and Carbon brushes should always be replaced dur-
smooth surface of greyish black colour and ing general repairs of the motor.
must be free from oil and grease. Contami-
The collector should be repaired by turning off on
nated collectors must be cleaned with a
a lathe whenever the carbon brushes are re-
clean and petrol-stained cloth (do not use
placed.
cleaning wool) and properly dried. Collectors
presenting scoring and out-of-roundness due
to wear must be repaired by turning off on a
lathe in a specialized workshop. Under no
circumstances must collectors be treated with
emery-paper or a file.
Fig. 13
22 2 796 980.00 us
TECHNICAL HANDBOOK
FUNDAMENTALES OF AUTOMOTIVE ELECTRICAL SYSTEMS

Current, voltage, resistance and power
Current (I) Power (W)
Electric current is the flow of free electrons in a Electric power is the current flowing through a
conductor. The current is measured with an am- consumer at a constant voltage. Power is symbol-
meter which must be connected in series with the ized by "P" and the unit of measure is symbolized
consumer. The quantity of electric current is des- by "W" (watt).
ignated by "I" and the unit of current is symbol-
ized by "A" (ampere).
Voltage (U)
Voltage is the potential difference existing be-

tween two conductors. Voltage is measured with
a voltmeter which must be connected in parallel
with the consumer or across the two points of
different potential. The quantity of electric voltage
is designated by "U" and the unit of voltage is
symbolized by "V" (volt).
Resistance (R)
Electric resistance is the resistance offered to the

electric current. The electric resistance depends
on the material of the resistor and its dimensions.
The quantity of electric resistance is designated
by "R" and the unit of resistance is symbolized by
" " (ohm). Fig. 1
2 796 980.00 us 23
TECHNICAL HANDBOOK
MEASUREMENTS WITH THE MULTIMETER

Adjustment of the multimeter Measuring current
Before connecting the meter to a circuit the fol-
lowing steps must be taken:
1) Set the meter to d.c. current or to a.c. cur-

rent, resp. voltage.
2) Select the highest measuring range.
3) Connect the instrument and switch down to

the measuring range offering the greatest
possible scale reading for the measurement
in question.
Fig. 2
Measuring voltage
Important:
If current is to be measured, the current-carrying
conductor must be separated and the instrument
connected in series, so that the current flows
through the measuring instrument.
Measuring resistance
Ohmmeter
Fig. 1
Important:
A voltmeter is always connected in parallel with
the consumers resp. across the voltage source.
Fig. 3
Important:
If resistance is to be measured, the component to
be measured must always be free from any vol-
tage. Components in a circuit can only be mea-
sured after removing them from the circuit.
24 2 796 980.00 us
TECHNICAL HANDBOOK
SERIES AND PARALLEL CONNECTION OF ELECTRICAL

COMPONENTS
Batteries Capacitors
If two or more batteries are connected in series, Series connection
the voltages of the individual batteries add up to
give the total voltage. If capacitors are connected in series, the total
capacitance (Ctot) is less than the smallest in-
If two or more batteries are connected in parallel dividual capacitance.
(the batteries having the same voltage rating, of
course), the total voltage remains the same. The
battery capacity, however, is the sum of the in-
dividual capacities.
Parallel connection
Important:
Observe the polarity when connecting batteries to If capacitors are connected in parallel, the
each other. capacitances add, i.e. the total capacitance (Ctot)
is the sum of the individual capacitances.
Important:
The results obtained for series or parallel connec-
tion are just the opposite of those found for resis-
Resistors tors.
Series connection
If two or more resistors are connected in series,
the total resistance (Rtot) is the sum of the individ- Electrolytic capacitors
ual resistances.
Electrolytic capacitors have the same behaviour
as the above-mentioned capacitors with the ex-
ception, however, that their polarity is of impor-
Parallel connection tance. The polarity is marked on the capacitor.
If two or more resistors are connected in parallel, Important:
the total resistance (Rtot) is less than the smallest Electrolytic capacitors must never be used with
of the individual resistances. When connecting wrong polarity. Risk of accident.
two resistors with the same resistance together,
the total resistance is half that of the individual
resistor. Remarks:
Further components or their schematic symbols
can be found in section "symbols used in elec-
trical engineering".
2 796 980.00 us 25
TECHNICAL HANDBOOK
Battery series connection
Battery parallel connection
Resistor series connection
Resistor parallel connection
Capacitor series connection
Capacitor parallel connection
Electrolytic capacitor
series connection
parallel connection
26 2 796 980.00 us
TECHNICAL HANDBOOK
VOLTAGE LOSSES AND CABLES

The values for Uvl set out in table 1 can be used The Uvg values indicated are check values which
for computing positive leads. The voltage loss in cannot be used for line calculations, as they take
the return lead to ground is not considered here. into account - beside the lines themselves - also
If the ground lead is insulated, however, the line the contact resistance of switches, fuses, etc.
length to be considered is equal to the total
length of the positive and the return lines.
Table 1 - Admissible loss of voltage
Type of line Adm. voltage drop Adm. voltage drop in Remarks

in positive lead overall circuit
Uvl Uvg
Lighting lines
from lighting switch terminal 30 0.1 V 0.6 V Current at
to lamps > 15 W nominal voltage
to trailer receptacle and nominal power
from trailer receptacle
to lamps
from lighting switch terminal 30 0.5 V 0,9 V ---

to lamps > 15 W
to trailer receptacle
from lighting switch terminal 30 0.3 V 0.6 V ---
to head lamps
Charging line
from alternator
terminal B 0.4 V at 12 V --- - current at nominal
voltage
to battery 0.8 V at 24 V --- - and nominal power
Control lines
from alternator 0.1 V at 12 V --- - At maximum
to regulator
(terminals D+, D-, DF) 0,2 V at 24 V --- - exciter current
(remark 1)
Starter main line 0.5 V at 12 V --- - Starter short-circuit

current
1.0 V at 24 V --- at +20C (68F)
(remarks 2 and 3)
Starter control line

from starter switch to starter
terminal 50 1.4 V at 12 V 1.7 V at 12 V Max. control current
Engaging relay with simple 2.0 V at 24 V 2.5 V at 24 V (remarks 4 and 5)
winding
Engaging relay with pull-in 1.5 V at 12 V 1.9 V at 12 V
and hold-in winding 2.2 V at 24 V 2.8 V at 24 V
Other control lines
from switches to relays, 0.5 V at 12 V 1.5 V at 12 V Current at
horn, etc. 1.0 V at 24 V 2.0 V at 24 V nominal voltage
2 796 980.00 us 27
TECHNICAL HANDBOOK
Remarks: Calculation of lines

1) All three control lines, if possible, of the Quantities and units
same length and resistance.
Quan- Unit
2) In special cases and very long starter main tity
lines, the Uvl value can be exceeded for re- I Electric current A
duced limit starting temperatures. l Line length m
P Power consumption of consumer W
3) In case of an insulated return of the starter
q Line cross-section mm2
main line, the voltage drop in the return line
R Resistance (consumer)
must not exceed that of the positive line.
S Current density in the line A/mm2
Admissible values for each line are 4 % of
UN Nominal voltage V
nominal voltage, i.e. 8 % altogether.
Uvl Admissible voltage drop of insulated V
lines
4) The Uvl values are applicable to engaging Uvg Admissible voltage drop in overall V
relay temperatures between 50 and 80C circuit
(122 and 176F). rho Resistivity mm2/m
5) If required, the line from the starting switch

must be accounted for.
Computation
When determining the line cross-section, the volt-

age drop and the temperature rise must be taken
into consideration.
1) Determine the electric current I flowing

through the consumer
I = P/UN = UN/R
2) Calculate line cross-section q based on the

Uvl values in table 2
(for copper = 0.0185 mm2/m)
q = I rho l/Uvl
3) Round up q to the next higher line cross-

section according to table 1. Individual lines
below a cross-section of less than 1 mm2 are
not recommended because of insufficient me-
chanical resistance.
4) Compute the effective voltage drop Uvl.

Uvl = I rho l/q and
5) check current density S to avoid inadmissible

warming (for short-time operation S < 30
A/mm2, values for permanent operation cf.
table 1).
S = I/q
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TECHNICAL HANDBOOK
Lines and wires in automotive electrical systems

Table 2 - Electrical copper wires for motor vehicles
Single-conductor, untinned, PVC-insulated
Nominal Resistance Diameter Diameter Admissible permanent Admissible

cross-section per meter of conductor of cable current current
(recommended value) density
at 20C Largest Largest at + 30C at + 50C Permanent
(68F) dimension dimension (86F) (122F) operation
mm2 m /m mm mm A A A/mm2
0,5 37,1 1,0 2,3 11 7,8 10

0,75 24,7 1,2 2,5 15 10,6 10
1 18,5 1,4 2,7 19 13,5 10
1,5 12,7 1,6 3,0 24 17,0 10
2,5 7,6 2,1 3,7 32 22,7 10
4 4,71 2,7 4,5 42 29,8 10
6 3,14 3,4 5,2 54 38,3 6
10 1,82 4,3 6,6 73 51,8 6
16 1,16 6,0 8,1 98 69,6 6
25 0,743 7,5 10,2 129 91,6 4
35 0,527 8,8 11,5 158 112 4
50 0,368 10,3 13,2 198 140 4
70 0,259 12,0 15,5 245 174 3
95 0,196 14,7 18,0 292 207 3
120 0,153 16,5 19,8 344 244 3
Design example
If an electrical component is to be installed in With reference to table 2 and for an ambient
addition to those existing, we must know the temperature of 50C (122F) (always used for
cross-section of the cable to be used. calculations, as it cannot be excluded that the
cable crosses the engine compartment), we can
Example: use a cable having a conductor cross-section of
Installation of a floodlamp (two bulbs) 0.5 mm2.
The following characteristics must be known: op- Important:
erating voltage of the vehicle and power con- The cables should be laid in a flexible tubing to
sumption of the floodlamp. In our example, we avoid chafing or squeezing.
assume the operating voltage to be 24 volts (28
volts) and the power consumption of one flood-
lamp bulb to be 70 W. When retrofitting electrical components, it must be
ensured that only "brown" cables are used for
The first step consists in calculating the current ground connections or negative leads. It must not
flowing through the bulb (cf. chapter 4 - variations be forgotten to protect all circuits with suitable
of ohms law). fuses. If switches are used, the contacts must be
designed for the currents expected.
J= P 70
- = --- W = 2.9 A
U 24 W
The current flowing through one of the bulbs

would be 3 A. As we are installing two lamps in
our example, we have to take twice this current
(6 Ampere).
2 796 980.00 us 29
TECHNICAL HANDBOOK
LIGHTING Malfunctions of the lighting

Vehicle lighting is of particular importance for the
system and their causes
operating safety of the vehicle. The vehicles Important:
headlamps must be designed and installed in Always remember that the lighting installation is
accordance with the Federal Motor-Vehicle Safety part of the vehicles operating safety. The operat-
Standards. ing safety must be checked before using the
vehicle.
The headlamps must be adjusted in accordance
with the Motor-Vehicle Traffic Regulations. If they
are incorrectly adjusted, oncoming traffic may be One of the most frequent deficiencies of head-
dazzled by the headlamps. lamps is that their light is "yellowish" and not
white as it usually should be. If the power supply
is o.k., the main cause of this deficiency is an
Headlamps adjustment hints inadmissibly high ground transition resistance, so
that the allowed voltage drop is exceeded (cf.
1) The vehicle must be parked on a level sur- chapter "VOLTAGE LOSSES AND CABLES").
face.
2) The tyre pressure must be checked.
Headlamps should only be adjusted with a head- Transition resistance in electrical

light setter after the two above-mentioned require- circuits
ments have been met.
Transition resistances are most often found in
cable connections, ground connections and de-
fective switches. A transition resistance in a cir-
Floodlamps cuit causes a loss of voltage.
The admissible voltage losses are set out in the
Floodlamps may only be switched on for working.
table of chapter "VOLTAGE LOSSES AND CA-
They are mostly installed on a mobile mount and
BLES".
can be turned to the required direction.
Bulbs
Light bulbs exist for electrical systems having 6,
12 and 24 volts. To avoid confusion, the bulbs
are equipped with different bases. Voltage and
wattage are marked on the bulb. Halogen bulbs
are designated by the symbols H 1 .... H 4.
Compared to conventional bulbs, the light effi-
ciency of halogen bulbs has been improved by
70 % on average.
Important:
Bulbs must only be replaced by those stated in
the circuit diagram.
30 2 796 980.00 us
TECHNICAL HANDBOOK
SPECIAL CIRCUITS IN AUTOMOTIVE ELECTRICAL SYSTEMS

The diode The "free-wheeling" diode
Diodes are mainly made of germanium or silicon The term "free-wheeling" used in connection with
(both semi-conductors). They are mainly used in a diode, only makes sense if considered in con-
electronics and in automotive electrical systems. junction with a circuit including wire coils as in-
ductors.
Diodes are components permit the current to flow
only in one direction, comparable to the non- Electrical circuit with a diode used as a "free-
return valves in hydraulics. The two connections wheeling" diode.
are designated as the anode and the cathode.
If a positive voltage is applied to the cathode of

such a diode, the current cannot flow to the
anode because the diode is in a non-conducting
state (operation in reverse direction). In the op-
posite case, the anode is connected to the posi-
tive supply, so that the current can flow to the
cathode (operation in forward direction). For a
negative voltage, the diodes behaviour is just the
Fig. 1
opposite of that with a positive voltage.
1 = Solenoid valve
N.B.: 2 = Free-wheeling diode
Positive voltage at the cathode - 3 = Switch
diode in non-conducting state. 4 = Fuse
Negative voltage at the cathode - When the solenoid valve is switched off, the coil
diode in conducting state. produces an inductive voltage with a polarity op-
Positive voltage at the anode - posite to that of the supply voltage. This voltage
diode in conducting state. is so high that - when a switch is opened - an
Negative voltage at the anode - electric arc is struck which is capable of welding
diode in non-conducting state. the switch contacts together.
As the induced voltage is negative at switch-off

and as this voltage is applied to the cathode, the
diode is in a conducting state for this voltage.
The inductive voltage is short-circuited to ground
which is an efficient protection against melting of
the switch contacts.
2 796 980.00 us 31
TECHNICAL HANDBOOK
Varistors Voltage rectification in three-phase

bridge circuits
A varistor is a voltage-dependent resistor which Since the alternator in a motor vehicle generates
fulfils on principle the same function as a free- a three-phase alternating current, this current
wheeling diode and which is used in circuits in must be rectified if it is to be used for charging
the same way. the battery.
If the three-phase alternating voltage generated

by the alternator is displayed on an oscilloscope,
we obtain 3 sine curves phase-shifted by 120
each. This is dependent on generator design.
Basic behaviour of a varistor: the higher the vol-
tage the smaller the resistance.
Fig. 2
Let us first consider one of the curves. The curve

rises to the highest voltage value U+ max (plus)
and then drops to the lowest voltage value U-
max (minus) after crossing the "0" line.
If we now apply this alternating voltage to the

anode of a diode, the negative half-wave is
blocked and the positive one is allowed to pass.
32 2 796 980.00 us
TECHNICAL HANDBOOK
Anode input voltage Cathode output voltage
As we see from the diagram, only the positive If we consider the principle of rectifying three-
(plus) voltage is left at the cathode. phase currents, we see that several diodes are
connected to form a bridge, as can be seen from
the diagram below.
Three-phase current
Input Direct current
Output
Three-phase current - Input Direct current - Output

into the bridge circuit from bridge circuit
As we have seen from the above diagrams, only This d.c. current is used to buffer the battery.
positive half-waves are left at the rectifier bridge
output, which means that the output carries only Important:
d.c. currents or d.c. voltages. The individual diodes of this bridge are desig-
nated by the term of "main diodes".
2 796 980.00 us 33
TECHNICAL HANDBOOK
Alternator regulator
The alternator regulator regulates the current from The charge monitoring lamp (2) serves the pur-
the field windings of the alternator in such a way pose of pre-magnetizing the alternator. If the igni-
that in spite of varying alternator speeds there is tion switch is closed, the current flows from the
always a constant voltage for charging the battery battery through the regulator and the field winding
depending on battery condition. The field current to ground. The lamp circuit is now closed and the
is produced by the main windings of the alterna- lamp lights up.
tor (4) and converted to direct current by means
of the so-called field diodes. This d.c. voltage The current causes a weak magnetic field to build
passes to the regulator (1) which controls the up in the field winding. When the alternator starts
field current of the alternator. to turn, the main winding produces three-phase
alternating current which is rectified in the field
diodes (5). This direct current is then returned in
a controlled state to the field winding where it
generates a greater magnetic field depending on
battery condition. At the same time, the field volt-
age is present at the regulator and charge moni-
toring lamp.
As the voltage on both sides of the lamp is now

positive, the lamp goes out. Terminal "W" carries
an alternating voltage which can be used for
control purposes. The winding terminals of the
alternator (4) are designated by U, V and W.
Fig. 3
1 Voltage regulator
2 - Charge monitoring lamp
3 - Ignition switch
4 - Alternator
5 - Field diode
Fig. 4
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TECHNICAL HANDBOOK
FUSES IN MOTOR VEHICLES
Type Nominal current Colour coding

A
Round fuses 5 yellow

8 black
8 white
16 red
25 blue
25 white
Strip fuses 25 white
30, 50, 100 grey
125, 150, 250
35, 60, 100 grey
Plug-in 3 violet
type fuses 4 pink
5 beige / transparent
7,5 brown
10 red
15 blue
20 yellow
25 neutral / white
30 green
Glas 5 red
fuses 10 yellow
15 blue
20 green
25 silver
Radio 2 transparent
fuses
2 796 980.00 us 35
TECHNICAL HANDBOOK
DESIGNATION OF INDIVIDUAL COMPONENTS

Extract from DIN 40 719
Letter Designation Examples
A Assembly, sub-assemblies Amplifiers, magnetic amplifiers, assembly

combinations
B Conversion of non-electrical to electrical Measuring transducers, thermo-electric
quantities (and vice versa) probes, thermo cells, photo-electric cells,
dynamometers, quartz cristals,
phase-sequence transmitters, phase-angle
sensors
C Capacitors ---
D Time-delay elements, storage devices, logic elements, bi-stable elements,
binary elements mono-stable elements
E Miscellaneous Lighting devices, heating devices
F Protective devices Fuses, surge voltage protectors, blocking
devices, isolated fuses, protective relays,
tripping elements
G Alternators Rotating alternators, rotating frequency
Power supply converters, battery, power supply units,
oscillators
H Signalling equipment Optical and acoustical signalling equipment
I ---
K Relays, contactors Power contactors, auxiliary contactors,
auxiliary relays, flasher relays, timer relays
L Inductors Chokes
M Motors ---
P Measuring instruments, testers Indicating, recording and counting meters,
pulse transmitters, clocks
Q Power-current switching relays Power switches, disconnectors, protective
switches, motor protection switches, circuit
breakers, fuse switches
R Resistors Variable resistors, potentiometers, rheostats
S Switches, selectors Pushbuttons, limit switches, control switches,
signal transmitters
T Transformers voltage transformers, current transformers
U Modulators, converters Frequency converters, transducers,
invertors, changers, d.c. inverters, power
inverters
W Transmission lines, wave-guides Wires, cables, bus bars
X Terminals, plugs, receptacles Plugs and receptacles, test connectors,
terminal strips, soldering strips
Y Electrically operated mechanical devices Brakes, couplings, valves
Z Terminations, Equalizers, filters, limiters, Cable equivalents

Y-terminations
36 2 796 980.00 us
TECHNICAL HANDBOOK
STANDARDIZED DESIGNATIONS OF TERMINALS

Terminal designation
(extract from DIN 72 552)
Designations of terminals are not identical to cable designations as appliances with different terminal
designations can be connected to both ends of a line. If the terminal designations are insufficient
(multi-pole connectors), the terminals are designated by running numbers or letters for which no function
is standardized.
Terminal Designation Terminal Designation
1 Ignition coil, Electric motors

ignition distributor 32 Return line 1)
Low voltage 33 Main connection 1)
33 a Limit stop shut-off
Ignition distributor with two separate 33 b Shunt field
circuits 33 f for second lower speed
1a to contact breaker I 33 g for third lower speed
1b to contact breaker II 33 h for fourth lower speed
33 L Lefthand sense of rotation
2 Short-circuit terminal 33 R Righthand sense of rotation
(magnetic ignition)
Starter
4 Ignition coil, ignition distributor 45 Separate starter relay, output; starter,
high-voltage input (main current)
Ignition distributor with two separate Double starter parallel operation
circuits Starter relay for engaging current
4a from ignition coil I, 45 a Output starter I,
terminal 4 input starters I and II
4b from ignition coil II, 45 b Output starter II
terminal 4
48 Terminal at starter and at start repeat
15 Switched positive behind battery, relay
(output ignition switch) Start monitor
15 a Output at ballast resistor to ignition Flasher relay
coil and starter (pulse transmitter)
49 Input
Glow-starting switch 49 a Output
17 Starting 49 b Output, 2nd flasher relay
19 Preheating 49 a Output, 3rd flasher relay
Battery Starter
30 Input from battery Plus, direct 50 Starter control
(direct)
Battery change-over relay 12/24 V
30 a Input from battery II Plus Battery change-over relay
50 a Output for starter control
Return line to battery
31 b Minus or ground, via switch or relay Starter control
(switched negative) 50 b for parallel operation of two starters
with sequential control
Battery change-over relay 12/24 V
31 a Return line to battery II Minus Starter relay for sequential control of
31 c Return line to battery I Minus enganging current in parallel operation
of two starters
50 a Input to starter relay for starter I
50 d Input to starter relay for starter II
2 796 980.00 us 37
TECHNICAL HANDBOOK
Terminal Designation Terminal Designation
Start inhibit relay Alternator

50 e Input (Magnetic ignition alternator)
50 h Output 59 Alternating voltage, output, rectifier,
input
Alternator 59 a Charging armature, output
51 D.c. voltage at rectifier 59 b Tail-lamp armature, output
51 e D.c. voltage at rectifier with choke 59 c Stop-lamp armature, output
Trailer signals 61 Alternator monitor

52 General signalling from trailer to
tractor vehicle Tone-sequence switch
71 Input
53 Wiper motor 71 a Output to horn 1 + 2 low-tones
Input (+) 71 b Output to horn 1 + 2 high-tones
53 a Wiper (+), limit stop
53 b Wiper (shunt winding) 72 Alarm switch
53 c Electrical washer pump (Rotary beacon)
53 e Wiper
(Brake winding) 75 Radio, cigarette lighter
53 i Wiper motor with permanent magnet
and third brush (for higher speed) 76 Loudspeaker
Stoplight 77 Door-valve control

54 for lamp clusters and trailer
connectors Switch
Trailer signal normally closed and change-over
54 g Compressed-air valve for permanent contacts
brake, electro-magnetically operated 81 Input
81 a 1st output, break contact
55 Fog lamp 81 b 2nd output, break contact
56 Headlamps Make contact

56 a Main beam and main beam warning 82 Input
56 b Dipped beam 82 a 1st output
56 d Flasher contact 82 b 2nd output
82 z 1st input
57 Position lamp for motor-cycles (in 82 y 2nd input
foreign countries also for cars, trucks,
etc.) Multi-point switch
57 a Parking lamp 83 Input
57 L Parking lamp, left 83 a Output, position 1
57 R Parking lamp, right 83 b Output, position 2
83 L Output, position left
58 Position, tail, licence plate and 83 R Output, position right
instrument-panel lamps
58 b Tail lamp change-over for single-axle Current relay input
trailers 84 Input,
58 c Trailer connectors for tail lamp drive and relay contact
connected with single-conductor 84 a Output,
cable, fuse-protected in trailer drive
58 d Adjustable instrument panel 84 b Output,
illumination, tail and position lamp relay contact
58 L left
58 R right, Switching relay
licence-plate lamp 85 Output, drive
(end of winding minus and ground)
Input, drive
86 Beginning of winding
86 a Beginning of winding or 1st winding
86 b Winding tap or 2nd winding
38 2 796 980.00 us
TECHNICAL HANDBOOK
Terminal Designation Generator and generator regulator
Relay contact for normally closed and B+ Battery plus
change-over contacts
87 Input B- Battery minus
87 a 1st output (break contact side) D+ Dynamo plus
87 b 2nd output D- Dynamo minus
87 c 3rd output DF Dynamo field
87 z 1st input DF 1 Dynamo field 1
87 y 2nd input
87 x 3rd input DF 2 Dynamo field 2
Relay contact for normally open Alternator

operation U, V, W Alternator terminals
88 Input
Relay contact for normally open and

change-over operation
(break contact side)
88 a 1st input Turn-signal indicator (flasher relay)
88 b 2nd output
88 c 3rd output
C First monitoring lamp
Relay contact for normally open C0 Main connection for control
operation circuits separated from flasher
88 z 1st input C2 Second monitoring lamp
88 y 2nd input C3 Third monitoring lamp (e.g. for
88 x 3rd input
double-trailer operation)
L Turn-signal lamp, left
1)
Polarity change terminal 32 - 33 possible R Turn-signal lamp, right
2 796 980.00 us 39
TECHNICAL HANDBOOK
Symbols used in electrical engineering

Extract from DIN 40 900.
Direct current
Alternating current
3-phase alternating current
Ground, general
Lines, variable line thickness for emphasized ele-

ments
Grounding N, formerly Mp
Protective earth PE, formerly SL
Assembly
Loose cable end
Grouping of lines for simplified representation in

circuit diagrams.
Lines in arbitrary order, lines must be identified
Line crossings without connection
Crossings and branches with connection
Connection, firm (soldered)
Connection, detachable, general (terminal or plug)
Male plug
Female plug
40 2 796 980.00 us
TECHNICAL HANDBOOK
Plug-in type connector with male plug and female

plug.
Switching element, two-way make contact with

three switch positions
Mechanical link
Driven by human force, generally hand-driven
Notch
Notch with number of notch position
Example: hand-operated make contact with notch
Identification of positions with numbers. The

ground position can be identified as "0"
Application cf. under "Switches"
Hand operation, pushing, pulling
Hand operation, turning, toggling
Foot operation
Removable hand-operated element, e.g. key
Driven by pressure
Driven by temperature
Indirect drive, e.g. limit switch
2 796 980.00 us 41
TECHNICAL HANDBOOK
Multi-pole connector (terminal strips)
Modular terminals (terminal strips, lamp-wire con-

nectors), also with firm or detachable connection
Sliding contact
Primary element. Battery in general; battery with

several cells (if required)
Fuse, general
Voltage surge protector

(lightning arrester)
Switch make contact
Switch break contact
Switch change-over contact
Fuse with thermally operated tripping (automatic)
42 2 796 980.00 us
TECHNICAL HANDBOOK
Example: ignition switch

(notched in Pos. 0 and 1)
Electromechanical drive, e.g. with indication of an

effective coil
Example: relay with make and break contacts
Resistor, general; also symbol for glow-plugs and

heating resistors
Variable resistor, e.g. potentiometer
Capacitor, general
Light bulb
Bulb with two filaments, e,g. Bilux
V = Voltmeter
A = Ammeter
= Ohmmeter
W = Wattmeter
etc.
D.C. Generator
Alternator, general
2 796 980.00 us 43
TECHNICAL HANDBOOK
Alternator with rectifier set (3-phase alternating

current generator)
Symbol for motors, starters (motor vehicles)
Windscreen wiper with motor drive
A.c. motor
Solenoid valve
Horn
Electrical fan
Buzzer
Operating-hours meter
Electrical clock
Spark gap, e.g. spark plug
44 2 796 980.00 us
TECHNICAL HANDBOOK
Ground, general
Winding, inductor, general (e.g. chokes)
Winding with magnetic core (choke with core)
Transformer, converter, general
Symbol for 3-phase motor with squirrel cage
Shield with ground connection
Diode rectifier, forward bias for positive current in

the direction of the arrow point
Z diode (suitable for operation at breakdown volt-

age)
Thyristor
Light-ermitting diode
PNP transistor
Switching resp. regulating
E = Ermitter
C = Collector } connections
B = Base (control connection)
2 796 980.00 us 45
TECHNICAL HANDBOOK
NPN transistor
Photo-transistor
Temperature-dependent resistor
Voltage-dependent resistor, e.g. NTC
Electronic amplifier
Operational amplifier (amplifies the voltage be-

tween E1 and E2)
D.c. converter
Voltage converter (24 to 15 volts)
Initiator
Optocoupler
46 2 796 980.00 us
TECHNICAL HANDBOOK
Symbols for directions of motion
2 796 980.00 us 47
TECHNICAL HANDBOOK
Notes 2800145
48 2 796 980.00 us
F
A Floodlamps ........................................................ 30
Adjustment of the multimeter .............................. 24 Free electron ........................................................ 3
Alternating current diagram .................................. 5 Function of the alternator .................................... 16
Alternator ...................................................... 16, 17 Function of the starter ........................................ 20
Alternator regulator ............................................ 34 FUNDAMENTALES OF AUTOMOTIVE ELEC-

TRICAL SYSTEMS ............................................ 23
B FUSES IN MOTOR VEHICLES .......................... 35
Batteries ............................................................ 25
G
Battery ................................................................ 10
Generator and generator regulator .................... 39
Battery charging .................................................. 7
Bulbs .................................................................. 30
H
Headlamps adjustment hints .............................. 30
C
Calculation of lines ............................................ 28
I
Capacitors .......................................................... 25
IMPORTANT INSTRUCTIONS ............................ 1
Checking the battery .......................................... 12
Checking the vehicle starter system .................. 21 L

Circuit with fault indication on interruption in LIGHTING .......................................................... 30
the exciter circuit .................................................. 8
Lines and wires in automotive electrical sys-
Claw-pole alternator ...................................... 8, 17 tems .................................................................... 29
Computation ...................................................... 28 Low-maintenance batteries ................................ 12
Current, voltage, resistance and power .............. 23 Lubrication .......................................................... 22
D M
Density values of diluted sulphuric acid .............. 12 MAIN COMPONENTS OF AUTOMOTIVE
ELECTRICAL SYSTEM...................................... 10
Design example .................................................. 29
Maintenance .......................................... 13, 17, 22
DESIGNATION OF INDIVIDUAL COMPO-
NENTS .............................................................. 36 Maintenance-free starter battery ........................ 11
Malfunctions of the lighting system and their

E causes ................................................................ 30
Electric motors .................................................... 18 MEASUREMENTS WITH THE MULTIMETER .. 24
ELECTRICAL SYSTEMS IN GENERAL .............. 2 Measuring current .............................................. 24
Electrolytic capacitors ........................................ 25 Measuring resistance ........................................ 24
Electromagnetic field ............................................ 4 Measuring voltage .............................................. 24
Mixing fresh battery acid .................................... 13
Mixing instructions .............................................. 13

O V
Ohmmeter .......................................................... 24 Varistors ............................................................ 32
VOLTAGE LOSSES AND CABLES.................... 27

P Voltage rectification in three-phase bridge cir-
Parallel connection ............................................ 25 cuits .................................................................... 32
POWER GENERATION ...................................... 6
Power generation in motor vehicles...................... 6
PREFACE ............................................................ 1
Principle of the electric motor ............................ 18
R
Resistors ............................................................ 25
S
SERIES AND PARALLEL CONNECTION OF
ELECTRICAL COMPONENTS .......................... 25
Series connection .............................................. 25
SPECIAL CIRCUITS IN AUTOMOTIVE ELEC-

TRICAL SYSTEMS ............................................ 31
STANDARDIZED DESIGNATIONS OF TER-

MINALS .............................................................. 37
Starter ................................................................ 21
Starting motor (starter)........................................ 20
Structure of atoms ................................................ 2
Symbols for directions of motion ........................ 47
Symbols used in electrical engineering .............. 40
T
Terminal designation .......................................... 37
Testing the charging system ................................ 9
The "free-wheeling" diode .................................. 31
The atom .............................................................. 2
The diode............................................................ 31
Transition resistance in electrical circuits .......... 30
Troubleshooting .................................................. 14
Turn-signal indicator (flasher relay) .................... 39
Type designation ................................................ 16
Types of batteries .............................................. 11

Automotive electrical systems in
construction machinery
Interpretation of wiring diagrams

Troubleshooting
2 732 669.00 us
PREFACE .................................................................................................................................................. 1
NOTES ON SAFETY .................................................................................................................................. 2
ELECTRICAL SYSTEM DOCUMENTATION ............................................................................................ 3
THE WIRING DIAGRAM ............................................................................................................................ 4
Explanation of the wiring diagram

Current paths .......................................................................................................................................... 5
Main circuits ............................................................................................................................................ 5
Branches ................................................................................................................................................ 5
Relay contacts ........................................................................................................................................ 5
Cross reference to other current paths .................................................................................................... 5
Contacts of plug-in connectors ................................................................................................................ 5
Cable cross-section ................................................................................................................................ 7
Identification of contacts .......................................................................................................................... 7
Cable number .......................................................................................................................................... 7
Electronic units (Fig. 3) ............................................................................................................................ 7
WIRING DIAGRAM LEGEND .................................................................................................................... 8
Explanation of legend
Part .......................................................................................................................................................... 9
Quantity .................................................................................................................................................. 9
Description and function .......................................................................................................................... 9
Current path ............................................................................................................................................ 9
Location .................................................................................................................................................. 9
Part number ............................................................................................................................................ 9
CHECKING AND TESTING EQUIPMENT

Solenoid-valve tester ............................................................................................................................ 10
Test lamp .............................................................................................................................................. 10
Multimeter.............................................................................................................................................. 11
Testers .................................................................................................................................................. 11
BASIC MEASURING AND TESTING PROCEDURES

Voltage checks ...................................................................................................................................... 12
Checking the continuity ........................................................................................................................ 13
Checking the coil of a solenoid .............................................................................................................. 14
PRACTICAL TROUBLESHOOTING
Notes on troubleshooting in automotive electrical systems .................................................................. 15
Example of systematic troubleshooting ................................................................................................ 15
Fault-finding diagram ............................................................................................................................ 16
ANNEX .................................................................................................................................................... 20
Identification of components ................................................................................................................ 20
Schematic symbols
Electrical Connections .......................................................................................................................... 22
Switches, contacts ................................................................................................................................ 23
Indicators, measuring devices .............................................................................................................. 26
Motors, alternators ................................................................................................................................ 27
Semiconductors .................................................................................................................................... 28
Miscellaneous........................................................................................................................................ 29
Symbols for directions of motion .......................................................................................................... 30
Fuses
Fuse links .............................................................................................................................................. 31
Fuse strips ............................................................................................................................................ 31
TECHNICAL HANDBOOK
PREFACE 2732947
Electrical systems for construction machinery This has led to some differences between the old
have developed far beyond their original applica- and the new circuit diagrams.
tions as starting and lighting devices. The new
tasks are essentially monitoring and control func- The interpretation of these new CAD circuit dia-
tions. This has entailed an inevitable increase in grams and their accompanying documents will be
the number of circuits, so that the overall system explained in the following description.
appears complex and unclear to the non-electri-
cian. The present Technical Handbook applies to auto-
motive electrical systems in construction machin-
This impression was reinforced by the schematic ery. The relevant accident prevention rules and
block diagrams used in the past. the different requirements depending on various
operating voltages must always be observed.
For this reason our company, like the automobile These rules are not part of the handbook.
industry, has opted for another type of diagram,
the circuit diagram.
This new type of diagram has proved very suc-

cessful. Our company has now taken a further
step in this direction with the decision to establish
its documentation by means of a specially devel-
oped CAD system.
2 732 669.00 us 1
TECHNICAL HANDBOOK
NOTES ON SAFETY 2732948
Before working on the electrical When acid has splashed into the eyes,
system rinse thoroughly with large amounts of
water and go immediately to a doctor.
The repair personnel must have knowl-
Do not place tools on the battery. They
edge and experience in the repair of elec-
may produce a short-circuit destroying
trical systems of this or similar machines.
the battery and causing injury.
In case of insufficient knowledge, the can-
Do not wear necklaces, bracelets or watch
didates must be thoroughly instructed by
straps of metal when working on the bat-
experienced repair personnel.
tery. Metal parts can cause short-circuits
Before undertaking any maintenance and with the risk of resulting burns.
repair work, the machine must be secured
Dispose of used batteries separately from
as follows:
other waste and without polluting the en-
- Park the machine on level and stable vironment.
ground.
- Stand working equipment on the Alternator -
ground.
Handling instructions
- Block the articulated joint.
Never disconnect electrical cables from
- Shut off the engine.
alternators, regulators and battery when
- Withdraw the key from the electrical the engine is running to avoid damage to
system key-switch. the alternator and regulator.
- Protect the machine against rolling Do not mix up cables when connecting
away by placing chocks under the the batteries (observe polarity).
wheels.
Always use measuring instrument for volt-
- Disconnect the battery before undertak- age and continuity testing.
ing work on the electrical system or
before carrying out welding work. Never use a "test lamp".
Disconnect the negative terminal and then Never "tap against ground".
the positive terminal. This causes a short circuit with conse-
After the work: quent damage to the alternator and regu-
lator.
Connect first the positive and then the
negative terminal. When the engine is started, the alternator
is pre-excited by an electronic circuit.
This circuit ensures that the alternator
can supply power.
Battery handling
The circuit is part of the Central Elec-
Batteries give off explosive gases. tronic System in the control panel.
Avoid fire and unshielded light in the vi- An LED in the control panel (charge con-
cinity of batteries and do not smoke. trol) indicates the correct functioning of
Battery acid is toxic and caustic. the alternator. This LED must light up
when the keyswitch is turned to the "ON"
Avoid contact of battery acid with the position. It goes out when the engine is
skin, the mouth, the eyes and the clothes. running. If this is not the case, either the
Do not spill battery acid and do not inhale alternator circuit or the control panel are
the gases. defective.
Wear gloves, firm working clothing and To prevent further damage, the causes of
goggles when working on batteries. the fault must be located and rectified as
If the skin has come into contact with fast as possible.
acid, rinse thoroughly with water and con- Contact your nearest dealer service.
sult a doctor.
2 2 732 669.00 us
TECHNICAL HANDBOOK
ELECTRICAL SYSTEM
DOCUMENTATION 2732949
For organizational reasons, the documentation for

Fuses
the electrical system of the machine has been
Working on the fuse holder involves the annexed to the spare-parts list. The documenta-
risk of sparking and short-circuits. tion includes:
Therefore:
- the circuit diagram
Remove fuses only after the circuit has
been de-energized: - the circuit diagram legend with the electrical
components.
Shut off the engine and turn the key-
switch of the electrical system to 0. The components are identified in accordance with
For machines with main battery switch: DIN 40 719 by letters. An extract of this standard
is given in the ANNEX.
Switch off main battery switch.
Replace defective fuses only by those of With the help of the above-mentioned documents
the same current rating. and the present Technical Handbook, a qualified
electrician should be able to rectify faults in the
electrical system.
Simple works on the electrical system, e.g.

- the replacement of bulbs,
- of fuses and
- of relays
are described in the operating instructions of the

machine.
2 732 669.00 us 3
TECHNICAL HANDBOOK
THE WIRING DIAGRAM 2732950
The wiring diagram is a schematic representation The representation makes use of symbols in acc.
of the electrical system and its detailed compo- with DIN 40 900.
nents. The diagram shows the interconnection of
electrical components and the operation of an All components are identified by capital letters in
electrical system. acc. with DIN 40 719.
The wiring diagram consists of several individual Extracts of these DIN standards can be found at
sheets (see lower right corner of the sheet shown the end of the present Technical Handbook.
in fig. 1) representing functional groups.
The wiring layout plan shows the location of com-
All components are shown in a no-voltage resp. ponents and connectors of the machine.
no-current state and with none of the elements
being actuated.
Fig. 1
4 2 732 669.00 us
TECHNICAL HANDBOOK
Explanation of the wiring diagram 2732951
(sample page shown in fig. 1 is sheet 1 of 19 sheets)

Page 1/2
1. Current paths 4. Relay contacts

The current-path numbers are given at the upper Numbers on the relay contacts indicate the sheet
margin of the path diagram sheet. They appar- number of the wiring diagram and the current
ently subdivide the sheet into ten vertical columns path where the exciter coil for this contact can be
(0 to 9). found.
Reference to the sheet number and the current- Example:

path number facilitates the search of components
and the orientation in the wiring diagram. Label K5 means:
.3
The exciter coil for this make contact can be
2. Main circuits found in current path 3 on the same sheet of the
current diagram.
The main circuits are shown as horizontal lines at
the top and the bottom of the wiring diagram.
Positive potential main circuits are shown at the 5. Cross reference to other current
top and negative potential circuits are shown at paths
the bottom.
Relays whose make, break or change-over con-
Example: tacts are located in other current paths have
numbers under the current path of the exciter coil
30/2.0 = Plus (switched). The main circuit con- indicating in which current paths these contacts
tinues on sheet 2 of the circuit dia- are located.
gram with current path 0.
15/2.0 = Plus (switched). The main circuit con- Example:
tinues on sheet 2 of the circuit
The wiring diagram lable indicates that the relay
diagram with current path 0.
K 1.5 on the same sheet of the current wiring
31/2.0 = Minus (ground). The main circuit con- diagram in current circuit path has a make con-
tinues on sheet 2 of the circuit dia- tact at circuit path 2.
gram with current path 0.
6. Contacts of plug-in connectors

3. Branches
Plug-in connectors are identified by the number of
Current-path branches together with the letters the connector and the number of the plug-in con-
and numbers indicate the additional connection of tact.
current paths on other sheets of the wiring dia-
gram. Example:
Example: Label X101/2 refers to:
Label Z5 means: contact 2 in connector X101.

3.9
This branch is connected to point Z5 in current
path 9 on page 3 of the wiring diagram.
2 732 669.00 us 5
TECHNICAL HANDBOOK
Fig. 2
Fig. 3
6 2 732 669.00 us
TECHNICAL HANDBOOK
Page 2/2
7. Cable cross-section 9. Cable number

The following number refers to the cross-section The cable number (94 in this case) is printed on
of the cable 10 meaning that this cable has a the insulation at intervals of several centimeters.
conductor cross-section of 10 mm2. This number together with number of the connec-
tor permits easy identifaction of a cable even in a
cable harness or by the connector (e.g. for con-
8. Identification of contacts tinuity checking). The connectors are also marked
with their specific number (e.g X101). The con-
The numbers at relay contacts or at switch connection tables showing the pin assignment of
nections at contacts are identical with the num- each connector can be found after the wiring
bers found on the components themselves. diagram (e.g. X101, Fig. 4).
If a cable is defective and if you dont know
Example: which components are linked by this specific ca-
ble, then this can be determined from the con-
Label S113, 1,4 means:
nection tables.
The switch is the S113 with connections at con-
The example (Fig. 2 and 4) shows how to identify
tacts 1 and 4.
cable 94 in connector X 101:
One end is connected to terminal 5 of switch
S 1.7 (cable cross-section 1.5 mm2) and the other
end to solenoid valve Y 1.3 (cable cross-section
2.5 mm2). The cable is connected to pin 12 of the
connector which is part of the "engine cable har-
ness". The exact location of the connector at the
machine and the corresponding order number are
set out in the "WIRING DIAGRAM LEGEND".
Fig. 4
10. Electronic units (Fig. 3)

Electronic units (e.g. Central Electronic Unit, Load
Limit Governor) are displayed in the wiring dia-
gram as black boxes.
2 732 669.00 us 7
TECHNICAL HANDBOOK
WIRING DIAGRAM LEGEND 2732952
The legend "Electrical components in wiring dia-

gram" (Fig. 1) gives a systematic overview which
supplements the circuit diagram. The legend per-
mits to find electrical components in the circuit
diagram and on the machine. The legend also
contains the part numbers of the components.
31.050 -
Electrical components in wiring diagram
FX 270 Wiring diagram No. 2459343 T 2459344 - 000
B 2459343 - 010
Part Quantity Description and Function Curr. Path Location Part-No
A10 1,000 LOAD LIMIT GOVERNOR 2 - 0/61 - CONTROL PANEL

A10X4 1,000 DIAGNOSTIC UNIT CONNECTOR 4 - 2/18 - CONTROL PANEL 73172588
A10X4 1,000 FLANGE 4 - 2/18 - CONTROL PANEL 73172589
A100 1,000 2 - 1/16 - CAB 73172003
B10 1,000 PRESSURE SENSOR - TRAVEL 8 - 0/84 - SUPERSTRUCTRURE 73172592
B10.1 1,000 SPEED SENSOR 2 - 9/92 - ENGINE
B13.1 1,000 COOLING-WATER TEMPERATURE 2 - 1/94 - ENGINE 73172594
SENSOR
E1 1,000 LH HEADLIGHT 6 - 0/87 - SUPERSTRUCTURE 73172595
E1 1,000 BULB 6 - 0/87 - SUPERSTRUCTURE 73172596
E1 1,000 HOUSING 6 - 0/87 - SUPERSTRUCTURE 73172597
E1 1,000 PLUG 6 - 0/87 - SUPERSTRUCTURE 73172598
E1 2,000 COUNTER-SUNK SCREW 6 - 0/87 - SUPERSTRUCTURE 73172599
E1 2,000 LOCKING NUT 6 - 0/87 - SUPERSTRUCTURE 73172600
E2 1,000 RH HEDADLIGHT 6 - 1/87 - SUPERSTRUCTURE 73172595
E2 1,000 BULB 6 - 1/87 - SUPERSTRUCTURE 73172596
E2 1,000 HOUSING 6 - 1/87 - SUPERSTRUCTURE 73172597
E2 1,000 PLUG 6 - 1/87 - SUPERSTRUCTURE 73172598
E2 2,000 COUNTER-SUNK SCREW 6 - 1/87 - SUPERSTRUCTURE 73172599
E2 2,000 LOCKING NUT 6 - 1/87 - SUPERSTRUCTURE 73172600
E3 1,000 WORKING LIGHT, BOOM LEFT 6 - 2/87 - BOOM 73172602
E3 1,000 BULB 6 - 2/87 - BOOM 73172510
E4 1,000 WORKING LIGHT, BOOM LEFT 6 - 3/87 - BOOM 73172602
E4 1,000 BULB 6 - 3/87 - BOOM 73172510
E9 1,000 INTERIOR LIGHT 4 - 1/74 - CAB 73171604
E9 1,000 BULB 4 - 1/74 - CAB 73172605
F1 1,000 FUSE BOX, GREEN 4 - 1/16 - CONTROL PANEL 73172606
F2 1,000 FUSE BOX, BLACK 1 - 7/16 - CONTROL PANEL 73172606
F3 1,000 2 - 0/18 - CONTROL PANEL 73172606
F5 1,000 FUSE BOX, NATURAL 5 - 5/16 - CONTROL PANEL 73172608
F9 1,000 FUSE BOX, GREEN 1 - 4/16 - CONTROL PANEL 73172607
F11 1,000 FUSE BOX, NATURAL 4 - 0/16 - CONTROL PANEL 73172606
Fig. 1
8 2 732 669.00 us
TECHNICAL HANDBOOK
Explanation of legend (Fig. 1) 2732953
Part Location
The part column lists all components of the elec- The "Location" column indicates the place of in-
trical system in alphabetical order. The letters stallation of the component in the machine.
represent the type of component installed in acc.
with DIN 40 719. This information facilitates the location of compo-
(Extracts of DIN 40 719 cf. "ANNEX"). nents in the machine, e.g. when searching for
faults.
Quantity
Part number
Indicates how many of the components are in-
stalled in the machine. Order numbers for spare parts
If no part number is indicated, the component is
Description and function connected to the electrical system, but part of
another assembly. The part number for this com-
Refer to the kind of component and to its function ponent can then be found in the corresponding
(e.g. cooling-water temperature sensor). spare-parts sheet.
Current path Example:
The current-paths numbers are indicated at the Part numbers for solenoid valves can be found in
upper margin of the wiring diagram sheets. These the "Hydraulic system" section of the spare-parts
numbers permit to find electrical components in list.
the wiring diagrams.
Example:
Load limit governor

In the "Current path" column, we have: 2-0/61.
This means that the load limit governor can be
found on wiring diagram sheet 2 in current path
0.
Figure 61 is an internal CAD system coordinate
which is of no importance for the interpretation of
the documentation.
2 732 669.00 us 9
TECHNICAL HANDBOOK
CHECKING AND TESTING EQUIPMENT 2732954
All methods of fault detection described in the Test lamp

present Technical Handbook can be carried out
with simple measuring instruments and testers.
The use of these devices is explained in this

handbook by means of the step-by-step method
(cf. section "Basic measuring and testing proce-
dures").
The present handbook will not deal with techni-

cally more complicated testing devices for auto-
motive electrical systems. These devices have
their own operating instructions with detailed in-
formation about how to handle them. The operat-
ing instructions must therefore be read before
using such equipment.
Fig. 2
Depending on the manufacturer, the testing
equipment used in the field can differ from the Important:
instruments shown in this handbook. Due to the Never use the test lamp for testing on circuit
large number of commercially available types it is boards equipped with electronic components.
impossible to show all the types in this handbook. Sensitive electronic components may be
For this reason, the handbook dispenses with damaged by the strong current flowing
brand names and names of manufacturers. through the test lamp. The housing of the test
lamp is metallic and therefore conducts elec-
tric currents. The housing may therefore
cause a short-circuit between two adjacent
Solenoid-valve tester components on the board.
The test lamp lights up when the tested compo-

nent is under tension.
Test lamps are manufactured for different system

voltages. The test lamp must be designed for the
voltage of the electrical system, as a 12-volt test
lamp will be damaged if it is used in 24-volt
systems.
Fig. 1
The solenoid-valve tester indicates whether the

coil of a solenoid valve or a relay produces a
magnetic field.
The magnetic field is generated when current

flows through the coil.
Operation of the solenoid tester shown requires

two batteries (1.5 V, type AAA).
10 2 732 669.00 us
TECHNICAL HANDBOOK
Multimeter Testers
Fig. 3 Fig. 4
The following quantities can be measured with Important:

multimeters: Never use the test buzzer for testing on circuit
- voltage, boards equipped with electronic components.
Sensitive electronic components may be
- current, damaged by the strong current flowing
- resistance. through the test buzzer.
Many multimeters have additional functions, e.g.: Testers indicate by means of

- capacitance measurement, - optical signals (lamp) and
- diode and transistor testing, - acoustical signals (buzzer)
- testing facilities (continuity check). whether a current flows through a component
(e.g. cable, fuse, bulb). In this case, we say that
Measuring instruments display the measured val- the component "lets the current pass".
ue in two ways:
- as analogue devices with pointer-type instru- Acoustical continuity checks have the advantage
ments and that the person carrying out the test can con-
centrate on the test prods. It is not necessary to
- as digital devices with numerical read-out watch a lamp, so that incorrect measurements
(Fig. 3). due to a displaced testing prod are excluded.
Read the operating instructions before using the The continuity tester requires batteries for opera-
instruments. These measuring instruments are tion (number and type of the battery depend on
highly precise but also very sensitive devices the type of tester used).
which may be damaged if operated incorrectly.
2 732 669.00 us 11
TECHNICAL HANDBOOK
BASIC MEASURING AND TESTING PROCEDURES 2732955
Risk of injury
Some testing procedures must be carried
out with the electrical system under ten-
sion.
Therefore protect the machine against in-
advertent movements before carrying out
work on electrical systems under tension.
Close the door of the drivers cab or place
a warning sign at an easily visible place
inside the cab. Fig. 1
2. Checking with the multimeter (Fig. 2)

Voltage checks
Switch multimeter to the "voltage mode" and
In the present example we are going to check select the suitable measuring range.
whether the coil of solenoid (Y 1.3) for the flame-
Connect the ground terminal to vehicle ground.
glow pre-heating system of an diesel - engine is
under tension. Press the positive test prod against the positive
component terminal (plus +).
The instrument indicates the magnitude of the
1. Checking with the test lamp (Fig. 1) voltage present.
Select a suitable test lamp (12 V or 24 V).
Connect the ground terminal of the test lamp to

vehicle ground.
Press the tip of test lamp against the live com-

ponent terminal (positive terminal).
The test lamp lights up if the component is
under tension.
If the test lamp has a needle tip, it is possible to

penetrate the insulation of the connecting cable. If
the test lamp lights up, the connection cable is
under tension.
Fig. 2
12 2 732 669.00 us
TECHNICAL HANDBOOK
Checking the continuity
Risk of short-circuit
Never carry out continuity checks on
components under tension. Checking may
cause short-circuits or overloading with
resulting damage to the component or
test equipment.
The component to be tested must there-
fore be de-energized. To do so, discon-
nect all electrical connections from the
component.
Fig. 3
Continuity checks permit show whether a current

flows through a component. 2. Checking with the multimeter (Fig. 4)
This check is always recommended if invisible
Switch the multimeter to the "resistance mode".
interruptions of conductors inside a component
are suspected as the cause of trouble (e.g. in Attach the ground connector to one end of the
cables, coils, contacts, bulbs). conductor.
In the present example we will check whether the Hold the test prod to the other end of the
conductors of a cable allow current to pass or conductor (observe insulation colour coding).
whether they are interrupted.
The instrument now shows the resistance of the
conductor in ohms.
1. Checking with the tester (Fig. 3)
If nothing is indicated, the conductor is inter-
Connect the ground terminal of the continuity rupted.
tester to one end of the conductor.
Hold the test prod against the other end of the

same conductor (observe insulation colour cod-
ing).
In this example, the continuity tester and the

component under test form a closed current cir-
cuit.
The continuity tester checks the conductor with

low voltage. If the conductor is continuous, the
current circuit is closed. The lamp lights up and
the buzzer sounds.
Fig. 4
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TECHNICAL HANDBOOK
Checking the coil of a solenoid

In this case we will check whether the coil of the
switching magnet of the "start boost system"
(Y 1.1) generates a magnetic field when under
tension.
Fig. 5
Using the solenoid valve tester (Fig. 5)
Hold the test prod of the solenoid valve tester

to the coil.
The signal lamp of the tester lights up if a mag-

netic field is generated by the coil.
This test does not permit a statement about the

mechanical function of the component. It is still
possible that the switching pin jams although the
coil itself is o.k.
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PRACTICAL TROUBLESHOOTING 2732956
Notes on troubleshooting in automotive electrical systems

In order to rectify faults fast and safely, it is Required documents:
important to proceed systematically when search-
- operating instructions,
ing for faults.
Beside the technical qualification of the electri- - wiring diagram with legend and
cian, knowledge of the following facts is required
- spare-parts list.
for successful troubleshooting:
- Which assembly is defective? Measuring and testing devices
- Which is the location of the assembly in the Recommended measuring and testing devices
machine? are described in the "Measuring and testing de-
- Which is the correct function of the assembly? vices" section.
- Which components are interacting? Measuring and testing procedures

- In which way do the components interact? How to carry out testing with simple means is
- Where are the components located in the ma- described in the "Basic measuring and testing
chine? procedures" section.
- Under which conditions and in which operation- Wiring diagrams

al state is the fault present?
Knowledge and understanding of the wiring dia-
Questions to the operator of the machine: grams and the symbols used in these diagrams
- Which warning signs have preceded the fault? are an essential prerequisite for successful
troubleshooting in automotive electrical systems.
- Which maintenance or repair works have been The symbols used in the wiring diagrams are
carried out beforehand? listed in the annex.
- Has the fault already been observed before?
Even more important than locating the defective
- Can the fault be rectified with the troubleshoot- component is the determination of the cause of
ing tables in the operating instructions? trouble.
In many cases, faults and defects repeat them-
- Has the machine been wrongly operated?
selves if the cause of the fault is not recognized
and eliminated.
Example of systematic troubleshooting

Starting situation:
- batteries fully charged,
- system voltage normal,
- tank filled with fuel,
- starter turns the engine with start - speed.
Fault:
- engine does not fire.
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TECHNICAL HANDBOOK
Fault-finding diagram (example)

The sequence of troubleshooting operations is If the answer is "Yes", the next testing step can
represented by means of a diagram. be performed.
Faul finding is divided into individual steps mak- If the answer is "No", the line leads to a square-
ing it clear and easy to follow. shaped symbol. This symbol indicates the repair
work to be carried out.
How to work with the fault-finding diagram.
Such a diagram must basically be read from top If the fault has been rectified after such repair,
to bottom. The top mentions the kind of fault. fault-finding ends here. If the fault persists, fault
This is the starting point for further actions de- detection must be continued with the next step.
scribed in the following symbols.
Electrical connections between the components
Diamond-shaped symbols contain a request to mentioned are set out in the circuit diagram
check the situation. This check can be answered (Fig. 1 and 3). Each testing step has a reference
with "Yes" or "No". Depending on the result of the to the corresponding position in the wiring dia-
check, follow either the "Yes" or the "No" line. gram.
Fig. 1
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Page 1/2
Fig. 2
2 732 669.00 us 17
TECHNICAL HANDBOOK
Fig. 3
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Page 2/2
Fig. 4
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TECHNICAL HANDBOOK
ANNEX 2732957
Identification of components
(Exerpt from DIN 40719)
A Assembly group, parts of groups Control unit, switch unit, magnetic amplifi-
ers, combinations of devices
B Transformation from non-electrical into Metering transformers: rev. transmitter, pres-

electrical magnitudes (and vice versal) sure sensor, pressure switch, thermic
sensors, photo-electric cells, pulse gener-
ator, inclinometers
C Capacitors ---
D Binary elements, memories Digital unit, integrated circuit, impulse coun-

ter
E Miscellaneous Lights, heaters
F Safety devices Fuses, overload guards, interlocks, circuit

breakers, safety relays, releases
G Generator Rotary generators, rotary frequency convert-

Electrical supplies ers, batteries, power supplies, oscillators
H Monitors Monitoring lamp, buzzer
K Relays, contactors Power contactors, auxiliary contactors, auxil-

iary relays, blinker relays, time-lag relays
L Inductive devices Throttle coils, coils
M Motors Fan motor, wiper motor
20 2 732 669.00 us
TECHNICAL HANDBOOK
P Meters, testers Indicating, recording and metering instru-

ments, impulse initiators, clocks
R Resistances Pre-glow plug, flame-glow plug, shunt,

potentiometer
S Switches, selectors Buttons, limit switches, control switches, sig-

nal ermitters
T Transformers Transformers, converters
U Modulators, converters Frequency converters, converters, inverters,

tansverters, demodulators, reversing con-
verters
V Semiconductors Cancelling diodes for solenoid valves,

variode
W Conductive paths, hollow conductors Switch lines, cables, busbar, antenna
X Terminals, plug, sockets Isolating plugs/sockets, test sockets, termi-

nal strips, solder strips
Y Electrically actuated mechanical devices Brakes, coupling, valves
Z Filters Interference suppression assembly
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TECHNICAL HANDBOOK
Schematic symbols (Exerpt from DIN 40900) 2732958
Electrical Connections
22 2 732 669.00 us
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Switches, contacts
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TECHNICAL HANDBOOK
Switches, contacts
24 2 732 669.00 us
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Switches, contacts
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TECHNICAL HANDBOOK
Indicators, measuring devices
26 2 732 669.00 us
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Motors, alternators
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TECHNICAL HANDBOOK
Semiconductors
28 2 732 669.00 us
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Miscellaneous
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TECHNICAL HANDBOOK
Symbols for directions of motion
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Fuses 2732959
Fuse links (DIN 72 581)

Type Nominal current, amperes Colour of fuse insulation
3 violet
4 pink
5 lightbrown
7,5 brown
10 red
15 lightblue
20 yellow
25 white (nature)
30 lightgreen
Fuse link, flat type
5 yellow
8 white
16 red
25 blue
Fuse link, round type
Fuse strips (DIN 72 581)

Nominal current, amperes
30
50
80
100
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TECHNICAL HANDBOOK
Notes 2800145
32 2 732 669.00 us
I
A Identification of components .............................. 20
ANNEX .............................................................. 20 Identification of contacts ...................................... 7
Indicators, measuring devices ............................ 26

B
BASIC MEASURING AND TESTING PROCE- L
DURES .............................................................. 12
Location ................................................................ 9
Branches .............................................................. 5
M
C
Main circuits.......................................................... 5
Cable cross-section .............................................. 7
Miscellaneous .................................................... 29
Cable number ...................................................... 7
Motors, alternators.............................................. 27
CHECKING AND TESTING EQUIPMENT ........ 10
Multimeter .......................................................... 11
Checking the coil of a solenoid .......................... 14
Checking the continuity ...................................... 13 N

Contacts of plug-in connectors ............................ 5 NOTES ON SAFETY ............................................ 2
Cross reference to other current paths ................ 5 Notes on troubleshooting in automotive elec-
trical systems ...................................................... 15
Current path.......................................................... 9
Current paths ........................................................ 5

P
Part ...................................................................... 9
D
Part number .......................................................... 9
Description and function ...................................... 9
PRACTICAL TROUBLESHOOTING .................. 15
E PREFACE ............................................................ 1
Electrical Connections ........................................ 22

Q
ELECTRICAL SYSTEM DOCUMENTATION ...... 3
Quantity ................................................................ 9
Electronic units (Fig. 3) ........................................ 7
Example of systematic troubleshooting .............. 15

R
Explanation of legend .......................................... 9
Relay contacts ...................................................... 5
Explanation of the wiring diagram ........................ 5
S
F
Schematic symbols ............................................ 22
Fault-finding diagram .......................................... 16
Semiconductors .................................................. 28
Fuse links .......................................................... 31
Solenoid-valve tester .......................................... 10
Fuse strips .......................................................... 31
Switches, contacts .................................. 23, 24, 25
Fuses .................................................................. 31
Symbols for directions of motion ........................ 30
T
Test lamp ............................................................ 10
Testers................................................................ 11
THE WIRING DIAGRAM ...................................... 4
V
Voltage checks .................................................. 12
W
WIRING DIAGRAM LEGEND .............................. 8
PCS (Electronic-power-limit control system)
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PCS functional description
Power-limiting control .............................................................................................................................. 1
Simplified control loop in an electronic power-limiting control system .................................................... 2
Control loop ............................................................................................................................................ 3
Example of motor measurements............................................................................................................ 3
Nominal speed determination.................................................................................................................. 5
PCS functional diagram .......................................................................................................................... 7
Description of PCS .................................................................................................................................. 9
Sequence of operations ........................................................................................................................ 10
ODC - On-Board Diagnostic Computer ................................................................................................ 11
PCS Troubleshooting
Locating and rectifying faults ................................................................................................................ 13
Ensuring proper test conditions for the machine .................................................................................. 14
Checking the power-limiting control ...................................................................................................... 14
Checking the temperature control ........................................................................................................ 14
Checking the mode of operation and the special functions .................................................................. 14
On-Board Computer (A10) .................................................................................................................... 15
Control Panel (A100) ............................................................................................................................ 16
Central electrical system ...................................................................................................................... 17
Magnetic PICKUP (B10.1) .................................................................................................................... 18
Diesel speed actuator (M10) ................................................................................................................ 19
Checking / adjusting the high IDLE speed ............................................................................................ 20
Engine STOP solenoid (Y1.4) .............................................................................................................. 21
Speed poteniometer (R10) .................................................................................................................... 22
Connector (C5/C6) Centry .................................................................................................................... 23
Pressure switch - servo pressure (S10.1) ............................................................................................ 24
Pressure switch - travelling (S10.2) ...................................................................................................... 25
Proportional valve (Y10) ........................................................................................................................ 26
Valve connector (Y10) .......................................................................................................................... 27
Proportional valve characteristic............................................................................................................ 28
Measuring port (X3) at main pumps ...................................................................................................... 29
Coolant temperature sensor B13.1 / R10.2 .......................................................................................... 30
Coolant temperature sensor (B13.1) (R10.2) ........................................................................................ 31
Fault signalling in the ODC (ON-BOARD DIAGNOSTIC SYSTEM)

Fault code - Table ................................................................................................................................ 32
FAULT CODE table .............................................................................................................................. 33
Emergency operation ............................................................................................................................ 34
Emergency operation setting ................................................................................................................ 34
Failure memory .................................................................................................................................... 35
CENTRY system - fault messages and remedial actions ...................................................................... 36
EDS special functions

Deleting the NV RAM ............................................................................................................................ 37
Resetting the servicing interval.............................................................................................................. 38
Changing the machine start disabling code .......................................................................................... 39
Example: Hammer current adjustment with the EDS-diagnostic tester ................................................ 40
Programming: DSH current .................................................................................................................. 40
Switching the hydraulic hammer on ...................................................................................................... 42
Switching the hydraulic hammer off ...................................................................................................... 42
TECHNICAL HANDBOOK
PCS functional description 2801313
Power-limiting control
Hydraulic excavators play an outstanding role in To achieve an increase in overall machine perfor-
building and construction work. The demands mance, it is necessary for the power-limiting units
made on their hydraulic system are manifold. To- to work together.
days hydraulic excavators therefore have to fulfill
a broad spectrum of work-related requirements The drive engine and the hydraulic system cannot
such as: be treated as separate and independent units but
rather as individual units that have to work in
Maximum lifting capacity in conjunction with common.
high ripping and breaking forces.
The aim here is an increase of efficiency for a
High speeds of all consumers with minimal better utilization of the energy resources.
loads.
The summation control or the the cross-over con-
Precise movements and high operating comfort.
trol have the disadvantage that the diesel engine
Simultaneous operation of several consumers itself is not part of the control loop.
at the same time.
The operation of auxiliary consumers that are
As low as possible circulation losses in stand- additionally activated only from time to time re-
by operation maintaining at the same time a quires that a corresponding power reserve must
sufficient cooling capacity for hydraulic oil cool- be allowed for.
ing.
This applies also to work carried out at greater
Low losses when the safety relief valves re- altitudes and in extremely high ambient air tem-
spond to overpressure conditions. peratures.
Low losses in part-load operation for work re- Such jobs require an adaptation of the engine
quiring precision control. power to prevent the engine from being over-
Minimal losses of energy when the superstruc- loaded.
ture swing movement is initiated.
The above-mentioned disadvantages can be
As low as possible consumption of fuel and avoided when the machine is equipped with a
reduced emissions of noise and pollutants. control system that works under all possible op-
erating conditions in such a way that the power of
the diesel engine available at any moment is
sensed and measured.
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TECHNICAL HANDBOOK
Simplified control loop in an electronic power-limiting control system
Fig. 1
1 Diesel engine A Actual speed

2 Main hydraulic pump B Nominal speed
3 Swing pump C Control current
4 Servo pump
5 Swing motor
6 Proportional valve
7 Servo-pressure limiting valve
8 Microcontroller
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TECHNICAL HANDBOOK
Control loop
This is where the power-limiting function sets in. On reaching a preset value of speed loss (see
chapter "Types of engines"), the main hydraulic
The speed of a diesel engine is reduced imme- pumps (2) are tilted back electronically by means
diately when the engine is loaded. In extreme of proportional valve (6) until the pump reaches a
cases, this condition may even lead to the engine stable point of operation.
being throttled down to n = 0 and stalling.
This point is defined by an equilibrium between
A power-limiting controller makes use of this ef- the power supplied by the engine and the power
fect for the indirect measurement of engine pow- consumed by the hydraulic system.
er.
The main reference variable of the electronic
Because of the high precision requirements, the power-limiting control PCS III is the speed of the
speed of the drive engine is determined electron- diesel engine.
ically by sensing the teeth of the gearing of the
starter motor in the flywheel housing.
The actual speed measured (A) is compared by a

micro-controller (8, Fig. 1) to the pre-determined
nominal speed (B) of the engine.
Example of motor measurements

Engine Net flywheel Fuel system Controller Max. coolant
CUMMINS power HP regulation temperature
(kW) P-Grad (C)
Controlled
rpm
6 BTA 165 (123) / Bosch A/RSV 8% 100

2200
1 kW = 1.341 HP
The power set out in the table are continuous net

effective output in acc. with SAEJ1995/ISO 3046 /
1 IFN blocked.
Reference:
These special appliance data for the motor-measurement you can find in chapter 2 of the
technical handbook, the service-data-sheets.
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TECHNICAL HANDBOOK
Output diagram of one working pump with spring governor

131 HP / 98 kW at X3 = 5 bars 2200 rpm
Fig. 2
Example:
Mode L=LIFT E=ECO H=HEAVY
Ql/min 136 151 167
PX3 (bar) 26,5 17,0 11,0
rpm 1800 2000 2200
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Nominal speed determination
As an excavator must be able to work in different The output of both main pumps is reduced by an
engine speed ranges, the power-limiting control amount equivalent to the power consumed by the
must permit stable working also under such op- swing pump.
erating conditions.
An installed Swing-MODE (active after engine
The controller must be informed about each start-up) reduces the power consumption of the
change of the nominal speed value. swing pump for normal operations - small tilt
angles up to 90 - and boom lifting is given
This is achieved by hydraulic pressure switches priority.
with contacts in the servo circuit opening at > 3,5
bars (S10.1 DLS / S10.2 DSF). After deactivation of the Swing-MODE, the swing
circuit can make use of maximum power.
In the travelling mode, S10.2 opens (with mobile
excavators and some excavators) and sets the Within its control range, the power-limiting control-
pump to maximum tilt (100% with one pump). ler keeps the sum of all consumers at a value
equal to 100% of the net drive power installed.
When a switch opens, the nominal speed cal-
culated by the PCS on-board computer based on Within the control range, any change of the pres-
the preset high idle speed is being frozen as the sure level in a pump causes the control pressure
reference speed. If the engine is now loaded (X3, Fig. 2) to be changed too by the variation of
further with the speed dropping briefly below the diesel engine speed, with the delivery rate of
nominal rpm, proportional valve (Y10) sets the the two main pumps being changed accordingly.
two output regulators by means of control pres-
sure (X3) to a lower regulating threshold (Fig. 2).
Pressure fluctuations are compensated by the in-

ternal spring-type governors in the pump.
If needed, the preset output of the main pumps is

reduced from the swing output. Increasing, the
swing output reduces the diesel engine r.p.m.
Governer starts to reduce the preset output of the
main pumps by increasing their control-pressure
(X3).
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TECHNICAL HANDBOOK
Fig. 3
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PCS functional diagram

Legend of PCS components (Fig. 3).
A10 On-Board Computer (ODC)
A10X4 Diagnosis socket for hand-held tester EDS
A100 Control Panel
B10.1 Inductive speed pickup (engine)
B13.1 Coolant temperature sensor

R10.2
M10 Engine speed actuator

Y1.4 Shut-off solenoid Engine-STOP
R10 Engine speed potentiometer
R14 Hydraulic oil temperature sensor
S10.1 Servo-pressure switch

(DSL)
S10.2 Travelling pressure switch (mobile excavators only)

(DSF)
Y10 Proportional valve (output control of main pumps)
M Servo-pressure measuring port (45+1 bar)
X3 Measuring port - control pressure from proportional valve
1 Servo valve - stick and swinging
2 Servo valve - boom and bucket
3 Servo valve - travelling right track
4 Servo valve - travelling left track
5 Servo valve - travelling (mobile excavators only)
6 Shuttle valve logic
7 Diesel engine
8 Main pump P1
9 Main pump P2
10 Swing pump P3
11 Swing motor
12 Servo pump
13 Pressure relief from servo circuit
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TECHNICAL HANDBOOK
Fig. 4
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Description of PCS
The main components of the PCS are the Control The Power-MODE can be used to adapt machine
Panel (A100, Fig. 4) and the On-Board Computer performance to the job on hand for 6 different
(A10). kinds of applications. (engine speed and pump
output are here in a fixed relationship).
Both electronic modules are interconnected by
means of a CAN data bus system (Control Area HEAVY 100% - Maximum machine perfor-
Network) permitting the mutual exchange of in- mance
formations. The On-Board Computer receives
real-time data such as diesel engine rpm, sensor ECO 90% - Normal jobs with opti-
data and switching status data and controls the mized engine / pump set-
proportional valve ensuring the output regulation ting
of the hydraulic system.
LIFT 65% - Handling and lifting of
At the same time, the computer assumes the task heavy loads
of monitoring the engine and hydraulic system
temperatures and of permanently checking the Power boost 65% - Lifting of heavy loads with
sensors for broken cables and short-circuits increased pressure
(ODC: ON-BOARD DIAGNOSTIC SYSTEM).
Hammer max. 100% - power transfer up to
An integrated non-volatile data memory block (Option) 100% with one pump
stores all essential data in the event of malfunc-
The electrical engine speed adjusting system
tions and facilitates subsequent troubleshooting.
(R10/M10) permits superposing a freely chosen
A specially designed hand-held tester (EDS) can speed independent of the MODE selected.
be used to read out system parameters and, if To reduce noise and and exhaust emissions, the
necessary, to perform system programming oper- PCS has a low-level and a high-level speed re-
ations via a seriell (CAN-Bus) interface (A10X4). duction function.
The Control Panel (A100) assumes application- Low-level reduction: 30 - 100 RPM less, in load-
related tasks such as: free phases (always active).
display functions High-level reduction: Low idling 850 - 900 RPM if

the work is interrupted for
monitoring functions in the conventional elec- more than 10 seconds (can
trical system be activated/deactivated
with the Auto-Idle switch).
controlling of operator functions
All switching conditions essential for the overall

functioning and data are transmitted over the
CAN bus to the On-Board Computer and vice
versa.
PCS switching conditions:
Engine speed
Warm-up
Auto-Idle
Power Boost
Swing-MODE
Swing brake
Power-MODE
Hydraulic hammer (optional)
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TECHNICAL HANDBOOK
Sequence of operations
Engine warm-up Power Boost

- PCS is configured for warm-up Activated when:
- Control Panel reads the option during the - the PCS has been configured for "Power
starting phase Boost"
- PCS recognizes warm-up phase < 40C - the excavator is working in ECO or HEAVY
mode
- PCS sends information to Control Panel
- the pushbutton in the control lever has been
- PCS sets engine and pumps to LIFT mode depressed
- Control Panel displays warm-up - the Power Boost time has not yet elapsed
- Control Panel displays ECO
Response:
POWER mode HEAVY - the Control Panel sends information to PCS
- Operator selects the HEAVY mode - the Control Panel and PCS set outputs for
- Control Panel sends information to PCS "Power Boost" operation
- PCS sets pump and engine to the HEAVY - the PCS presets maximum machine power
mode output (HEAVY mode)
- PICKUP sends speed information to PCS - the machine works with increased pressure.
- Load information to PCS from S10.1 and/or
S10.2
- PCS determines nominal rpm
- PCS starts load regulation by means of Y10
- ODC monitors the temperatures
- PCS detects no-load condition
- PCS sets engine to low-level reduction
- PCS sets engine to idling after 10 seconds
(default setting)
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TECHNICAL HANDBOOK
ODC - On-Board Diagnostic Computer

The temperature control integrated in the ODC
The On-Board Computer ensures permanent lowers the pump output via the control flow from
monitoring of the coolant temperature and the the proportional valve to reduce strain on the
hydraulic oil temperature by means of sensors machine.
(B10.1 and R14, Fig. 4).
Condition: temperature too high
The ODC signals a fault when the pre-established
program limit values are exceeded (Fig. 5) and Engine temperature
stores the event in a special failure memory. stepless lowering down to minimum output
The temperature measurements may be dis- Hydraulic oil temperature

played, during operation, by using the EDS-Test- switching over into the LIFT mode
er (Fig. 5). Also the temperature limits are shown
As a system protection measure, the ODC addi-
by the EDS display.
tionally monitors the control loop for broken cable
and short-circuits (proportional valve / hydraulic
oil sensor / coolant sensor)
Condition: cable broken / short-circuit
Proportional valve
Power limiting is not fuctional.
Both pumps can no longer be adjusted via X3.
In extreme cases, the diesel engine is over-
loaded when power is demanded.
Hydraulic oil sensor

In the LIFT mode, the pump output is reduced
Coolant sensor
Fig. 5 In the LIFT mode, the pump output is reduced
The operator is informed of the fault by a special Both conditions are sensed after a response time
screen of the Control Panel display (see table of 3 - 5 seconds by the ODC, automatically
ERROR-CODE). stored and displayed by an ERROR CODE ap-
pearing on the display screen.
Exception: Warm-up
Hydraulic oil sensor and coolant sensor
In this case, the response time after engine
start is 5 minutes, the sensors not being able
to distinguish between "Cable broken: yes / no"
because of the high resistance of the sensors
when the machine is cold.
Fig. 6
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TECHNICAL HANDBOOK
PCS Troubleshooting 2801314
Fig. 7
12 2 801 730.00 us
TECHNICAL HANDBOOK
The layout plan (Fig. 1) shows the location of all Locating and rectifying faults
PCS-related components of the machine.
In order to be able to rectify faults systematically,
Control Panel it is necessary to study first the location and the
Central electrical system arrangement of components and assemblies (Fig.
1) to gain an overview of the complete PCS
On-Board Computer system.
Actuators Then, track down the lines and connectors with
the help of the circuit diagram in the machine
Sensors
documentation and check the power supply and
Switches the sensor signals.
A good ground connection is always of prime
Connectors importance as, for instance, the grounding termi-
nal in the central electrical system (Fig. 3).
Measuring points
Further instructions in the event of malfunc-
tions
Modifications reserved. If too high temperatures are detected it is neces-

Locations and components in some types sary to check the thermostats, fan blades and the
of machines may slightly deviate from combined radiator.
those shown in the layout plan (Fig. 1).
In the event of cable and/or connector prob-
The indications in the spare-parts docu- lems the continuity of the line (broken cable)
mentation of the machine are binding. must be checked and the leakage resistance
For abbreviations please refer to "PCS measured with a multimeter.
functional diagram".
Temperature probes must have an ohmic resis-
tance of more than 20 ohms and less than 8
kiloohms when measured with a multimeter.
The proportional valve has an ohmic resistance

of less than 30 ohms and more than 15 ohms.
The pressure-operated switches DSL (S10.1)

and DSF (S10.2) always work as break contact
elements. That means, open contacts announces
travel or/and load.
The pickup signal must be greater than 3 volts

when the engine is running and have a frequency
of between 100 - 5000 Hz.
If the cause of intermittent failures (re-

duced machine performance) cannot be
clearly defined, always check the digital
rpm indication on the Control Panel dis-
play first.
With the engine in no-load condition, the
speed should not vary by more than 20 -
30 rpm.
2 801 730.00 us 13
TECHNICAL HANDBOOK
Ensuring proper test conditions for the Checking the mode of operation and the spe-
machine cial functions
For proper troubleshooting with the EDS diagnos- Mode of operation

tic tester, the excavator must be brought to a
Setting the POWER switch to HEAVY / ECO and
defined state suitable for testing.
LIFT results in a change of the current values
The diesel engine must be started and the speed and HEAVY / ECO or LIFT will be displayed in
potentiometer be adjusted to the full-throttle posi- the pressure switch line. The display additionally
tion. The excavator must be allowed to run in this indicates DSL for working functions and DSF for
position for at least five minutes . The reason is travelling functions (mobile excavators only).
the time required for warming up of the tempera- The current values indicated are changed only
ture probes. Only after the WARM-up the EDS after DSL and/or DSF has / have opened.
diagnostic tester and the ERROR CODE display
Special functions
will then indicate possible faults.
When the lifting power boost function is active,
Checking the power-limiting control
the current corresponds to the LIFT current value.
Start by setting the power selector to HEAVY and The hammer function has a separately adjustable
then move the Stick cylinder against block. Re- DSH current value. Pressure switches DSS and
peat this check several times. DSH are displayed.
The EDS now permits reading out of the current The current values indicated are changed only
(in troubleshooting menu F1/F2). In balanced- after DSL and/or DSF has / have opened.
state condition, the current should rise between
With the speed reduction function activated, the
50 mA and 100 mA. In machines with pressure
current goes up to 800 mA (stand-by operation)
cut-off, this check must be carried out when the
after the preset reduction delay.
boom is being lifted.
Checking the temperature control
Engine and hydraulic system temperatures can

be checked with the help of the troubleshooting
menu (F1/F3). To see the tendency of tempera-
ture variations, move the stick cylinder once
again against block (in HEAVY mode). Both tem-
peratures must rise steadily in this case and not
exceed the limit values.
14 2 801 730.00 us
TECHNICAL HANDBOOK
On-Board Computer (A10)
Fig. 1
Connector A10X1 (Fig. 1):

AMP Junior Timer 25 poles
The contacts of female connector A10X1 are numbered in numerical order from 1 thru 25 following the
arrow.
2 801 730.00 us 15
TECHNICAL HANDBOOK
Control Panel (A100)
Fig. 2
Connector (Fig. 2)
A100X1 AMP MAT-N LOK 15 poles
A100X2 SUB-D 25 poles
A100X3 SUB-D 25 poles
16 2 801 730.00 us
TECHNICAL HANDBOOK
Central electrical system

Connector X100 - X109 (Fig. 3)
Fig. 3
AMP MAT-N LOK 15 poles (Fig. 4)
Fig. 4
2 801 730.00 us 17
TECHNICAL HANDBOOK
Magnetic PICKUP (B10.1)
Fig. 5
Cable (Fig. 5)
86 - to central electrical system X101.1 and to on-board computer A10X1.24
170 - to grounding terminal of central electrical system
Technica data
Thread 3/4 - 16
Spacing:
Screw PICKUP down onto flywheel and then
back by half turn. The PICKUP is secured firmly
in place by means of the hex nut.
18 2 801 730.00 us
TECHNICAL HANDBOOK
Diesel speed actuator (M10)
Fig. 6
Connector M10 (Fig. 6):

ITT Cannon 5 poles
Cable
56 - to central electrical system X100.7 to panel X3.16
2 801 730.00 us 19
TECHNICAL HANDBOOK
Checking / adjusting the high IDLE speed

The PCS has fixed rpm ranges for each machine Nominal speed: Too low
type (Fig. 7).
If the HEAVY nominal rpm is, for instance, too
MODE: H = E - L low and if it cant be increased further by lowering
An incorrectly set HEAVY rpm value may lead to the HEAVY current (Fig. 7), the adjusting lever of
a wrong power setting. the injection pump (Fig. 9) contacts the limit stop
screw (1).
In this case, it might be necessary to re-adjust

the limit stop screw (1) and to set the nominal
speed as described with the EDSIII to the speci-
fied value.
Fig. 7
Nominal speed: Too high
Start the engine and set the potentiometer to

maximum rpm in the HEAVY power mode.
Read the nominal speed in EDS menu F2/1 Fig. 9

(Fig. 7).
- If the nominal speed is too high, increase the
HEAVY current in programming menu P3/1
(Fig. 8) in steps of 2- 5 mA and read the
nominal speed in menu F2/1 after depressing
ESC (Fig. 8).
If necessary, repeat this step several times
until the nominal speed corresponds to the
stored value (Fig. 8).
Fig. 8
20 2 801 730.00 us
TECHNICAL HANDBOOK
Engine STOP solenoid (Y1.4)

The shut-off lever of the engines injection pump If the shut-off lever is not in the specified START
(Fig. 10) is pulled with a STOP solenoid during position after engine START, there is no sufficient
activation of the electrical system into starting fuel supply.
position and held there with a low hold current.
When the voltage drops (ignition OFF), the fuel
supply is interrupted by resetting the shut-off le-
ver (Fig. 10) and the engine stopped.
Fig. 10
2 801 730.00 us 21
TECHNICAL HANDBOOK
Speed poteniometer (R10)

Cummins engine without Centry-Sys-
tem
Fig. 11
Cable (Fig. 11)

105 - to on-board computer A10X1.6
142 - to grounding terminal of central electrical
system
Checking
The electrical resistance between PIN 1 and

PIN 2 is:
at lefthand limit stop 0 ohms
at righthand limit stop 250 ohms
22 2 801 730.00 us
TECHNICAL HANDBOOK
Connector (C5/C6) Centry

Cummins engine with Centry system
Fig. 12
Cable (Fig. 12)

330 Engine connector (C6) PIN B to central electrical system X100A1 and to potentiometer board A68
PIN 3, from PIN 4 to potentiometer XR10 PIN 1.
331 Engine connector (C6) PIN E to central electrical system X100A2 and to potentiometer board A68
PIN 5, from PIN 6 to potentiometer XR10 PIN 2.
332 Engine connector (C6) PIN D to central electrical system X100A3 and to potentiometer XR10
PIN 3.
2 801 730.00 us 23
TECHNICAL HANDBOOK
Pressure switch - servo pressure (S10.1)
Fig. 13
Cable (Fig. 13)

107 - to central electrical system X102.2 and to on-board computer A10X.13
Technical data
Thread: M 10 x 1 tapered
Break contact: opening pressure = 3.5 bars
2 tabs AMP 6,3 x 0,8 mm
24 2 801 730.00 us
TECHNICAL HANDBOOK
Pressure switch - travelling (S10.2)

(mobil excavators and some excavators only)
Fig. 14
Cable (Fig. 14)

98 - to central electrical system X102.1 and to on-board computer A10X.14
Technical data
Thread: M 10 x 1 tapered
Break contact: opening pressure = 3.5 bars
2 tabs AMP 6,3 x 0,8 mm
Remark:
In some excavator a second pressure switch
(S10.2) sets the travelling pump to maximum
power X3 = 5 bars (one pump: 100%). Together
with S10.1, S10.2 has the higher priority.
2 801 730.00 us 25
TECHNICAL HANDBOOK
Proportional valve (Y10)
Fig. 15
(Fig. 15)
1 valve logic
2 proportional valve cartridge
3 mechanical adjusting spindle (emergency pressure setting)
4 pressure-limiting valve - servo pressure
5 pressure accumulator - servo pressure
M measuring port - servo pressure (45+1 bars)
Technical data
Coil resistance 17 - 20 ohms
Working range 180 mA - 800 mA (5 bars - 40+2 bars)
26 2 801 730.00 us
TECHNICAL HANDBOOK
Valve connector (Y10)
Fig. 16
The valve connector of Y10 is marked by numeral "1".

The double-core rubber cable terminates in the central electrical system.
Cable (Fig. 16)

GND to grounding terminal of central electrical system
2 801 730.00 us 27
TECHNICAL HANDBOOK
Proportional valve characteristic
Fig. 17
Control pressure as a function of input current (Fig. 17)
28 2 801 730.00 us
TECHNICAL HANDBOOK
Measuring port (X3) at main pumps
Fig. 18
Port (X3, Fig. 18)) serves to measure the control

pressure from the proportional valve output.
Depending on the preselcted power mode and

the operating mode, the pressure values range
from 5 bars - 40+2 bars (180 mA - 800 mA).
Individual machine types have fixed con-

trol pressure values (cf. the Service Data
belonging to the respective machine).
2 801 730.00 us 29
TECHNICAL HANDBOOK
Coolant temperature sensor B13.1 / R10.2
Fig. 19
Cable (Fig. 19)

Technical data
Thread M 14 x 1.5
Tightening torque 20 Nm
Operating temperature range - 30C to + 150C
Transducer: NTC resistor
30 2 801 730.00 us
TECHNICAL HANDBOOK
Coolant temperature sensor (B13.1) (R10.2)
Fig. 20
Cable (Fig. 20)

Technical data
Thread M 14 x 1.5
Tightening torque 20 Nm
Operating temperature range - 30C to + 150C
Transducer: NTC resistor
2 801 730.00 us 31
TECHNICAL HANDBOOK
Fault signalling in the ODC (ON-BOARD DIAGNOSTIC SYSTEM) 2801315
Fault code - Table
The ODC constantly monitors all essential ma- Example:

chine functions for faults in the system. Engine coolant temperature too high.
Code indication displayed: ERROR 1000
When a fault is detected, the indication ERROR Since this is a severe fault, a buzzer in the
appears on the control panel display and a fault control panel sounds additionally and the red
code indication alternates with the operating warning lamp signals: coolant temperature too
hours indicated high.
(z.B. 2345 WORKING HOUR
02 ERROR The following fault codes can be displayed:
2345 WORKING HOUR
100 ERROR 02 8000
2345 WORKING HOUR ....).
04 200 10000
08 400
10 800 40000
1000 80000
2000 05
09
Fig. 1
32 2 801 730.00 us
TECHNICAL HANDBOOK
To evaluate the reported faults and to analyze Most of the faults listed in the table are stored by
the amount of damage (spare-parts requirements the ODC automatically after occurrence of the
/ scope of repair work), the table below (FAULT event in a non-volatile memory in the form of text
CODE) sets out the individual codes and the building blocks (see "Fault storage").
effect on the machine for servicing purposes.
FAULT CODE table

Code Trouble Fault Effect
02 engine temperature sensor cable broken power loss
04 engine temperature sensor short-circuit power loss
05 Centry error Centry
08 proportional valve 1, PLC short-circuit engine power reduction
09 engine error engine
10 proportional valve 1, PLC cable broken engine power reduction
200 hydr. temperature sensor cable broken power loss
400 hydr. temperature sensor short circuit power loss
800 hydraulik temperature too high power loss
1000 engine temperature too high power loss
2000 speed 0 and DSl active power loss
8000 internal software error
10000 sensor E-speed cable broken
40000 communication error control panel engine power reduction
80000 pressure sensor SLI cable broken
PLC = Power-Limiting Control
2 801 730.00 us 33
TECHNICAL HANDBOOK
Emergency operation Emergency operation setting
To maintain the machine functions in the event of Proportional valve (1, Fig. 2):
electronic system failures, the proportional valve
Withdraw valve plug for emergency operation.
is equipped with a mechanical device permitting
to set a fixed control pressure (Fig. 2) for the Remove protective cap.
electronic PCS output regulator
Slacken lock-nut (2) by holding adjusting spin-
dle (3).
Screw adjusting spindle (3) into the valve by

four turns.
Start the diesel engine and allow to run at

maximum speed.
Fill the bucket and extend the working equip-

ment completely.
Lift the boom with maximum speed, swinging

the superstructure at the same time also at
maximum speed.
Fig. 2 Under these circumstances, the engine speed

must not drop below nominal rpm (set control
With this setting, it is possible to continue using panel to display the engine speed).
the machine at reduced speed without electronic
system. If necessary, screw adjusting spindle (3) further
down into the valve and tighten lock-nut (2)
2 Hex nut 13 mm width over flats (torque: 15 Nm).
3 Allen screw 4 mm width over flats
During emergency operation, the valve plug re-
mains disconnected from the valve.
After removal of the fault and before re-

connecting of the valve plug to restore the
purely electrical function, the adjusting
spindle (3) must be turned out of the valve
until the control presssure measured at
port (X3) of the main pumps is equal to 0
bar.
This procedure ensures that the spring
inside the valve no longer rests on the
solenoid armature.
If the adjusting spindle (3) is not turned
back far enough, the valve cannot reach
the low pressure setting of 5.0 bars (mobil
excavators).
34 2 801 730.00 us
TECHNICAL HANDBOOK
Failure memory
The ODC internally processes the occurrence of
failures together with the operating hours counter
in such a way that the time at beginning and the
end of the fault event is taken (hours/minutes)
and stored in a non-volatile CMOS-RAM.
The faults "speed = 0" and "low battery voltage"

are not stored since they occur at every start of
the system.
If the failure memory (S1, Fig. 4) is not reset and

if 40 faults have been reported (depending on
length of text), the faults are automatically over-
written and renumbered.
The failure memory can be displayed, printed and

stored by the EDS-diagnostic tester
2 801 730.00 us 35
TECHNICAL HANDBOOK
CENTRY system - fault messages and remedial actions 2801316
Push-button (44) can be used to read out in-

formation about the cause of the fault from the
CENTRY memory.
Use this function of push-button (44) only

in the presence of critical faults and if the
CUMMINS after-sales service requests the
machine user to provide information on
the fault cause.
Depressing push-button (44) cuts the elec-
trical connection between the operating
Fig. 3 panel and the engine.
The buzzer stops sounding and the "EN-
The yellow warning lamp in push-button (44, GINE ERROR" message on the display is
fig. 3) indicates that a fault has occurred in the extinguished.
CENTRY system (part of the engine control unit). Buzzer and display are re-activated only
after the key-switch of the electrical sys-
Two indicating modes are provided: tem has been set first to position "0" and
then back to position "I".
- Yellow warning lamp permanently lit:
CENTRY reports a non-critical fault. Contact
the CUMMINS after-sales service soon and Recalling information on the cause of faults from
have the fault rectified. memory:
- Yellow warning lamp flashing: - Shut off the engine
ERROR 09 appears on display (5, Fig. 4).
- Pull push-button lock backwards (arrow, Fig. 3)
CENTRY reports a critical fault! and depress the button ca. 2 seconds.
Shut off the engine immediately, contact the
The yellow warning lamp now emits a flash
CUMMINS after-sales service and have the
code. If several faults are stored in memory,
fault rectified.
they are displayed one by one with the help of
Together with the flashing warning lamp, the
different flash codes. The code sequences are
buzzer sounds and the system displays "EN-
separated by a short pause.
GINE ERROR".
- Note the flash codes and transmit them to the
CUMMINS after-sales service where the codes
will be analyzed and the corresponding fault
causes determined.
Fig. 4
36 2 801 730.00 us
TECHNICAL HANDBOOK
EDS special functions 2801317
Deleting the NV RAM

In some special cases, the NV RAM of the con- After depressing "1" (Fig. 4), the "Reset operating
trol panel must be deleted with the EDS: hours" request appears on the screen (Fig. 3).
after installing a new panel,
when a number > 15 appears on entering the

code (starting trouble),
to reset the operating-hours counter.
Depressing F3 in the main menu for the program-

ming mode and the F6 for the control parameters
and then the PgDn key displays the "NV RAM
erase" menu" (Fig. 1).
Fig. 3
If needed, the operating hours counter can now

also be reset by depressing "1" (Fig. 4).
Fig. 1
Depressing F1 displays the request to confirm

deleting of the NV RAM (Fig. 2).
Fig. 4
Fig. 2
2 801 730.00 us 37
TECHNICAL HANDBOOK
Resetting the servicing interval

Up to 1500 OH, after 50 OH and then at 500,
1000 and 1500 OH, the control panel automati-
cally displays the message "Next Service" (see
operating instructions).
Up to 1500 OH, the servicing interval display

must be acknowledged with the EDS.
Beyond this value, the option can be omitted in
the PCS configuration menu.
Depressing F6 in the "Main Menu" displays the

"Special Functions" menu and F6 again the "Con-
trol Panel" (Fig. 5).
Fig. 7
Fig. 5
After depressing F1 (Fig. 6) the request "Reset

servicing interval" appears (Fig. 7).
Fig. 6
The command is executed by depressing "1".

After switching the ignition first off and then on
again, the control panel displays the next servic-
ing interval (see operating instructions).
38 2 801 730.00 us
TECHNICAL HANDBOOK
Changing the machine start disabling code

In the "Control Panel" menu (Fig. 5), key F2 Entering the new number with the ENTER key
(Fig. 6) can be used to select the code enabling and confirming the selection with "1" programs
the start function of the machine from any num- the new code into the system (Fig. 9).
ber between 0 and 15 (Fig. 8).
Fig. 8 Fig. 9
2 801 730.00 us 39
TECHNICAL HANDBOOK
Example: Hammer current adjustment with the EDS-diagnostic tester 2801318
The machine must be factory-equipped with origi-

nal hammer hydraulics. Programming: DSH current
The hammer function will then appear in cofigura- Depressing first key F3 in the "Main Menu" and
tion menu P4/2/2 (Fig. 10). then F3 again displays the "Programming Mode
Menu" (Fig. 11).
Fig. 10
For optimal hammer operation, the hydraulic-ham- Fig. 11

mer manufacturer must have information about
the volume flow and the working pressure. The cursor is in line DSF. The arrow key moves
If these data are known, the hammer mode DSH the cursor down to line DSH.
current value can be determined as follows. The current must be entered with the numerical
Example: keyboard and programmed by depressing EN-
A maximum flow rate of 100 l/min and an operat- TER.
ing pressure of 150 bars are assumed.
Functional sequence of hammer operation:
These values are then applied to the pump out- - The PCS ist configured for the hammer option.
put diagram of the machine (see service data)
and the spring-type regulator characteristic shifted - The operator depresses the hammer key on
onto this point (Fig. 12). The control pressure the control panel.
(X3) is then the value at the lower intersection of - The control panel transmits the corresponding
the curve (31 bars). information to the PCS.
The proportional valve characteristic (Fig. 13) - The operator depresses the button in the con-
shows a current value of 625 mA. This value is trol lever.
now programmed with the EDS tester in the load-
- The PCS switches to the HEAVY mode and
limit regulator menu in line DSH (Fig. 11).
presets the programmed DSH current.
- The ODC monitors the temperature of the en-
gine and the hydraulic system.
40 2 801 730.00 us
TECHNICAL HANDBOOK
Fig. 12
Fig. 13
2 801 730.00 us 41
TECHNICAL HANDBOOK
Switching the hydraulic hammer on

2486244
Switching the hydraulic hammer off

Read and observe the section "Working Release key (82) or pedal (60).
with hydraulic hammers - Safety instruc-
Depress key (19). The LED above the key
tions".
goes out.
Fig. 1
Preselect the "Hydraulic hammer" function by

depressing key (19, Fig. 1). The LED above
the key lights up.
The PMS switches into the HEAVY mode (see:
"Programming the hammer current").
Fig. 2
Hammer operation with fixed impact sequence:

- Place chisel on the material and start hammer
with key (82, Fig. 2).
Hammer operation with variable impact sequence:

- Place chisel on the material and depress pedal
(60). Depressing the pedal increases the ham-
mering frequence proportionately.
(The adjusting cylinder is deactivated in this
case).
42 2 801 730.00 us
TECHNICAL HANDBOOK
2 801 730.00 us 43
L
C Locating and rectifying faults .............................. 13
Central electrical system .................................... 17

M
CENTRY system - fault messages and reme-
dial actions.......................................................... 36 Magnetic PICKUP (B10.1) .................................. 18
Changing the machine start disabling code ........ 39 Measuring port (X3) at main pumps .................. 29
Checking / adjusting the high IDLE speed .......... 20
Checking the mode of operation and the spe- N

cial functions ...................................................... 14 Nominal speed determination .............................. 5
Checking the power-limiting control .................... 14
Checking the temperature control ...................... 14 O

Connector (C5/C6) Centry .................................. 23 ODC - On-Board Diagnostic Computer .............. 11
Control loop .......................................................... 3 On-Board Computer (A10) ................................ 15
Control Panel (A100) .......................................... 16

P
Coolant temperature sensor (B13.1) (R10.2) .... 31
PCS functional description .................................. 1
Coolant temperature sensor B13.1 / R10.2 ........ 30
PCS functional diagram ........................................ 7
D PCS Troubleshooting ........................................ 12
Deleting the NV RAM ........................................ 37 Power-limiting control .......................................... 1
Description of PCS .............................................. 9 Pressure switch - servo pressure (S10.1) .......... 24
Diesel speed actuator (M10) .............................. 19 Pressure switch - travelling (S10.2) .................... 25
Programming: DSH current ................................ 40

E Proportional valve (Y10) .................................... 26
EDS special functions ........................................ 37 Proportional valve characteristic ........................ 28
Emergency operation ........................................ 34
Emergency operation setting .............................. 34 R

Engine STOP solenoid (Y1.4) ............................ 21 Resetting the servicing interval .......................... 38
Ensuring proper test conditions for the ma-

chine .................................................................. 14 S
Example of motor measurements ........................ 3 Sequence of operations...................................... 10
Example: Hammer current adjustment with the Simplified control loop in an electronic power-
EDS-diagnostic tester ........................................ 40 limiting control system .......................................... 2
Speed poteniometer (R10) ................................ 22

F Switching the hydraulic hammer off .................... 42
Failure memory .................................................. 35
Switching the hydraulic hammer on .................... 42
Fault code - Table .............................................. 32
FAULT CODE table ............................................ 33 V

Fault signalling in the ODC (ON-BOARD DI- Valve connector (Y10) ........................................ 27
AGNOSTIC SYSTEM) ........................................ 32
31.050 -
Electrical components in circuit diagram
Circuit diagram No. 1287787 T 73180453 - 00
B 1287787 - 100
Part Quantity Description and function Curr. Path Location Part no.
A10 1,000 LOAD LIMIT GOVERNOR 3 - 0/61 CONTROL PANEL

A10X4 1,000 DIAGNOSTIC UNIT CONNECTOR 5 - 1/18 CONTROL PANEL 73172588
A10X4 1,000 FLANGE 5 - 1/18 CONTROL PANEL 73172589
A100 1,000 CENTRAL ELECTRONIC UNIT 3 - 1/16 CAB 72183317
B10 1,000 PRESSURE SENSOR - TRAVEL 9 - 2/89 SUPERSTRUCTURE
B10 1,000 HOUSING 9 - 2/89 SUPERSTRUCTURE 73179304
B10 3,000 BUSHING CONTACT 9 - 2/89 SUPERSTRUCTURE 73179303
B10 3,000 GASKET 9 - 2/89 SUPERSTRUCTURE 73179306
B10 1,000 CAP 9 - 2/89 SUPERSTRUCTURE 73179305
B10.1 1,000 SPEED SENSOR 3 - 9/92 ENGINE
B13.1 1,000 COOLING-WATER TEMPERATURE 3 - 1/94 ENGINE
SENSOR
B13.1 1,000 HOUSING 3 - 1/94 ENGINE 73179346
B13.1 1,000 CONTACT 3 - 1/94 ENGINE 73179347
B13.1 1,000 GASKET 3 - 1/94 ENGINE 73179348
B13.1 1,000 CAP 3 - 1/94 ENGINE 73179349
B2 1,000 TANK SENSOR 6 - 8/84 FUEL TANK
B2 4,000 BUSHING CONTACT 6 - 8/84 FUEL TANK 73179303
B2 1,000 HOUSING 6 - 8/84 FUEL TANK 73179304
B2 1,000 CAP 6 - 8/84 FUEL TANK 73179305
B2 4,000 GASKET 6 - 8/84 FUEL TANK 73179306
E1 1,000 LH HEADLIGHT 7 - 4/87 SUPERSTRUCTURE 73172595
E1 1,000 BULB 7 - 4/87 SUPERSTRUCTURE 73172596
E1 1,000 HOUSING 7 - 4/87 SUPERSTRUCTURE 73172597
E1 1,000 PLUG 7 - 4/87 SUPERSTRUCTURE 73172598
E1 1,000 CONTER-SUNK SCREW 7 - 4/87 SUPERSTRUCTURE 73177378
E2 1,000 RH HEADLIGHT 7 - 4/87 SUPERSTRUCTURE 73172595
E2 1,000 BULB 7 - 4/87 SUPERSTRUCTURE 73172596
E2 1,000 HOUSING 7 - 4/87 SUPERSTRUCTURE 73172597
E2 1,000 PLUG 7 - 4/87 SUPERSTRUCTURE 73172598
E2 1,000 CONTER-SUNK SCREW 7 - 4/87 SUPERSTRUCTURE 73177378
E3 1,000 WORKING LIGHT, BOOM LEFT 7 - 5/87 BOOM 73172602
E3 1,000 BULB 7 - 5/87 BOOM 73172510
E3.4 1,000 WORKING LIGHT CAB L.H.(UP-AND DOWN) 7 - 6/87 CAB ROOF 73172509
31.050 -
B 1287787 - 100
E3.4 1,000 BULB 7 - 6/87 CAB ROOF 73172510

E3.6 1,000 HEADLAMP DRIVER S CAB,REAR LEFT 7 - 1/87 CAB ROOF 73172509
E3.6 1,000 BULB 7 - 1/87 CAB ROOF 73172510
E36 1,000 ROTARY BEACON 7 - 0/87 CAB ROOF
E36.1 1,000 ROTARY BEACON 7 - 1/87 CAB ROOF
E4 1,000 WORKING LIGHT, BOOM RIGHT 7 - 5/87 BOOM 73172602
E4 1,000 BULB 7 - 5/87 BOOM 73172510
E4.4 1,000 WORKING LIGHT CAB R.H.(UP-AND-DOWN) 7 - 6/87 CAB ROOF 73172509
E4.4 1,000 BULB 7 - 6/87 CAB ROOF 73172510
E4.6 1,000 HEADLIGHT DRIVER CABREAR LEFT 7 - 2/87 CAB ROOF 73172509
E4.6 1,000 BULB 7 - 2/87 CAB ROOF 73172510
E9 1,000 INTERIOR LIGHT 7 - 9/83 CAB
E9 2,000 BULB 7 - 9/83 CAB 73172605
F1 1,000 FUSE 7 - 9/16 CONTROL PANEL 73172607
F15 1,000 7 - 1/16 CONTROL PANEL 73172607
F20 1,000 FUSE: COLD STARTING SYSTEM 2 - 4/16 CONTROL PANEL 73177291
F33 1,000 6 - 0/54 CAB 73177535
FM2 1,000 6 - 4/67 CONTROL PANEL 73172607
FM2 1,000 FUSE HOLDER 6 - 4/67 CONTROL PANEL 73175261
FM2 2,000 CONTACT 6 - 4/67 CONTROL PANEL 73176480
G1 1,000 ALTERNATOR 2 - 1/80 ENGINE
G1.1 1,000 BATTERY 2 - 0/61 BATTERY BOX
G1.1 1,000 CAP 2 - 0/61 BATTERY BOX 73172610
31.050 -
B 1287787 - 100
G1.2 1,000 BATTERY 2 - 0/73 BATTERY BOX

G1.2 1,000 CAP 2 - 0/73 BATTERY BOX 73172610
H7 1,000 HORN 6 - 6/81 PLATFORM PLATE 73172611
H7.1 1,000 HORN 9 - 8/89 COUNTERWEIGHT 73175766
K1.5 1,000 POWER RELAY 2 - 3/80 ENGINE 72183320
K1.8 1,000 RELAY HUBMAGNET MOTORSTOP 2 - 4/84 ENGINE 72183320
K10.2 1,000 9 - 5/37 SEAT CONSOLE,LH 72183321
K10.2 1,000 PLUG BASE 9 - 5/37 SEAT CONSOLE,LH 73179345
K10.4 1,000 9 - 4/37 SEAT CONSOLE,LH 72183321
K10.4 1,000 PLUG BASE 9 - 4/37 SEAT CONSOLE,LH 73179345
K39 1,000 12 - 2/88 SEAT CONSOLE,RH 72183321
K39 1,000 PLUG BASE 12 - 2/88 SEAT CONSOLE,RH 73174165
K53 1,000 WORKING LIGHT RELAY 7 - 2/46 SEAT CONSOLE,RH 72183321
K53 1,000 PLUG BASE 7 - 2/46 SEAT CONSOLE,RH 73174165
K7 1,000 RELAY HORN 9 - 7/37 SEAT CONSOLE,LH 73174128
K7 1,000 PLUG BASE 9 - 7/37 SEAT CONSOLE,LH 73179345
M1 1,000 STARTER 2 - 2/80 ENGINE
M10 1,000 SPEED ADJUSTING ACTUATOR 5 - 4/18 ENGINE
M10 1,000 SOCKET 5 - 4/18 ENGINE 73173022
M10 1,000 PIN 5 - 4/18 ENGINE 73172626
M10 3,000 BUSHING 5 - 4/18 ENGINE 73172627
M10 1,000 CLAMP 5 - 4/18 ENGINE 73173023
M10 1,000 HOUSING 5 - 4/18 ENGINE 73175397
M2 1,000 FAN 6 - 4/80 CAB
M3 1,000 WINDSCREEN WIPER MOTOR 7 - 7/85 CAB
M4 1,000 W/S WASHER PUMP 6 - 3/80 CAB
M52 1,000 LUBE PUMP MOTOR 8 - 7/88
R10 1,000 SPEED CONTROL 3 - 2/92 SEAT CONSOLE,RH
R14 1,000 TEMPERATURE PROBE - HYDRAULIC OIL 3 - 7/94 SUPERSTRUCTURE REAR
R14 1,000 HOUSING 3 - 7/94 SUPERSTRUCTURE REAR
73179346
R14 1,000 CONTACT 3 - 7/94 SUPERSTRUCTURE REAR
73179347
R14 1,000 GASKET 3 - 7/94 SUPERSTRUCTURE REAR
73179348
R14 1,000 CAP 3 - 7/94 SUPERSTRUCTURE REAR
73179349
31.050 -
B 1287787 - 100
S1 1,000 START BUTTON 2 - 2/18 SEAT CONSOLE,RH

S1.1 1,000 BATTERY ISOLATOR 2 - 0/86 SUPERSTRUCTURE 73175263
S1.7 1,000 PUSHBUTTON COLD STARTING 2 - 4/47 SEAT CONSOLE,RH 73175267
S1.7 1,000 SNAP-ON PANEL 2 - 4/47 SEAT CONSOLE,RH 73172516
S10.1 1,000 PRESSURE SWITCH - SERVO 3 - 3/94 PLATFORM PLATE
S113 1,000 LIMIT SWITCH PILOT PRESSURE CUT-OFF 2 - 7/47 SEAT CONSOLE,LH 73171211
S12 1,000 OIL PRESSURE SWITCH 4 - 0/86 ENGINE
S13.2 1,000 LEVEL SWITCH - WATER MIN 4 - 8/84 ENGINE COMPART.
S13.2 1,000 RIGHT ANGLE PLUG 4 - 8/84 ENGINE COMPART. 73172620
S15 1,000 FILTER SWITCH 4 - 3/86 HYD.OIL TANK
S15 1,000 FLAT-PIN PLUG 4 - 3/86 HYD.OIL TANK 73176494
S15 1,000 SLEEVE 4 - 3/86 HYD.OIL TANK 73172512
S15.1 1,000 SWITCH - AIR FILTER CONTAMINATED 4 - 2/86 ENGINE AIR FILTER
S35.1 1,000 PUSHBUTTON SWITCH - SLEWING-GEAR 4 - 6/86 PLATFORM PLATE
BRAKE
S35.2 1,000 SPEED SENSOR - SLEWING-GEAR BRAKE 4 - 7/84 SUPERSTRUCTURE
S35.2 1,000 SOCKET 4 - 7/84 SUPERSTRUCTURE 73172624
S35.2 1,000 HOUSING 4 - 7/84 SUPERSTRUCTURE 73172625
S35.2 1,000 PIN 4 - 7/84 SUPERSTRUCTURE 73172626
S35.2 2,000 BUSHING 4 - 7/84 SUPERSTRUCTURE 73172627
S35.2 1,000 CLAMP 4 - 7/84 SUPERSTRUCTURE 73172628
S36 1,000 SWITCH - GIRATORY BEACON 7 - 0/35 SEAT CONSOLE,RH 73176304
S36 1,000 SNAP-ON PANEL 7 - 0/35 SEAT CONSOLE,RH 73179350
S37.1 1,000 BUTTON - ROTATE GRAB LEFT 10 - 7/39 JOYSTICK,TOP RH
S37.2 1,000 BUTTON - ROTATE GRAB RIGHT 10 - 8/39 JOYSTICK,TOP RH
S39.1 1,000 BUTTON HAMMER 10 - 1/43 JOYSTICK,TOP LH
S39.3 1,000 12 - 8/38 SEAT CONSOLE,RH 73176304
S39.5 1,000 12 - 4/38 SEAT CONSOLE,RH 73176304
S46.2 1,000 PRESSURE SWITCH - HYDRAULICS 11 - 3/85 SUPERSTRUCTURE FRONT
S46.3 1,000 PRESSURE SWITCH - HYDRAULICS 11 - 4/85 SUPERSTRUCTURE FRONT
S53.2 1,000 SWITCH - WORKING LIGHT, REAR 7 - 2/35 SEAT CONSOLE,RH 73176304
S53.2 1,000 7 - 2/35 SEAT CONSOLE,RH 73179351
31.050 -
B 1287787 - 100
S66 1,000 PRESSURE SWITCH - BOOM 8 - 5/89 VALVE BLOCK

S66 2,000 FLAT-PIN PLUG 8 - 5/89 VALVE BLOCK 73176494
S66 2,000 SLEEVE 8 - 5/89 VALVE BLOCK 73172512
S7 1,000 HORN BUTTON 10 - 5/50 JOYSTICK,TOP RH
S7.1 1,000 TRAVEL ALARM 9 - 5/78 PLATFORM PLATE
S7.1 2,000 FLAT-PIN PLUG 9 - 5/78 PLATFORM PLATE 73176494
S7.1 2,000 SLEEVE 9 - 5/78 PLATFORM PLATE 73172512
S72 1,000 ROCKER SWITCH AIR CONDITION 13 - 2/50 SEAT CONSOLE,RH 73177969
S72 1,000 SNAP-ON PANEL 13 - 2/50 SEAT CONSOLE,RH 73177970
S72 1,000 HOUSING 13 - 2/50 SEAT CONSOLE,RH 73176310
S72 6,000 CONTACT 13 - 2/50 SEAT CONSOLE,RH 73177971
S72.1 1,000 PRESSUR. SWITCH AIR CONDITION 13 - 2/75 SUPERSTRUCTURE
S72.2 1,000 TEMPERATUR SELECT. AIR CONDITION 13 - 3/75 PLATFORM/CAB
S72.2 1,000 HOUSING 13 - 3/75 PLATFORM/CAB 73176065
S72.2 2,000 FLAT-PIN PLUG 13 - 3/75 PLATFORM/CAB 73176494
S8.3 1,000 BUTTON BOOSTER 10 - 6/43 JOYSTICK,TOP RH
S9 1,000 SWITCH - INTERIOR LIGHT 7 - 8/87 CAB
T33 1,000 VOLTAGE CONVERTER 24V/12V 6 - 0/63 CAB
V39 1,000 12 - 1/51 SEAT CONSOLE,RH 73175270
V39 0,200 PLUG-IN CONNECTOR 12 - 1/51 SEAT CONSOLE,RH 73174171
V39 2,000 FLAT-PIN PLUG 12 - 1/51 SEAT CONSOLE,RH 73176494
V67.1 1,000 RELEASING DIODE 2 - 8/31 CONTROL PANEL 73175270
V67.1 0,200 PLUG-IN CONNECTOR 2 - 8/31 CONTROL PANEL 73174171
V67.1 2,000 FLAT-PIN PLUG 2 - 8/31 CONTROL PANEL 73176494
31.050 -
B 1287787 - 100
V67.2 1,000 RELEASING DIODE 2 - 6/31 CONTROL PANEL 73175270

V67.2 0,200 PLUG-IN CONNECTOR 2 - 6/31 CONTROL PANEL 73174171
V67.2 2,000 FLAT-PIN PLUG 2 - 6/31 CONTROL PANEL 73176494
W01 1,000 CABLE HARNESS, CONTROL PANEL 26 - 1/15 CONTROL PANEL 72183323
W03 1,000 CABLE HARNESS, ENGINE 26 - 1/23 SUPERSTRUCTURE 73180456
W04 1,000 CABLE HARNESS, VALVES 26 - 1/31 SUPERSTRUCTURE 73173025
W05 1,000 MAIN CABLE SET 26 - 1/39 SUPERSTRUCTURE 73180457
W06 1,000 CABLE HARNESS, PLATFORM 26 - 1/47 PLATFORM PLATE 72183327
W08 1,000 CABLE BATTERY PLUS 26 - 1/55 SUPERSTRUCTURE 73173028
W15 1,000 CABLE FOR JOYSTICK 26 - 1/63 JOYSTICK 73172634
W16 1,000 CABLE BATTERY 26 - 4/14 BATTERY BOX 73175147
W17 1,000 PLATFORM EARTH CABLE 26 - 4/23 PLATFORM 73172000
W18 1,000 HEADLIGHT EARTH CABLE 26 - 4/31 BOOM 73172508
W22 1,000 BATTERY EARTH 26 - 4/39 BATTERY BOX 73173030
W23 1,000 ENGINE EARTH 26 - 4/47 ENGINE COMPART. 73173031
W25 1,000 POWER CABLE, WORKING LIGHT 26 - 4/55 BOOM 73175150
W81 1,000 CABLE - BATTERY MAIN SWITCH/EARTH 26 - 7/15 SUPERSTRUCTURE 73175264
W82 1,000 CABLE - BATTERY MINUS/BATTERIY MAIN 26 - 7/23 SUPERSTRUCTURE 73177355
SWITCH
W90 1,000 CABLE SET FUSE COLD STARTING 26 - 7/31 CONTROL PANEL 73177291
W96 1,000 26 - 7/39 SEAT CONSOLE,LH 72183329
X10 2,000 B+ DISTRIBUTOR - 0/ 0 73170164
X10 1,000 CLIP - 0/ 0 73172640
X100 1,000 26 - 1/92 CONTROL PANEL 73177972
X100 15,000 MALE CONNECTOR 26 - 1/92 CONTROL PANEL 73176308
X100 1,000 HOUSING 26 - 1/92 CONTROL PANEL 72182587
X100 15,000 BUSHING 26 - 1/92 CONTROL PANEL 73176493
X101 1,000 26 - 1/96 CONTROL PANEL 73177972
X102 1,000 26 - 1/10 CONTROL PANEL 73177972
31.050 -
B 1287787 - 100

X104 1,000 26 - 1/10 CONTROL PANEL 73177972
X106 1,000 26 - 1/10 CONTROL PANEL 73177972
X107 1,000 26 - 1/11 CONTROL PANEL 73177972
X108 1,000 PLUG/SOCKET 26 - 1/11 CONTROL PANEL 73177972
X110 1,000 6 - 2/77 CAB 73176064
X110 2,000 PLUG-IN SLEEVE 6 - 2/77 CAB 73176063
X110 1,000 HOUSING 6 - 2/77 CAB 73176065
X110 2,000 FLAT-PIN PLUG 6 - 2/77 CAB 73176061
X111 2,000 - 0/ 0 73176061
X111 2,000 PLUG-IN SLEEVE - 0/ 0 73176063
X111 1,000 RECEPTACLE HOUSING - 0/ 0 73176064
X111 1,000 HOUSING - 0/ 0 73176065
X115 1,000 PLUG/SOCKET RESERVE 26 - 5/88 SEAT CONSOLE,RH 73177972
X115 15,000 MALE CONNECTOR 26 - 5/88 SEAT CONSOLE,RH 73176308
X115 1,000 HOUSING 26 - 5/88 SEAT CONSOLE,RH 72182587
X115 15,000 BUSHING 26 - 5/88 SEAT CONSOLE,RH 73176493
31.050 -
B 1287787 - 100

X118 1,000 26 - 5/10 SEAT CONSOLE,LH 72183043
X118 6,000 MALE CONNECTOR 26 - 5/10 SEAT CONSOLE,LH 73176308
X118 1,000 HOUSING 26 - 5/10 SEAT CONSOLE,LH 72183330
X118 6,000 BUSHING 26 - 5/10 SEAT CONSOLE,LH 73176493
X119 1,000 26 - 5/10 SEAT CONSOLE,LH 73177972
X119 1,000 HOUSING 26 - 5/10 SEAT CONSOLE,LH 72182587
X12 1,000 PLUG/SOCKET - CAB 7 - 0/72 CAB 72182588
X12 10,000 BUSHING 7 - 0/72 CAB 73176493
X12 2,000 BUSHING 7 - 0/72 CAB 73175274
X12 1,000 RECEPTACLE HOUSING 7 - 0/72 CAB 73172635
X12 12,000 MALE CONNECTOR 7 - 0/72 CAB 73176308
X17 1,000 PLUG/SOCKET - LH JOYSTICK 10 - 0/58 SEAT CONSOLE,LH 72182588
X17 1,000 RECEPTACLE HOUSING 10 - 0/58 SEAT CONSOLE,LH 73172635
X18 1,000 PLUG/SOCKET - RH JOYSTICK 10 - 5/58 SEAT CONSOLE,RH 72182588
X18 1,000 RECEPTACLE HOUSING 10 - 5/58 SEAT CONSOLE,RH 73172635
X19 1,000 PLUG/SOCKET - BLOWER - 0/ 0 73176061
X19 1,000 PLUG-IN SLEEVE - 0/ 0 73176063
X19 1,000 HOUSING - 0/ 0 73176065
31.050 -
B 1287787 - 100
X20 1,000 CONNECTOR SCREEN WIPER MOTOR - 0/ 0

X32.1 1,000 PLUG CONNECTION INSTRUMENT 26 - 5/10 SEAT CONSOLE,RH 73175271
BOARD-MACHINEMARKING NO 3
X32.1 3,000 PLUG-IN SLEEVE 26 - 5/10 SEAT CONSOLE,RH 73172511
X32.1 3,000 SLEEVE 26 - 5/10 SEAT CONSOLE,RH 73172512
X33 1,000 PLUG/SOCKET 6 - 0/48 CAB 73176064
X33 2,000 PLUG-IN SLEEVE 6 - 0/48 CAB 73176063
X33 1,000 HOUSING 6 - 0/48 CAB 73176065
X33 2,000 FLAT-PIN PLUG 6 - 0/48 CAB 73176061
X33.6 1,000 SOCKET 12V 6 - 0/86 CAB 73177315
X67.1 1,000 PLUG / SOCKET FILLING PUMP 2 - 6/24 73176481
X67.1 3,000 PLUG-IN SLEEVE 2 - 6/24 73176063
X72 2,000 - 0/ 0 73176063
X72.1 2,000 - 0/ 0 73176063
X72.1 1,000 RECEPTACLE HOUSING - 0/ 0 73176064
X72.1 1,000 HOUSING - 0/ 0 73176065
X72.1 2,000 FLAT-PIN PLUG - 0/ 0 73176494
X99 1,000 26 - 1/88 CONTROL PANEL 72182547
XF13 1,000 CONNECTOR ADDITIONAL FUSE 2 - 5/24 CONTROL PANEL 73177822
XF13 2,000 BUSHING 2 - 5/24 CONTROL PANEL 73175274
XF20 1,000 PLUG/SOCKET COLD START 2 - 4/24 CONTROL PANEL 73175273
XF20 2,000 BUSHING 2 - 4/24 CONTROL PANEL 73175274
Y1.3 1,000 SOLENOID VALVE COLD START 2 - 4/84 ENGINE COMPART.
Y1.4 1,000 LIFTING MAGNET MOTOR STOP 5 - 3/86 ENGINE
Y10 1,000 PROPOTIONAL VALVE 3 - 0/94 VALVE BLOCK
Y113 1,000 SOLENOID FOR PILOT CONTROL 2 - 6/84 PLATFORM PLATE
PRESSURE
Y21.3 1,000 SOLENOID VALVE - 2ND GEAR 9 - 1/91 VALVE BLOCK
Y35 1,000 SOLENOID - SLEWING-GEAR BRAKE 4 - 5/86 VALVE BLOCK
Y35.1 1,000 SOLENOID VALVE - SLEWING 8 - 4/90 SUPERSTRUCTURE
Y37.1 1,000 SOLENOID VALVE - GRAB ROTATOR 10 - 7/87 SUPERSTRUCTURE
Y39 1,000 SOLENOID VALVE - SWITCHINGONE TASK 12 - 0/88 SUPERSTRUCTURE
CYLINDER / HAMMER
31.050 -
B 1287787 - 100
Y39.1 1,000 SOLENOID VALVE - HAMMER 10 - 1/87 VALVE BLOCK

Y39.3 1,000 12 - 8/88 VALVE BLOCK
Y39.5 1,000 12 - 4/88 VALVE BLOCK
Y63 1,000 POWER BOOSTER 8 - 3/90 VALVE BLOCK
Y72 1,000 ELECTR. MAGNETCLUTCH AIR CONDITION 13 - 1/90 ENGINE
Y72 1,000 HOUSING 13 - 1/90 ENGINE 73177973
Y72 1,000 PLUG-IN SLEEVE 13 - 1/90 ENGINE 73176063
Y72 1,000 FLAT-PIN PLUG 13 - 1/90 ENGINE 73177974
Y72 1,000 FLAT-PIN PLUG 13 - 1/90 ENGINE 73176494
WORKING EQUIPMENT ............................................................................................................................ 1
Foreword.................................................................................................................................................... 1
Safety Instructions
Assembling working equipment - safety instructions .......................................................................... 2
Securing the machine .............................................................................................................................. 3
Corrosion protection for pins and bearings (bushings and hubs)

Part nos. for Voler A.C............................................................................................................................. 4
Application of Voler A.C. ........................................................................................................................ 4
Detaching / attaching the backhoe bucket ............................................................................................ 5
Attaching and detaching the grab equipment

Attaching and detaching the grab equipment - Safety instructions.......................................................... 6
Attaching the grab .................................................................................................................................. 6
Detaching the grab .................................................................................................................................. 7
WORKING EQUIPMENT 2800137


tact with it
spare parts.
73179380 10 1
Assembling working equipment - safety instructions 2732243
Personnel Tools and auxiliaries

Assembly work may be carried out only Tools, hoists, slings, chocks and other
by operating or maintenance personnel devices must be in a reliable, safe state.
who have the necessary know-how at Metal spinters may cause injury when ac-
their disposal. cessory bolts are being driven in or out. A
If such know-how is lacking, meticulous brass or copper mandrel should therefore
instruction must be given by experienced be used for this purpose, and goggles
personnel, e.g. from the manufacturer. must be worn.
The operating manual, and in particular Use steps and handrails when climbing
the section headed "Fundamental Safety onto or off the machine.
Instructions", must have been read and Always keep steps and platforms in a
understood. non-slip state. Remove any oil, grease,
earth, clay, snow, ice and other foreign
Only such persons may start up the ma- matter immediately.
chine during assembly work in order to
adjust the attachments.
Incorrect operation of the machine or the
attachments may give rise to life-threaten-
ing situations. Securing working equipment
Stand working equipment on the ground
in such a way that no movements can be
made if mechanical or hydraulic connec-
Personal protective gear and tions become detached.
working clothing When working in jointed areas, block off
the joints. Remove the blocks on finishing
Wear closely fitting working clothing
work.
when working on the machine. Loose,
wide garments may catch on machine Secure any equipment or component
parts and result in injury. which is to be mounted or dismantled, or
whose position is to be changed, with
Wear a safety helmet, safety footwear,
hoists or appropriate slinging/supporting
devices to prevent them from moving,
slipping or falling inadvertently.
Securing the machine

Carry out work on the attachment only if
the machine is secured as decribed in the
section "Securing the Machine".
2 10 73179380
Securing the machine 2472317
Selecting the attachments Risk of injury!
The machine can be equipped with var- The machine must not be started by un-
ious attachments. The components of the authorized persons.
attachments are assembled with hydraulic Therefore, the machine must be secured.
cylinders and connectors. Components
can be combined in various ways for opti-
mum adaptation of the attachments to the The machine must be secured as described
specific application. below:
Operate the machine only with the equip- - before fitting or changing the working equip-
ment and component combinations ex- ment, and
pressly approved by the manufacturer.
- before carrying out any servicing or repair work
on the machine.
Park machine on level and firm ground.
Stand working equipment on the ground.
Shut off engine.
Turn key switch to position I (ignition ON).
Depressurize the hydraulic system.
Switch off pilot control.
Withdraw key from key switch of the electrical

system.
Before carrying out work on the electrical sys-

tem or welding work on the machine, the bat-
teries must be disconnected.
Insulate connecting clamps.
73179380 10 3
Corrosion protection for pins and bearings (bushings and hubs) 2732241
Application of Voler A.C.
Clean off grease, oil, dirt and corrosion protec-

Use Voler A.C. anti-corrosive agent only. tion agents from pins and bearings using white
Other agents are not approved by the spirit or diesel fuel.
manufacturer. Rust patches must be thoroughly removed, if
any.
All pins and bearings (bushings and hubs) of the All parts must present a dry, bright metal sur-
working equipment or in equipment components face.
must be treated with Voler A.C. anti-corrosive Apply a thin layer of Voler A.C. on pins and all
agent before fitting. bearings using a brush or a spray can. Pin
shafts and bearings must be completely co-
Voler A.C.:
vered by the protective layer.
permits easy fitting and dismantling If the protective layer of a pin already treated
protects against rust, oxidation and similar wear with Voler A.C. is damaged, these areas must
be touched up before fitting the part.
prevents seizing and fretting corrosion in non-
moving parts of bearings. Fitting and securing of pins
If the pin is too heavy to be fitted manually,
This is achieved by aluminium and copper par- apply Voler A.C. at first only on abt. a quarter
ticles forming a protective layer on the metal. This of the pins length
layer removes surface irregularities and does not
sweat, seize or harden. Then position pin by means of a lifting gear
ready for fitting.
Part nos. for Voler A.C. Apply Voler A.C. on the remaining length of pin
shaft, fit pin and secure.
P/N 73171461 - 0,5 l spray can (CFC-free)
P/N 73171462 - 0,5 kg tin
P/N 73171463 - 4,5 kg bucket
Available from the Spare-Parts Service
4 10 73179380
Detaching / attaching the backhoe bucket 2411343
Stand working equipment on the ground.
Place safety wedges under the backhoe bucket

Danger of injury. (arrow, Fig. 1).
The bucket may otherwise overturn as soon as
Risk of crushing when working equipment
the linkage pins have been driven out.
or backhoe is moved.
Therfore, do not attempt to alter the posi- Turn out screws (2 and 4).
tion of the backhoe manually.
Drive out pins (1 and 3).
Stand back from the backhoe when the
working equipment is moved.
Read and observe:
"Fitting of working equipment - Safety
instructions".
Fig. 2
Raise working equipment cautiously (Fig. 1).

The bucket stands now freely on the ground.
Clean linkage pins and bearing bushes before

refitting and protect them against corrosion as
Fig. 1 described in the section "Corrosion protection
for pins and bearings (bushings and hubs)".
Attach another backhoe bucket by proceeding

in reverse order.
73179380 10 5
Attaching and detaching the grab equipment 2486242
(special equipment)
Attaching and detaching the grab Attaching the grab

equipment - Safety instructions
Movements of working or grab equipment Read and observe: "Attaching and detach-
involve a risk of injury. ing the grab equipment, safety instruc-
So never attempt to change position of tions".
grab or grab suspension by hand.
Keep away from grab when working Detach backhoe bucket as described in section
equipment is being moved. "Detaching and attaching the backhoe bucket".
This description applies to machines with Retract backhoe cylinder until safety device for
cabinet terminal block control according toggle link and lever (1, Fig. 1) can be moun-
to SAE (see section "Control elements"). ted.
If the machine is equipped with a different
control, activities "Depressurize hydraulic Shut off engine.
lines to grab" must be adapted to the Turn key switch to position I.
control.
Read and observe: Depressurize hydraulic lines to grab:
"Fitting of working equipment, safety - push control lever (70, Fig. 2) to left and hold
instructions". in place,
- depress "Rotate grab" rocker button (69) to
the right and to the left,
- push control lever to right,
- release rocker button and control lever.
Before fitting, check that grab and ma- Turn key switch to position 0.
chine are filled with identical or mixable
hydraulic oil. Shut off pilot control with lever (77).
If this is not the case, drain oil out of
hydraulic system of grab.
Conventional hydraulic oil and biodeg-
radable hydraulic fluid should not be
mixed, as this affects biodegradability.
Fig. 1
6 10 73179380
Fig. 2 Fig. 4
The marker grooves on the valves squares Grease all nipples on grab and gearing of grab
(arrow, Fig. 3) must be in vertical position. rotating mechanism.
Start up engine and lift grab clear of ground.
Bleed grab hydraulic system by opening and

closing grab repeatedly and turning clockwise
and counter-clockwise.
Detaching the grab

Open grab shells completely and set grab
down on level surface.
Shut off engine.
Turn key switch to position I.

Fig. 3
Depressurize hydraulic lines to grab:
Clean and grease bearing pins and bushings. - push control lever (70, Fig. 2) to left and hold
in place,
Drive machine towards grab.
- depress "Rotate grab" rocker button (69) to
Insert stick into grab bearing, push bearing pin the right and to the left,
home and secure (2, Fig. 1).
- push control lever to right,
Shut off engine and depressurize hydraulic - release rocker button and control lever.
lines to grab as described.
Turn key switch to position 0.
Clean express couplings on grab and stick.
Shut off pilot control with lever (77).
Connect hydraulic hoses to grab cylinder
(1, Fig. 4) and grab rotation motor (2). Disconnect hydraulic hoses (1 and 2, Fig. 4)
from express couplings.
Check that the express couplings are perfectly
engaged. Protect express couplings at grab and stick
from soiling by fitting dust caps.
Unscrew safety device of bearing pin (2, Fig. 1)

and withdraw pin.
Start up engine.
Lift working equipment carefully to release
grab.
73179380 10 7
Notes 2800145
8 10 73179380
A
Application of Voler A.C. ...................................... 4
Assembling working equipment - safety

instructions .......................................................... 2
Attaching and detaching the grab equipment ...... 6
Attaching and detaching the grab equipment -

Safety instructions ................................................ 6
Attaching the grab ................................................ 6
C
Corrosion protection for pins and bearings
(bushings and hubs) ............................................ 4
D
Detaching / attaching the backhoe bucket ............ 5
Detaching the grab .............................................. 7
F
Foreword .............................................................. 1
P
Part nos. for Voler A.C. ........................................ 4
S
Securing the machine .......................................... 3
W
WORKING EQUIPMENT...................................... 1
Fittings, pipes and hoses
2 796 712.00 us
INTRODUCTION ........................................................................................................................................ 1
FUNDAMENTAL SAFETY INSTRUCTIONS ............................................................................................ 2
Organizational measures ........................................................................................................................ 2
Selection and qualification of personnel - basic responsibilities ........................................................ 3
Safety instructions governing specific operational phases

Standard operation .................................................................................................................................. 3
Special work in conjunction with utilization of the machine - maintenance and repairs during operation -
disposal of parts and consumables ........................................................................................................ 4

Electric energy ........................................................................................................................................ 5
Gas, dust, steam and smoke .................................................................................................................. 5
Hydraulic and pneumatic equipment ...................................................................................................... 6
Noise ...................................................................................................................................................... 6
Oil, grease and other chemical substances ............................................................................................ 6
Transporting and towing - recommissioning ........................................................................................ 6
WORKING EQUIPMENT ............................................................................................................................ 7
Assembling working equipment - safety instructions .......................................................................... 7
Repair work - safety instructions ............................................................................................................ 8
LINES FOR VARIOUS MEDIA .................................................................................................................. 8
Materials for pipes and hoses.................................................................................................................. 9
Conditions and deviations in the line system ........................................................................................ 9
Steel pipes .............................................................................................................................................. 10
Hoses ...................................................................................................................................................... 12
Plastic pipes ............................................................................................................................................ 14
CONNECTIONS ...................................................................................................................................... 15
Pipe couplings
Sealing pipe couplings .......................................................................................................................... 19
Bulkhead couplings ................................................................................................................................ 20

Stud couplings and male nipples
Stircomatic seal rings ............................................................................................................................ 21
Swivel couplings
Swivel couplings .................................................................................................................................... 22
Swivel coupling with straight male thread acc. to DIN .......................................................................... 22
Swivel coupling with long male adaptor ................................................................................................ 22
Fixed angle couplings ............................................................................................................................ 23
Banjo couplings
Banjo coupling ...................................................................................................................................... 23
Banjo coupling with long male adaptor .................................................................................................. 24
FLANGE COUPLINGS WITH SAE BOLT PATTERN

Flanged pipe couplings - Flanit system (F-system) .............................................................................. 25
Flanged pipe couplings - Zako system (Z-system) ................................................................................ 25
Flanged hose couplings ........................................................................................................................ 26
Sealing and connecting components

Flanges.................................................................................................................................................. 27
Wedge rings .......................................................................................................................................... 27
Seal rings .............................................................................................................................................. 27
Double-hex bolts .................................................................................................................................. 28
Assembly aids for wedge rings

Pre-assembly device for F-rings ............................................................................................................ 29
Inserter for Z-rings ................................................................................................................................ 29
Inserting the Z-ring ................................................................................................................................ 30
Assembling flange couplings

Flange coupling - pipe / connection surface, F-system ........................................................................ 31
Zako-system .......................................................................................................................................... 32
Flange coupling hose / connection surface .......................................................................................... 34
Flange coupling - pipe / hose ................................................................................................................ 34
Flange coupling - hose / hose .............................................................................................................. 36
Flange coupling - pipe / pipe ................................................................................................................ 37
Appendix
Table 1: Seal rings for flange couplings ................................................................................................ 39
Table 2: Double - Hex. Bolts.................................................................................................................. 40
Accessories
Pre-assembly aids for pipe flange couplings ........................................................................................ 41
Flanges-90 .......................................................................................................................................... 42
Table 3: Parts Nos. for 90 flanges ...................................................................................................... 42
Gauge connections .............................................................................................................................. 43
Table 4: Parts Nos. for gauge connections and accessories ................................................................ 43
FITTINGS, PIPES AND HOSES
INTRODUCTION 2800470
The various units of a machine are intercon-

nected by pipe or hose lines so that the transfer
of consumables, energy and control commands
becomes possible. The hydraulic, brake and fuel
supply systems of a machine are just such units.
Numerous line and coupling systems are avail-

able, especially in the spheres of hydraulics and
pneumatics.
This handbook is intended to give an impression

of the pipe and hose lines, as well as their cou-
pling elements. Working directions are also in-
cluded for servicing procedures which involve the
re-routing or changing of such line and coupling
systems.
2 796 712.00 us 1
FUNDAMENTAL SAFETY INSTRUCTIONS
Warnings and symbols 2800455
The following signs are used in the manual to Check - at least from time to time - whether the
designate instructions of particular importance: personnel is carrying out the work in compliance
with the operating instructions and paying atten-
tion to risks and safety factors.
Precautionary rules and measures de- For reasons of security, long hair must be tied
signed to protect the machine operator back or otherwise secured, garments must be
and other persons from life-threatening close-fitting and no jewellery, such as rings, may
danger or injuries and to prevent exten- be worn. Injury may result from being caught up
sive damage. in the machinery or from rings catching on mov-
ing parts.
Use protective equipment wherever required by

the circumstances or by law.
Information and precautionary measures
designed to prevent damage to the ma- Observe all safety instructions and warnings at-
chine or other property. tached to the machine.
See to it that safety instructions and warnings

attached to the machine are always complete and
perfectly legible.
Organizational measures 2261965
In the event of safety-relevant modifications or
The operating instructions must always be at changes in the behaviour of the machine during
hand at the place of use of the machine, e.g. by operation, stop the machine immediately and re-
stowing them in the tool compartment or tool-box port the malfunction to the competent author-
provided for such purpose. ity/person.
In addition to the operating instructions, observe Never make any modifications, additions or con-
and instruct the user in all other generally ap- versions which might affect safety without the
plicable legal and other mandatory regulations suppliers approval. This also applies to the in-
relevant to accident prevention and environmental stallation and adjustment of safety devices and
protection. valves as well as to welding work on load-bearing
elements.
These compulsory regulations may also deal with
the handling of hazardous substances, issuing Spare parts must comply with the technical re-
and/or wearing of personal protective equipment quirements specified by the manufacturer. Spare
or traffic regulations. parts from original equipment manufacturers can
be relied to do so.
The operating instructions must be supplemented
by instructions covering the duties involved in Replace hydraulic hoses within stipulated and ap-
supervising and notifying special organizational propriate intervals, even if no safety-relevant de-
features, such as job organization, working se- fects have been detected.
quences or the personnel entrusted with the
work. Adhere to prescribed intervals or those specified
in the operating instructions for routine checks
Personnel entrusted with work on the machine and inspections.
must have read the operating instructions and in
particular the chapter on safety before beginning For the execution of maintenance work, tools and
work. Reading the instructions after work has be- workshop equipment adapted to the task on hand
gun is too late. This applies especially to persons are absolutely indispensable.
working only occasionally on the machine, e.g.
The personnel must be familiar with the location
during setting up or maintenance.
and operation of fire extinguishers.
Observe all fire-warning and fire-fighting proce-

dures.
2 2 796 712.00 us
Selection and qualification of per- Safety instructions governing
sonnel - basic responsibilities specific operational phases
Any work on and with the machine must be ex- Standard operation
ecuted by reliable personnel only. Statutory
minimum age limits must be observed. Avoid any operational mode that might be prejudi-
cial to safety.
Employ only trained or instructed staff and set out
clearly the individual responsibilities of the per- Before beginning work, familiarize yourself with
sonnel for operation, set-up, maintenance and re- the surroundings and circumstances of the site,
pair. such as obstacles in the working and travelling
area, the soil bearing capacity and any barriers
Make sure that only authorized personnel works separating the construction site from public roads.
on or with the machine.
Take the necessary precautions to ensure that
Define the machine operators responsibilities - the machine is used only when in a safe and
also with regard to observing traffic regulations - reliable state.
giving the operator the authority to refuse instruc-
tions by third parties that are contrary to safety. Operate the machine only if all protective and
safety-oriented devices, such as removable safety
Do not allow persons to be trained or instructed devices, emergency shut-off equipment, sound-
or persons taking part in a general training proofing elements and exhausters, are in place
course to work on or with the machine without and fully functional.
being permanently supervised by an experienced
person. Check the machine at least once per working
shift for obvious damage and defects. Report any
Work on the electrical system and equipment of changes (incl. changes in the machines working
the machine must be carried out only by a skilled behaviour) to the competent organization/person
electrician or by instructed persons under the su- immediately. If necessary, stop the machine im-
pervision and guidance of a skilled electrician and mediately and lock it.
in accordance with electrical engineering rules
and regulations. In the event of malfunctions, stop the machine
immediately and lock it. Have any defects recti-
Work on chassis, brake and steering systems fied immediately.
must be performed by skilled personnel only,
which has been specially trained for such work. Start the machine from the drivers seat only.
Work on the hydraulic system must be carried out During start-up and shut-down procedures always
only by personnel with special knowledge and watch the indicators in accordance with the op-
experience of hydraulic equipment. erating instructions.
Before setting the machine in motion, make sure

that nobody is at risk.
Before starting work or travelling with the ma-

chine, check that the braking, steering, signalling
and lighting systems are fully functional.
Before setting the machine in motion always

check that the accessories have been safely
stowed away.
When travelling on public roads, ways and places

always observe the valid traffic regulations and, if
necessary, make sure beforehand that the ma-
chine is in a condition compatible with these reg-
ulations.
In conditions of poor visibility and after dark al-

ways switch on the lighting system.
2 796 712.00 us 3
Persons accompanying the driver must be seated Special work in conjunction with utili-
on the passenger seats provided for this purpose. zation of the machine - maintenance
When crossing underpasses, bridges and tunnels and repairs during operation - disposal
or when passing under overhead lines always of parts and consumables
make sure that there is is sufficient clearance.
Observe the adjusting, maintenance and inspec-
Always keep at a distance from the edges of tion activities and intervals set out in the operat-
building pits and slopes. ing instructions, including information on the re-
placement of parts and equipment. These
Avoid any operation that might be a risk to ma- activities may be executed by skilled personnel
chine stability. only.
Never travel across slopes; always keep the Brief operating personnel before beginning spe-
working equipment and the load close to the cial operations and maintenance work, and ap-
ground, especially when travelling downhill. point a person to supervise the activities.
On sloping terrain always adapt your travelling In any work concerning the operation, conversion
speed to the prevailing ground conditions. Never or adjustment of the machine and its safety-ori-
change to a lower gear on a slope but always ented devices or any work related to mainten-
before reaching it. ance, inspection and repair, always observe the
start-up and shut-down procedures set out in the
Before leaving the drivers seat always secure the operating instructions and the information on
machine against inadvertent movement and un- maintenance work.
authorized use.
Ensure that the maintenance area is adequately
secured.
If the machine is completely shut down for main-

tenance and repair work, it must be secured
against inadvertent starting by:
- removing the ignition key and
- attaching a warning sign.
Carry out maintenance and repair work only if the

machine is positioned on stable and level ground
and has been secured against inadvertent move-
ment and buckling.
To avoid the risk of accidents, individual parts

and large assemblies being moved for replace-
ment purposes should be carefully attached to
lifting tackle and secured. Use only suitable and
technically perfect lifting gear and suspension
systems with adequate lifting capacity. Never
work or stand under suspended loads.
The fastening of loads and the instructing of

crane operators should be entrusted to exper-
ienced persons only. The marshaller giving the
instructions must be within sight or sound of the
operator.
For carrying out overhead assembly work always

use specially designed or otherwise safety-ori-
ented ladders and working platforms. Never use
machine parts as a climbing aid.
4 2 796 712.00 us
Wear a safety harness when carrying out main-

tenance work at greater heights.
Electric energy
Keep all handles, steps, handrails, platforms,
Use only original fuses with the specified current
landings and ladders free from dirt, snow and ice.
rating. Switch off the machine immediately if trou-
Clean the machine, especially connections and ble occurs in the electrical system.
threaded unions, of any traces of oil, fuel or
When working with the machine, maintain a safe
preservatives before carrying out mainten-
distance from overhead electric lines. If work is to
ance/repair. Never use aggressive detergents.
be carried out close to overhead lines, the work-
Use lint-free cleaning rags.
ing equipment must be kept well away from them.
Before cleaning the machine with water, steam jet Caution, danger! Check out the prescribed safety
(high-pressure cleaning) or detergents, cover or distances.
tape up all openings which - for safety and func-
If your machine comes into contact with a live
tional reasons - must be protected against water,
wire
steam or detergent penetration. Special care must
be taken with electric motors and switchgear - do not leave the machine
cabinets.
- drive the machine out of the hazard zone
Ensure during cleaning of the machine that the - warn others against approaching and touching
temperature sensors of the fire-warning and fire- the machine
fighting systems do not come into contact with
hot cleaning agents as this might activate the - have the live wire de-energized
fire-fighting system. - do not leave the machine until the damaged
line has been safely de-energized.
After cleaning, remove all covers and tapes ap-
plied for that purpose. The electrical equipment of machines is to be
inspected and checked at regular intervals. De-
After cleaning, examine all fuel, lubricant, and fects such as loose connections or scorched ca-
hydraulic fluid lines for leaks, loose connections, bles must be rectified immediately.
chafe marks and damage. Any defects found
must be rectified without delay.
Gas, dust, steam and smoke
Always tighten any screwed connections that
have been loosened during maintenance and re- Operate internal combustion engines and fuel-
pair. operated heating systems only on adequately
ventilated premises. Before starting the machine
Any safety devices removed for set-up, main- on enclosed premises, make sure that there is
tenance or repair purposes must be refitted and sufficient ventilation.
checked immediately upon completion of the
maintenance and repair work. Observe the regulations in force at the respective
site.
Ensure that all consumables and replaced parts
are disposed of safely and with minimum envi- Carry out welding, flame-cutting and grinding
ronmental impact. work on the machine only if this has been ex-
pressly authorized, as there may be a risk of
explosion and fire.
Before carrying out welding, flame-cutting and

grinding operations, clean the machine and its
surroundings from dust and other inflammable
substances and make sure that the premises are
adequately ventilated (risk of explosion).
2 796 712.00 us 5
Transporting and towing - recom-
Hydraulic and pneumatic equipment
missioning
Check all lines, hoses and screwed connections
regularly for leaks and obvious damage. Repair The machine must be towed, loaded and trans-
damage immediately. Splashed oil may cause in- ported only in accordance with the operating
jury and fire. instructions.
Depressurize all system sections and pressure For towing the machine observe the prescribed
pipes (hydraulic system, compressed-air system) transport position, admissible speed and itinerary.
to be removed in accordance with the specific
Use only appropriate means of transport and lift-
instructions for the unit concerned before carrying
ing gear of adequate capacity.
out any repair work.
The recommissioning procedure must be strictly
Hydraulic and compressed-air lines must be laid
in accordance with the operating instructions.
and fitted properly. Ensure that no connections
are interchanged. The fittings, lengths and quality
of the hoses must comply with the technical re-
quirements.
Noise
During operation, all sound baffles of the machine
must be closed.
Always wear the prescribed ear protectors.
Oil, grease and other chemical sub-

stances
When handling oil, grease and other chemical
substances, observe the product-related safety
regulations.
Be careful when handling hot consumables (risk

of burning or scalding).
6 2 796 712.00 us
WORKING EQUIPMENT 2732243
Assembling working equipment - safety instructions
Personnel Securing working equipment

Assembly work may be carried out only Stand working equipment on the ground
by operating or maintenance personnel in such a way that no movements can be
who have the necessary know-how at made if mechanical or hydraulic connec-
their disposal. tions become detached.
If such know-how is lacking, meticulous When working in jointed areas, block off
instruction must be given by experienced the joints. Remove the blocks on finishing
personnel. work.
The operating manual, and in particular Secure any equipment or component
the section headed "Fundamental Safety which is to be mounted or dismantled, or
Instructions", must have been read and whose position is to be changed, with
understood. hoists or appropriate slinging/supporting
Only such persons may start up the ma- devices to prevent them from moving,
chine during assembly work in order to slipping or falling inadvertently.
attachments may give rise to life-threaten- Securing the machine
ing situations. Carry out work on the attachment only if
the machine is secured as decribed in the
section "Securing the Machine".
Personal protective gear and work-
ing clothing
Wear closely fitting working clothing Selecting the attachments
when working on the machine. Loose, The machine can be equipped with var-
wide garments may catch on machine ious attachments. The components of the
parts and result in injury. attachments are assembled with hydraulic
Wear a safety helmet, safety footwear and cylinders and connectors. Components
gloves. can be combined in various ways for opti-
mum adaptation of the attachments to the
specific application.
Tools and auxiliaries Operate the machine only with the equip-
ment and component combinations ex-
Tools, hoists, slings, chocks and other
pressly approved.
devices must be in a reliable, safe state.
Metal spinters may cause injury when ac-
cessory bolts are being driven in or out. A Protective roof against falling
brass or copper mandrel should therefore
be used for this purpose, and goggles objects
must be worn. If the machine is used in areas where
Use steps and handrails when climbing there is a risk of heavy objects falling,
onto or off the machine. e.g. for
Always keep steps and platforms in a - work on earth or rock faces,
non-slip state. Remove any oil, grease,
- demolition or forestry work,
earth, clay, snow, ice and other foreign
matter immediately. it can be equipped with a protective roof
(FOPS) and with a front guard.
Consult your local dealer.
2 796 712.00 us 7
Repair work - safety instructions 2732233
Operating instructions Dismantling components

Never carry out repair work without hav- Never dismantle while the machine is at
ing read and understood the operating operating temperature.
instructions. Oils, greases, brake fluid or coolants may
Pay special attention to: have a high temperature and result in
burning or scalding.
"Fundamental Safety Instructions",
"Inspection and servicing - safety instruc- Leave time for the machine to cool down.
tions" and all warnings and safety instruc- Before starting work, depressurize piping
tions attached to the machine. and hoses, cylinders, radiator, hydraulic
The descriptions of job sequences pro- tank, air-brake reservoir and other sys-
vide only experienced personnel with the tems or units.
necessary instructions. Replace defective components in good
The operating manual must be kept with time to prevent major damage.
the machine at all times. Clean the defective component carefully
before dismantling it.
Mark the dismantled parts in the correct
Repair personnel sequence to facilitate assembly.
Repair personnel must have know-how When dismantling the component, close
and experience relevant to repairing this off exposed hose and piping connections,
or comparable machines. exposed drill holes and housing carefully
to prevent any dust from penetrating.
Working at greater heights

Always wear safety harnesses when work- Never remove lead seals
ing at greater heights. Never change rated pressure of pressure
Wear an approved safety harness; it must relief valves without the explicit authoriza-
be equipped with stabilizers and safety tion.
cables. Never remove lead seals from pressure
relief valves and accumulators.
Pressurized or spring loaded units

Never open defective pressurized or After the repair work
spring loaded units but replace them as To prevent corrosion, coat all bright metal
an entirety. machine parts with a grease film.
In exceptional cases, open only when the On completing the work, reassemble all
system and the operating sequence are protective devices, covers, and sound-
precisely known and any special tools re- and vibration-insulation material.
quired are available.
Never start up the driving motor while
The operating manual contains no infor- work is being done on the machine.
mation on this point.
Check the repaired components and all
machine functions with a trial run.
Never release the machine for recommis-
sioning until it is fully functioning.
LINES FOR VARIOUS MEDIA

Depending upon the purpose for which they are
intended, a distinction is made between lines for
8 2 796 712.00 us
Conditions and deviations in the
hydraulic oil line system
brake fluid
compressed air The efficiency of a hydraulic system and the an-
fuel ticipated permanent operating temperature of the
cooling water pressure fluid during continuous operation depend
combustion air upon the line dimensions, the way the line is
engine exhausts routed and the arrangement of bends and con-
lubricating oil nection points in the system.
grease
Any change of direction or cross section in a line
or hose alters the flow resistance, and can there-
Materials for pipes and hoses fore lead to eddy formation and pressure losses
in the system. Every effort is therefore made to
The material used (copper, steel or plastic pipe,
keep line and hose systems as simple and clearly
armoured rubber or plastic hoses) is chosen ac-
arranged as possible, with a minimum of coupl-
cording to the structural and operational condi-
ings.
tions intended, as well as with regard to easy
installation in order to keep assembly and servic- The line system is, moreover, arranged in such a
ing costs to a minimum. way that any components which require setting,
servicing or regular changing, e.g. valves, pres-
Pressure, return and intake lines in hydraulic sys-
sure gauges, breathers and filters, are easily ac-
tems are generally made up using seamless pre-
cessible.
cision steel pipe according to DIN 2391 (annealed
and scale-free).
Pressure hoses are generally made of oil-resis-

tant, synthetic rubber.
Some types of hose have a steel wire spiral

between the textile braiding in order to improve
strength and bending resistance.
They are also often used as intake hoses in

systems in which the pressure within the hose is
lower than atmospheric pressure.
Depending upon the pressure range to which

they are to be subjected, high-pressure hoses
have a number of tear-resistant textile braid in-
lays to absorb bursting, tensional and pressure
forces. Extra high-pressure hoses have, additional
steel wire inlays vulcanised into their covering
layers.
Practically all types of hose have an external
covering of oil-resistant, synthetic rubber which
makes them especially wear-resistant.
2 796 712.00 us 9
Steel pipes
Pressure, return and intake lines are practically
always made up of precision steel pipe according
to DIN 2391 - annealed and scale-free.
Cold bending:
When cold bending with mechanical bending ma-

chines, or when using spindles for manual bend-
ing, certain minimum dimensions are to be ob-
served. These minimum dimensions are given in
Table 1 and illustrated in Figs. 1 - 3.
All dimensions in mm.

The maximum permissible bending angle is 180 Fig. 2
Fig. 1 Fig. 3
Pipe Wall Bending radius r I min A min A1 min Minimum length e for
outside thickness couplings1)
s LL L S
10 1.5 30 70 130 135 25 32 35

12 2.0 37,5 70 145 135 26 32 36
14 2.0 45 70 160 135 -- -- 40
15 1.5 45 70 160 135 30 35 --
16 2.0 45 70 160 135 -- -- 42
18 1.5 50 70 170 135 32 36 --
20 2.0 60 75 195 135 -- -- 48
22 2.0 85 75 245 135 33 41 --
25 3.0 90 85 265 135 -- -- 53
30 3.5 100 95 295 135 -- -- 59
35 2.0 125 115 365 135 -- 48 --
38 4.0 120 115 355 135 -- -- 65
42 2.0 100 130 330 135 -- -- --
50 2.0 150 155 455 135 -- -- --
50 6.0 160 155 475 135 -- -- --
1)
Table 1: Minimum dimensions for pipe bends LL = extra light; L = light; S = heavy duty
10 2 796 712.00 us
Cutting pipes:
Pipes are always to be cut at right angles to their After cutting, deburr the pipe inside and out
longitudinal axes (Figs. 4 & 5). A pipe cutting (Figs. 6 and 7).
clamp, as shown in Fig. 3 (P/N 73171493) facili-
tates the cutting of pipes at right angles.
Pipe cutters are not to be used on account of the Any metal particles inside the pipe must
cold deformation of the pipe which occurs. be removed.
Fig. 4
Fig. 6
Fig. 5
Fig. 7
2 796 712.00 us 11
Hoses
Hoses must be carefully chosen for the applica-
tion to which they are to be put. Operating pres-
sure, pressure peaks, fluid temperature, hose
length, bend angles and radii must be taken into
consideration. The hoses must be resistant to
mineral oil, water and their emulsions, as well as
to gas and air bubbles. Only the manufacturer of
a machine is able to determine such demands
exactly, e.g. as are made upon EHP hoses in a
hydraulic system.
Hoses are delivered ready to be installed. They

may have screw couplings (Fig. 1)
Fig. 3
Hoses may alter their length slightly when sub-

jected to high pressure. Permissible tolerances
range from -4 % to +2 %, based on nominal
dimension.
Examples for fitting hoses
Hoses must be installed free of tension and

kinks. Damage can otherwise occur to the hose
itself and to its end couplings. What is more, the
restoring torque of a hose installed incorrectly can
lead to the coupling loosening and leaking.
Fig. 1 Hoses installed in a straight line with both coupl-
ings lying at the same level must be allowed to
or SAE flange fittings (Fig. 2) at each end,
"sag" slightly. Only then is it possible for
fluctuations in length - due to pressure and tem-
perature deviation - to be taken up by the hose
itself.
Fig. 4 shows examples of correct hose installa-

tion.
Fig. 2
or may have one screw coupling and one SAE

flange fitting (Fig. 3).
Fig. 4
12 2 796 712.00 us
Fig. 5 shows mistakes to be avoided. Fig. 6 shows examples of good installation of

hoses.
Hoses subjected to alternating bending stress
during operation must be installed in such a way
that high stressing does not occur on couplings
or to the hoses themselves. The following must
therefore be considered:
Fig. 6
Fig. 7 shows mistakes which must be avoided.
Fig. 5
the hose bend radius must be large enough
sufficient hose material must be available to

take up the motion
suitable couplings, e.g. angle couplings, must

be used when sharp bends are required in the
hose routing
Fig. 7
2 796 712.00 us 13
Plastic pipes Cutting and installing
Pipelines for compressed air, e.g. in brake sys-
When installing new pipes, make sure that the
tems, are often made up of plastic pipe sections.
cut edge is at right angles to the pipes longitudi-
Such plastic pipes can be used within the tem- nal axis. If a pipe cutter is not available, a sharp
perature range of -140F to +212F. knife can be used to cut the plastic pipes.
During repair work, make sure that the pipes are Make sure that cut ends are de-burred before
not exposed to excessive temperatures which installation.
might cause damage. When welding, the pipes
Installation
are to be covered over to protect them against
sparks, flames, welding spatter and welding slag. First push the union nut (1, Fig. 1) and then the
If extensive work is to be carried out, the plastic clamping ring (2) onto the pipe. The shallow taper
pipes should be removed beforehand. (3) of the clamping ring must be towards the end
of the pipe. Push insert sleeve (4) fully into the
pipe until edge (5) aligns with pipe end.
Damaged plastic pipes must be changed -

even if they have only been slightly pene-
trated by welding spatter.
Plastic pipes must not be installed near
exhaust pipes or other sources of heat.
Bending and straightening
During fitting, plastic pipes can be bent for in-

stallation at ambient temperatures of at least
+ 68F.
As plastic pipes are not permanently deformed

Fig. 1
during bending, and return to their original shape
when released, they must be clamped in the
required position.
Plastic pipes can be straightened again by being
immersed in hot water (at least 158F). They then Push end of pipe, with insert sleeve, fully
return automatically to their original, linear shape. into the coupling until it is up against end
stop (6).
Push clamping ring (2) into the coupling and tight-

en union nut (1) by hand. To avoid damaging the
pipe, never tighten the union nut too hard. 1.5 to
1.75 turns are sufficient to tighten up the nut.
After tightening, edge (7) of union nut must reach
approximately to the thread run-out (8) of the
coupling piece.
14 2 796 712.00 us
CONNECTIONS
Pipe and hose connections must meet the follow-
ing requirements:
They must be able to be disconnected and

reconnected numerous times.
They must not leak whatever the operating

conditions.
The through-flow cross sections must be as

near as possible to that of the respective pipe
or hose line.
The strength of the connection must, on ac-

count of possible pressure peaks and vibra- Fig. 2
tions, be at least as high as that of the pipe it
connects.
Connections on machines:
1. Pipe couplings
2. Bulkhead couplings
3. Stud couplings and male nipples
4. Swivel couplings
5. Flange connections
Fig. 3
Pipe couplings
The best-known of the detachable pipe couplings
are those which make use of cutting rings. These
are supplied as:
straight couplings (Fig. 1),
angle couplings (Fig. 2),
"T" couplings (Fig. 3) and
"X" or cross couplings (Fig. 4).
Fig. 4
DIN 2353 gives a summary of the shapes and

dimensions of such couplings.
Besides different shapes, the couplings are also
manufactured in three pressure categories, name-
ly:
Series LL = extra light duty

Series L = light duty
Series S = heavy duty
Fig. 1
2 796 712.00 us 15
The individual components of a cutting ring cou- The wedging of the cutting ring between pipe wall
pling (Figs. 1 - 7) are: and inner cone prevents the cutting ring from
being pushed too far into the pipe wall and
1 - Coupling body possibly breaking off the end of the pipe. At the
2 - Cutting ring (DIN 3861) other end, underneath the nut, the pipe is
3 - Union nut (DIN 3871) wedged firmly in the cylindrical bore of the cutting
ring. This provides additional strength and re-
Function lieves the cut area of dynamic stress.
Fig. 5 shows a pipe connection prior to the union Fig. 6 shows the completed connection with the
nut being tightened. When the nut (3) is tight- union nut tightened.
ened, the pre-formed, hardened cutting ring (2) is
pushed into the internal cone of the coupling
body (1) and thereby cuts its way into the pipe, at
the same time throwing up a ridge of cut material.
The pipe is held firmly against the end shoulder
of the coupling body and cannot therefore move
while cutting is taking place.
Fig. 6
DIN 3861 does not specify a particular shape of

cutting edge for cutting rings. This is left open to
the manufacturer. Minor fluctuations are therefore
possible.
Fig. 5
It is absolutely essential that the pipe lie firmly Cutting ring and coupling body should al-
against this shoulder in the coupling - cutting ways be of the same make.
cannot otherwise take place.
A cutting ring coupling can be disconnected and

re-connected several times.
16 2 796 712.00 us
Fitting instructions
Pipe couplings with large diameters should be

assembled in a vice if possible. A wrench with a
grip approximately 15 times longer than the jaw
width should be used.
1. Cut pipe end at right angles and de-burr - see

section "Steel pipes"
2. Lightly oil (do not grease):

thread and internal cone (Figs. 1 + 2)
cutting ring all round (Fig. 3)
inside of union nut (Fig. 4)
Fig. 4
3. First push union nut and then cutting ring onto

the pipe (Fig. 5).
The thicker shoulder of the cutting ring must
point towards the union nut (Fig. 6).
Fig. 1
Fig. 5
Fig. 2
Fig. 6
Fig. 3
2 796 712.00 us 17
4. Push pipe into inner cone of coupling body Fig. 10 shows the coupling before tightening the
until it lies up against shoulder end stop union nut:
(Fig. 7). 1 - Coupling body
2 - Cutting ring
3 - Union nut
4 - Pipe
A - End stop in inner cone
B - Inner cone
Fig. 7
5. Tighten union nut by hand until resistance is

noticed (Fig. 8). The cutting ring must come
firmly into its position between union nut and
inner cone of the coupling body.
Fig. 10
7. Tighten union nut with a wrench / spanner

(Fig. 11).
Pipe outside diameter up to 18 mm: 1 turn
Pipe outside diameter over 20 mm: 1 turn
The edge of the cutting ring thereby cuts into
the pipe wall and throws up a visible ridge of
cut material.
Fig. 8
6. Make chalk marks on union nut and pipe

(Fig. 1) so that assembly can be checked
more easily.
Fig. 11
Fig. 9
18 2 796 712.00 us
Fig. 12 shows the coupling after tightening the

union nut.
Fig. 14
Fig. 12 9. Assemble the coupling again. Tighten union

nut until resistance is noticed and then a fur-
8. Loosen union nut and check the cut of the ther 1/6 of a turn (Fig. 14).
cutting ring (Fig. 13).
The ridge of material thrown up should cover
70 - 80 % of the cutting ring front edge. If this Sealing pipe couplings
is not the case, tighten the union nut further.
It does not matter if the ring can be rotated on If properly assembled, a leaking coupling can
the pipe. usually be sealed again by tightening the union
nut by approx. 1/2 a turn further. If the leak
cannot be stopped in this way, open up the cou-
pling and check that the pipes are aligned, check
whether couplings or pipes are distorted, scored
or cracked, check whether the connecting surface
of the other component is in order, check whether
any seal element is in order.
If it is still not possible to stop the leakage, then

the whole coupling is to be changed.
Fig. 13
2 796 712.00 us 19
Bulkhead couplings Stud couplings and male nipples
Straight bulkhead couplings (Fig. 1), angled bulk- Male thread and seals
head couplings (Fig. 2) and welded bulkhead
couplings (Fig. 3) are used when lines are to be Whitworth pipe thread (cylindrical) DIN 259
routed through the walls of structural components. Metric ISO thread (cylindrical) DIN 13
The couplings are secured to the structural com-
ponent by tightening the nuts 5 (Figs. 1 and 2), Cylindrical male threads are generally sealed with
or by welding into place. a sealing edge according to DIN 3852, Form B
(metal-to-metal, without seal disk). See Fig. 4.
Fig. 1
Fig. 4
In special cases, it is advantageous to seal the

male thread with a soft seal (Fig. 5).
Fig. 2
Fig. 5
Fig. 3
The assembly of connecting lines (pipes, cutting

rings, union nuts) is as described under "Pipe
couplings".
20 2 796 712.00 us
Male nipples with metric or Imperial (inch) threads Stircomatic seal rings
require a recess to accommodate the O-ring to
seal the nipple (Fig. 6). Stircomatic seal rings have been developed for
control units, port plates, valves, threaded flanges
and other connecting elements. They can be
used with hydraulic oil, water and emulsions.
Fig. 1 shows the shape and construction of a

Stircomatic seal ring:
1 - Cutting edge
2 - Textile inlay
3 - Rubber
Fig. 6
In hydraulic systems, straight male nipples with

sealing rings are often used. The ring is then
rectangular in cross section (Stircomatic ring) or
round (O-ring). Fig. 7 shows:
1 - Straight male nipple
2 - Stircomatic or O-ring
3 - Component to be sealed
If leakages occur, the nipple (1) should first be Fig. 1

tightened up. If no improvement is reached, the
seal ring must be changed. Stircomatic seal rings have long-term pressure
stability and high resistance to deformation.
O-rings previously used at such points can be

replaced by Stircomatic rings.
Fig. 7
2 796 712.00 us 21
Swivel couplings
Swivel couplings Swivel coupling with long male adaptor
(Fig. 2)
Application: in hydraulics for pipes with 25, 30
and 38 mm outside diameter The swivel coupling positioned on the adaptor (6,
Fig. 2) is made up of the same components as
Swivel coupling with straight male stated under "Swivel coupling with straight male
thread acc. to DIN (Fig. 1) thread acc. to DIN".
Components: Any leakages are to be remedied in the same

1 - Coupling body manner as given under "Swivel coupling with
2 - Union nut straight male thread acc. to DIN". The coupling is
3 - Cutting and wedging ring sealed in area "C" with a steel sealing ring (9).
4 - Union nut
5 - O-ring If sealing ring or male adaptor are damaged, they
6 - Straight male thread acc. to DIN are to be replaced.
7 - Component to be sealed
8 - Retaining ring body/nut
Leakages can be remedied as follows:

In area A; sealed with cutting and wedging ring
as described under "Sealing pipe coupl-
ings".
Fig. 2
Fig. 1
In area B; sealed with O-ring

tighten up by hand - otherwise change
O-ring.
in area C; sealed with sealing edge

tighten male nipple. Should this not
help, check sealing surface of main
component for pitting, grooving or
scoring - rework with a spot facer if
necessary. Male nipple to be changed
if sealing edge is damaged.
22 2 796 712.00 us
Fixed angle couplings (Fig. 1) Banjo couplings
Application: in hydraulics for pipes with outside Application : in hydraulics for pipes with outside
diameters from 6 to 22 mm diameters of 16 - 38 mm
Components: Banjo coupling (Fig. 2)

1 - Coupling body
2 - Union nut The banjo coupling comprises:
3 - Cutting and wedging ring 1 - Body
4 - Straight male nipple 2 - Hollow screw
5 - Component to be sealed 3 - Sealing ring
4 - Union nut
5 - Cutting and wedging ring
6 - Sealing ring
7 - Connecting surface
The banjo coupling is sealed by the cutting edges

of the sealing rings (3 and 6, Fig. 2). Leakages
can be remedied by tightening up the hollow
screw (2, Fig. 2) on its hex. head, or by following
the steps stated under "Swivel couplings".
Fig. 1
Leakages can be remedied as follows:
In area A; sealed with cutting and wedging ring

as described under "sealing pipe
couplings".
In area C; sealed with sealing edge

tighten male nipple. Should this not Fig. 2
help, check sealing surface of main
component for pitting, grooving or When tightening the hollow screw, make sure that
scoring - rework with a spot facer if body (1) is at right angles to connecting surface
necessary. Male nipple to be changed (7) or nipple (8, Fig. 3), as the sealing rings (3)
if sealing edge is damaged. and (6) cannot otherwise fulfil their function. The
connecting surface must be clean, even and at
right angles to the threaded port for the hollow
screw. Before tightening the hollow screw (2), it is
advisable to loosen the union nut (4) slightly so
that no stress forces are transferred through body
(1) into the connected pipe.
On the pipe side, the coupling is sealed with the

cutting and wedging ring (5). Measures to remedy
leakages have already been described.
2 796 712.00 us 23
Banjo coupling with long male adaptor

(Fig. 3)
The banjo coupling screwed into the adaptor

(8, Fig. 3) comprises the same components as
described under "Banjo coupling".
Leakages in area A can be remedied by tighten-

ing the adaptor (8) or by undertaking measures
as described under "Swivel coupling". Loosen
hollow screw (2) and union nut (4) slightly before
tightening up the adaptor.
Fig. 3
24 2 796 712.00 us
FLANGE COUPLINGS WITH SAE BOLT PATTERN
Flanged pipe couplings - Flanit system Flanged pipe couplings - Zako system
(F-system) (Z-system)
These couplings are for pipes between 25 x 3 These couplings are used for pipes 50 x 6
and 50 x 2. (1", 6000 psi).
Fig. 1 shows the components of the F-system; Fig. 1 shows the components of the Z-system;
Fig. 2 a finished coupling. The components are: Fig. 2 a finished coupling. The components are:
1 - Connection surface 1 - Connection surface
2 - Seal ring 2 - Seal ring
3 - F-ring (wedge ring) 3 - Z-ring (wedge ring)
4 - Flange 4 - Flange
5 - Double-hex bolt 5 - Double-hex bolt
6 - Pipe 6 - Pipe
In the F-system, the wedge ring (F-ring) is push-

ed onto the pipe
The secure connection of wedge ring and pipe is

achieved by tightening the double-hex bolts. A
pre-assembly device is not needed.
Gap dimension "L" is used to check whether the

connection has been correctly established.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
2 796 712.00 us 25
In the Z-system, the wedge ring (Z-ring) is

Flanged hose couplings
pressed into the pipe with a hydraulic tool. This Hydraulic hoses are supplied with ready-assem-
causes the pipe to be stretched. The high surface bled SAE coupling fittings. These always have a
pressure in the stretched area guarantees opti- seal ring groove.
mum sealing of the joint. Further advantages are:
The fitting is connected to the counter-component
high resistance to pressure peaks and vibration
using two flange halves.
maximum safety against pipe tearing out - the
pipe being firmly held between ring and flange Fig. 3 shows:
simple final assembly 1 - Connection surface

2 - Seal ring
Z-rings can be re-used 5 - Double-hex bolt
9 - Flange halves (2 in all)
10 - Hyd. hose with SAE flange fitting
Fig. 3
26 2 796 712.00 us
Sealing and connecting components
Flanges
In the case of flanged pipe couplings, one-part Used Z-rings can be removed from their pipe
flanges are used. Flanges of the same size, but seating and fitted to another pipe section. During
different systems (Flanit/Zako) differ mainly in the this repeated assembly, attention must be given
contour of the middle bore. that the cutting edges of the Z-ring are free of
metal chippings.
Flanged hose couplings are assembled with two-
part flanges. These are referred to as flange F-rings cannot be re-used.
halves.
Seal rings
The flanges can be used several times.
The seal rings are one-part plastic rings (Fig. 2).
Wedge rings They can be used several times and can be
installed in all connections previously sealed with
Wedge rings for flanged pipe couplings are avail- the old type of 2-part seal ring.
able in two designs.
Table 1 (Appendix) lists all of the available sizes,
Fig. 1 (F-system, for example) together with their appropriate Part Nos.
3 - Wedge ring with seal ring groove
7 - Wedge ring without seal ring groove
Fig. 2
Fig. 1
When making pipe/pipe connections with either

the new F-system or the Z-system, a wedge ring
with seal ring groove must always be mated op-
posite a wedge ring without a seal ring groove .
In the original F-system, nearly all connections

were made up of two wedge rings with grooves.
In such installations, a centre disk (see Section
"Centre disks") is necessary. Such a centre disk
is also to be used with other systems in excep-
tional cases in which two wedge rings with
grooves need to be mated together.
Direct assembly of two wedge ONLY rings with

seal ring grooves is permitted in cases of emer-
gency as a permanent seal cannot be achieved.
2 796 712.00 us 27
Double-hex bolts (Fig. 3)

When limited space is available, and therefore Double-hex bolts bring the following advantages:
whenever SAE flange couplings are being used,
- high rust resistance - bolts are galvanized
double-hexagon bolts are used. They have metric
threads (DIN 13), material quality 10.9 (DIN 267) - small wrench sizes, e.g. M 10 requires only
and surface protection A3B (DIN 267). wrench size 11 (the same size of hex. bolt
requires size 17)
- tidy, positive tightening using standard ring
spanners and socket spanners
- no danger of head becoming clogged, as with
hexagon sockets
- easier positioning of wrench, due to twelve-
sided head
Sizes of bolts available can be found in Table 2

(Appendix).
Fig. 3
28 2 796 712.00 us
Assembly aids for wedge rings
Pre-assembly device for F-rings Inserter for Z-rings
In series assembly, the F-ring should be fitted to Following tools are required (Fig. 2)
the pipe with a pre-assembly device. The relevant
operating instructions are therefore to be ob- 8 - Electro-hydraulic control unit (450 bar)
served. with hoses
9 - Assembly cylinder
Final assembly is direct on the respective ma- 10 - Jaws for pipe 50 x 6
chine component, as with manual assembly.
A manual pump can also be used instead of the
Fig. 1 shows a pre-assembly device, whereby: electro-hydraulic unit (8).
1 - Counter ring Detailed description - see Appendix.

2 - Assembly cone
3 - F-ring (wedge ring)
4 - Flange
6 - Pipe
Detailed description - see Appendix.
Fig. 2
Fig. 1
2 796 712.00 us 29
Inserting the Z-ring

Working procedures are illustrated in Figs. 3 - 6: 5. Lay jaws (10) around pipe (6) and push into
yoke cone of cylinder (9).
1. Pipe prepared for installation (see "Steel
pipes").
The straight pipe end must be at least
135 mm long before any bend occurs (Fig. 3).
Fig. 5
6. Push Z-ring hydraulically into pipe until

shoulder of ring lies up against end of pipe
(Fig. 6). Inserting the ring stretches the pipe,
Fig. 3
whereby the circular cutting edges of the Z-
2. Oil Z-ring (3) and inner contour of flange (4) ring cut into the pipe wall.
A gap of 1 mm is permissible between ring
3. Push flange (4) onto pipe (5)
shoulder and the end of the pipe (max. gap).
4. Insert Z-ring (3, Fig. 4) and push, together
with pipe (6, Fig. 5), against pressure plate of
cylinder (9)
Fig. 6
Fig. 4
30 2 796 712.00 us
Assembling flange couplings
The descriptions cover the following flange coupl- Assembly:
ings:
1. Pipe preparation
1 - Pipe / connection surface Saw the pipe off at right-angles (do not use
2 - Hose / connection surface pipe cutters). De-burr pipe inside and out.
3 - Pipe / hose
4 - Hose / hose 2. Oil threads of double-hex bolts (5) and inside
5 - Pipe / pipe contour of flange (4) to reduce assembly
forces
Flange coupling - pipe / connection 3. Push flange (4) and wedge ring (3) onto pipe
surface, F-system (6). If wedge ring has a seal groove, fit seal
first.
Figs. 1 & 2 show:
1 - Connection surface
2 - Seal ring
Do NOT grease ring or groove.
3 - F-ring (wedge ring)
4 - Flange Push pipe (6) against shoulder of wedge
5 - Double-hex bolt ring (3) and then push flange (4), with
6 - Pipe wedge ring, against connection surface
(1). Insert double-hex bolts (5) and tighten
as far as possible by hand.
Pipe (6) must be free of tension and at
right-angles to surface (1).
4. Tighten double-hex bolts (5) diagonally in

stages of max. 1/2 turn each time.
The coupling is correctly assembled when the
gap between parallel faces of connection sur-
face and flange edge is 2-0.5 mm (Fig. 3) (gap
for first installation/assembly).
Fig. 1
Fig. 3
Fig. 2
2 796 712.00 us 31
Leakage between wedge ring and pipe (oil
leaks between flange and pipe)
- Check that gap is parallel and smaller than
2 mm. Re-tighten otherwise.
- If above measure does not help, tighten bolts
by one stage, i.e. reduce existing gap by
0.2 mm. If leakage is only reduced, tighten
up a further stage.
- If coupling still leaks, change pipe, wedge
ring and seal ring (gap as for first assembly:
2-0.5 mm). If gap is smaller than 0.3 mm,
replace flange too.
Zako-system
Fig. 4
Figs. 5 & 6 show:
Check the gap at at least 3 separate points (see
arrows). Difference must not be greater than
1 - Connection surface
0.3 mm.
2 - Sealring
Repeated assembly: 3 - Z-ring (wedge ring)
4 - Flange
When a coupling is assembled a second (or fur- 5 - Double-hex bolt
ther) time, the gap must be at least 0.2 mm 6 - Pipe
smaller than the previous one.
Assembly:
Gaps must therefore be measured before coupl-
1. Pipe prepared for assembly (see "Inserting
ings are loosened.
the Z-ring")
A subsequent assembly or installation is not per- 2. Place seal ring (2) into Z-ring
mitted when the gap is smaller than 0.3 mm
3. Press pipe (6), with Z-ring (3), against the
In case of leakage: connection surface.
Leakage on seal ring (oil leaks between con-
nection surface and flange)
- Check that gap is parallel and smaller than Pipe (6) must be free of tension and at
2 mm. Re-tighten otherwise. right-angles to surface (1).
- If above measure does not help, check seal
ring and connection surface. If necessary,
change seal ring. Re-assemble coupling. 4. Push flange (4), with bolts (5), against sur-
- If coupling still leaks, change pipe, wedge face. Tighten up bolts as far as possible by
ring and seal ring (gap as for first assembly: hand.
2-0.5 mm). If gap is smaller than 0.3 mm,
replace flange too.
Flange (4) must be at right-angles to pipe

axis and parallel to the connection sur-
face. Permissible deviation from parallel:
max. 0.3 mm
Check visually.
5. Tighten bolts (5) diagonally and evenly.

Tightening torque: 250 Nm (185 lbft) (final
torque).
It is not necessary to check gap dimension.
32 2 796 712.00 us
In case of leakage:
Tighten up bolts (5) evenly. Torque = 250 Nm

(185 lbft). Otherwise change seal ring (2).
Fig. 5
Fig. 6
2 796 712.00 us 33
Flange coupling hose / connection In case of leakage:

surface Tighten up bolts (5) to prescribed torque. Other-
Fig. 1 shows: wise change seal ring (2).
1 - Connection surface Flange coupling - pipe / hose

2 - Seal ring
F-system
5 - Double-hex bolt
9 - Flange half Fig. 1 shows:
10 - Hyd. hose with SAE flange fitting
2 - Seal ring
Assembly:
4 - Flange (one-part)
1. Fit seal ring (2) into seal ring groove (see 5 - Double-hex bolt
"Seal rings") 6 - Pipe
7 - F-ring (wedge ring) without seal ring
2. Push hose (10) up against connection sur- groove1)
face. Face of fitting must make contact over 9 - Flange half
whole circumference. 10 - Hydraulic hose with SAE flange fitting
11 - Hex. nut
3. Fit the two flange halves (9) one after the
other. Screw in bolts (5) as far as possible by 1)
If F-ring has a seal ring groove (3, Fig. 3), a
hand. centre disk (8) and a second seal ring (2) must
4. Tighten up bolts (5) diagonally to the torques be used.
specified. The required torques (final torques)
can be found in Table 2.
Fig. 2
Fig. 1
Table 2: Tightening torques for double-hex bolts
Thread Wrench size Tightening

torque
Nm (lbft)
M 10 11 60 (44)
M 12 13 100 (74)
M 14 15 160 (118)
Fig. 3
M 16 19 250 (185)
It is not necessary to check the gap dimension.
34 2 796 712.00 us
Assembly:
1. Prepare pipe for assembly.
2. Oil bolts (5, Fig. 2) and inner contour of

flange (4).
3. Push F-ring (7) and flange (4) onto pipe.
4. Place seal ring (2) into groove. If necessary,

fit a second seal ring (2) and centre disk (8).
5. Push hydraulic hose (10) up against pipe (6)

with F-ring (7) and fit the two flange halves
(9) into position.
6. Insert bolts (5), fit nuts (11) and tighten up Fig. 4

bolts as far as possible by hand.
Assembly:
1. Prepare pipe for assembly (see " Inserting the

Flanges (4, 9) must be at right angles to Z-ring")
pipe or hose axes, and must be parallel to 2. Oil bolts (5) and inner contour of flange (4)
one another.
Permissible deviation from parallel = 0.3 3. Fit seal ring (2) into seal groove
mm.
4. Press hydraulic hose (10) up against pipe (6)
Check visually. with Z-ring (7) and fit both flange halves (9).
5. Fit bolts (5), add nuts (11) and tighten bolts

7. Tighten bolts (5) diagonally and evenly to pre-
as far as possible by hand.
scribed torque. The tightening torques re-
quired can be found in Table 2 (final torques).
It is not necessary to check the gap dimen-
sion.
Flanges (4 + 9) must be at right angles to
In case of leakage: the pipe or hose axes.
Permissible deviation from parallel = 0.3
Tighten up bolts (5) to prescribed torque. mm.
Otherwise change seal ring (2). Check visually.
Z-system
6. Tighten bolts (5) evenly and diagonally.
Fig. 4 shows: Tightening torque = 250 Nm (185 lbft) (final
torque)
2 - Seal ring It is not necessary to check the gap dimen-
4 - Flange (one-part) sion.
5 - Double-hex bolt
6 - Pipe
7 - Z-ring (wedge ring) without seal groove
9 - Flange half
10 - Hydraulic hose with SAE flange fitting
11 - Hex. nut
2 796 712.00 us 35
In case of leakage:
Tighten up bolts (5) to prescribed torque. Other-

wise renew seal ring (2).
Fig. 5 Fig. 6
4. Tighten bolts (5) diagonally and evenly to rel-

Flange coupling - hose / hose
evant torque. The required torques (final tor-
Fig. 1 shows: ques) can be found in Table 3 below.
1 - Seal ring
2 - Double-hex bolt Table 3: Tightening torques for double-hex bolts
3 - Centre disk Thread Wrench size Tightening
9 - Flange half torque
10 - Hydraulic hose with SAE flange fitting Nm (lbft)
11 - Hex. nut
M 10 11 60 (44)
Assembly:
M 12 13 100 (74)
1. Fit seal rings (2)
2. Oil bolts (5) M 14 15 160 (118)
3. Press the hose ends, with fittings, against one M 16 17 250 (185)
another, fit the flange halves (9), position the
bolts (5), add nuts (11) and tighten bolts as
It is not necessary to check the gap dimension.
far as possible by hand.
In case of leakage:
Tighten bolts (5) to the prescribed torque. Other-

Flanges (9) must be at right angles to the wise renew seal ring (2).
axis. Their faces must be parallel.
Check visually.
36 2 796 712.00 us
Flange coupling - pipe / pipe 4. Push pipes (6) against shoulders of F-rings (3
& 7). F-rings must lie firmly against one an-
F-system other and must be seated securely in the
flanges (4).
Figs. 1 and 2 show:
5. Insert bolts (5) and tighten as far as possible
2 - Seal ring by hand.
3 - F-ring (wedge ring) with seal ring groove
4 - Flange(one-part)
5 - Double-hex bolt
6 - Pipe
7 - F-ring (wedge ring) without seal ring
groove1)
11 - Hex. nut
1)
If the second F-ring also has a seal ring
groove (3, Fig. 3), a centre disk (8) and a
second seal ring (2) must be used.
Fig. 3
Flanges (4) must be at right angles to the

pipe axes and parallel to one another.
Tighten double-hex bolts (5) diagonally in
stages of max. 1/2 a turn each.
The coupling has been assembled correctly when

Fig. 1 the gap between the parallel faces of the flanges
is 4-1 mm (gap for first assembly).
Exception: If a centre disk (8) is being used, the

gap dimension increases by the thick-
ness of the relevant disk.
Check gap at least three separate points (see

arrows, Fig. 4). The difference must not be great-
er than 0.3 mm.
Fig. 2
Assembly:
1. Prepare pipe for assembly.
2. Oil bolts (5) and inner contours of flanges (4).
3. Push flanges (4) and F-rings (3 & 7) onto

pipes. Place seal ring (2) into groove. If nec-
essary, fit a second seal ring (2) and centre Fig. 4
disk (8).
2 796 712.00 us 37
Z-system Assembly:
Figs. 5 and 6 show: 1. Prepare pipe for assembly (see "Inserting the
Z-ring")
2 - Seal ring
2. Oil bolts (5) and inner contour of flanges (4)
3 - Z-ring (wedge ring) with seal groove
4 - Flange (one-part) 3. Fit seal ring (2) into seal ring groove. Press
5 - Double-hex bolt both pipes (6), with flanges (4), against each
6 - Pipe other. Fit bolts (5), position nuts (11) and
7 - Z-ring (wedge ring) without seal groove tighten up bolts as far as possible by hand.
11 - Hex. nut
Flanges (4) must be at right angles to the

pipe axes.
Permissible deviation from parallel = 0.3
mm
Check visually.
4. Tighten bolts (5) diagonally and evenly. Tight-

ening torque = 250 Nm (185 lbft) (final
torque). It is not necessary to check the gap
dimension.
In case of leakage:
Fig. 5
Tighten up bolts (5) evenly to prescribed torque.
Otherwise change seal ring (2).
Fig. 6
38 2 796 712.00 us
Appendix
Table 1: Seal rings for flange couplings
Size DN a b+0.4 c+0.1 Parts No.
1
/2 " 13 25.4+0.1 4 2.8 73170952
3
/4" 20 31.75+0.1 4 2.8 73170341
1" 25 39.6+0.1 4 2.8 73170327
1 1/4" 32 44.45+0.1 4 2.8 73170346
1 1/2 " 40 53.7+0.2 4 2.8 73170350
2" 50 63.3+0.2 4 2.8 73170468
(DN = nominal diameter; dimensions a, b, c - see Fig. 2, Page 27)
2 796 712.00 us 39
Table 2: Double - Hex. Bolts
d1 x l1 Part No. SW l1 l2 d2 h s Tightening torque

(mm) (mm) (mm) (mm) (mm) (mm) (mm) Nm (lbft)
M 10 x 30 73170470 11 30 20 17 7 4
M 10 x 45 73171494 11 45 26 17 7 4
M 10 x 55 73171495 11 55 26 17 7 4 60 (44)
M 10 x 80 73171496 11 80 26 17 7 4
M 10 x 100 73171497 11 100 26 17 7 4
M 12 x 30 73170469 13 30 22 19 8 5
M 12 x 50 73171498 13 50 30 19 8 5
M 12 x 65 73171499 13 65 30 19 8 5 100 (74)
M 12 x 90 73171500 13 90 30 19 8 5
M 12 x 120 73171501 13 120 30 19 8 5
M 14 x 60 73171502 15 60 34 21 9 6
M 14 x 105 73171503 15 105 34 21 9 6 160 (118)
M 14 x 150 73170356 15 150 40 21 9 6
M 16 x 40 73171504 19 40 35 24 19 6
M 16 x 70 73171505 19 70 38 24 10 6
M 16 x 90 73171506 19 90 38 26 10 4 250 (185)
M 16 x 100 73171507 19 100 38 24 10 6
M 16 x 120 73170351 19 120 44 24 10 6
M 20 x 120 73171508 22 120 52 30 12 6 490 (362)
Strength class: 10.9, Surface protection : A3B
40 2 796 712.00 us
Accessories
Pre-assembly aids for pipe flange couplings
1. Flanit system 2. Zako system
Following pre-assembly units can be used: Following pre-assembly units can be used:
Parts No. 73175994 Parts No. 73175996
electro-hydraulic unit, comprising electro-hydraulic unit, comprising

- control unit with foot switch - control unit with foot switch
- assembly cylinder - assembly cylinder
- connecting hose - connecting hose
Parts No. 73175995 Parts No. 73175997
manual hydraulic unit, comprising manual hydraulic unit, comprising

- hand pump - hand pump
- assembly cylinder - assembly cylinder
- connecting hose - connecting hose
In addition, the following pre-assembly jaw blocks In addition, a set of jaws for pipe 50 x 6, Parts
and counter-rings are also necessary. No. 73175998, is also required.
Pre-assembly jaw Counter-ring

blocks
Size Parts No. Pipe Parts No.

dimensions
3
/4" 73175999 25 x 3 73176146
28 x 2 73176147
1" 73176000 30 x 3,5 73176148
1 1/4" 73176001 35 x 2 73176149

38 x 4 73176150
1 1/2 " 73176002 42 x 2 73176151
2" 73176003 50 x 2 73176152
2 796 712.00 us 41
Flanges-90
90 flanges (Fig. 1) are used in cases in which
there is little or no room for a pipe or hose bend
(e.g. on hydraulic cylinders).
They are each provided with 4 through and 4

threaded holes, as well as with a seal ring groove
(seal ring - see Section "Flange coupling - pipe /
hose" ).
Parts Nos. for the various flange sizes, as well as

for the appropriate fixing bolts, can be taken from
Table 3 below.
Fig. 1
Table 3: Parts Nos. for 90 flanges

Size DN Pressure range Parts No. Parts No. Parts No.
(mm) (bar) (psi) 90-flange Double-hex bolt Hex. bolt
3
/4" 20 --- --- --- --- ---
420 6000 73175988 73171494 73175327
1" 25 210 3000 73175989 73171495 73175214
420 6000 73170357 73171498 73170360
1 1/4" 32 210 3000 73175990 73171495 73175987
420 6000 73171366 73171502 73171367
1 1/2 " 40 210 3000 73175991 73171439 73171187
420 6000 73175993 73171505 73175986
2" 50 210 3000 73175992 73171499 73171346
--- --- --- --- ---
42 2 796 712.00 us
Gauge connections
As it is often necessary, when checking over The gauge connections can be installed between
hydraulic systems, to undertake pressure mea- lines (pipes or hose) and relevant component
surements in large-diameter lines, special gauge (e.g. travel motor) - see Fig. 2. For this purpose,
connections (Fig. 1) have been developed. additional, longer double-hex bolts, as well as a
seal ring (see Section "Seal rings") are neces-
This type of connection allows manometers with sary.
mini measuring ports (M 14 x 1.5 - Parts No.
73715985) to be connected. Parts Nos. for such components can be found in
Table 4 below.
Fig. 1
Fig. 2
Table 4: Parts Nos. for gauge connections and accessories

Size DN Pressure range Parts No. Parts No. Parts No.
(mm) (bar) (psi) Gauge conn. Double-hex bolt Seal ring
(two-part)
3
/4" 20 210 3000 --- --- ---
420 6000 73175976 73171497 73170341
1" 25 210 3000 73175978 73171496 73170327
420 6000 73175979 73171494 73170327
1 1/4" 32 210 3000 73175980 73171496 73170346

420 6000 73175981 73171503 73170346
1 1/2 " 40 210 3000 73175982 73171500 73170350
420 6000 73175983 73170351 73170350
2" 50 210 3000 73175984 73171500 73170468
420 6000 --- --- ---
2 796 712.00 us 43
Notes 2800145
44 2 796 712.00 us
Flanged pipe couplings - Zako system (Z-
system) .............................................................. 25
A
Flanges .............................................................. 27
Accessories ........................................................ 41
Flanges-90 ........................................................ 42
Appendix ............................................................ 39
FUNDAMENTAL SAFETY INSTRUCTIONS ........ 2
Assembling flange couplings .............................. 31
Assembling working equipment - safety G

instructions .......................................................... 7
Gas, dust, steam and smoke ................................ 5
Assembly aids for wedge rings .......................... 29
Gauge connections ............................................ 43
B
H
Banjo coupling .................................................... 23
Hoses ................................................................ 12
Banjo coupling with long male adaptor .............. 24
Hydraulic and pneumatic equipment .................... 6
Banjo couplings .................................................. 23
Bulkhead couplings ............................................ 20

I
Inserter for Z-rings .............................................. 29
C
Inserting the Z-ring ............................................ 30
Conditions and deviations in the line system ........ 9
INTRODUCTION .................................................. 1
CONNECTIONS ................................................ 15
L
D
LINES FOR VARIOUS MEDIA ............................ 8
Double-hex bolts ................................................ 28
M
E
Materials for pipes and hoses .............................. 9
Electric energy ...................................................... 5
N
F
Noise .................................................................... 6
Fixed angle couplings ........................................ 23
Flange coupling - hose / hose ............................ 36

O
Flange coupling - pipe / connection surface,
Oil, grease and other chemical substances .......... 6
F-system ............................................................ 31
Organizational measures ...................................... 2
Flange coupling - pipe / hose ............................ 34
Flange coupling - pipe / pipe .............................. 37

P
Flange coupling hose / connection surface ........ 34
Pipe couplings .................................................... 15
FLANGE COUPLINGS WITH SAE BOLT
PATTERN .......................................................... 25 Plastic pipes ...................................................... 14
Flanged hose couplings...................................... 26 Pre-assembly aids for pipe flange couplings ...... 41
Flanged pipe couplings - Flanit system (F- Pre-assembly device for F-rings ........................ 29
system) .............................................................. 25
R
Repair work - safety instructions .......................... 8
S
Safety instructions governing specific oper-
ational phases ...................................................... 3
Seal rings............................................................ 27
Sealing and connecting components .................. 27
Sealing pipe couplings........................................ 19
Selection and qualification of personnel - basic

responsibilities ...................................................... 3
Special work in conjunction with utilization of

the machine - maintenance and repairs during
operation - disposal of parts and consumables .... 4
Standard operation .............................................. 3
Steel pipes .......................................................... 10
Stircomatic seal rings ........................................ 21
Stud couplings and male nipples ........................ 20
Swivel coupling with long male adaptor .............. 22
Swivel coupling with straight male thread acc.

to DIN ................................................................ 22
Swivel couplings ................................................ 22
T
Table 1: Seal rings for flange couplings.............. 39
Table 2: Double - Hex. Bolts .............................. 40
Table 3: Parts Nos. for 90 flanges .................. 42
Table 4: Parts Nos. for gauge connections and

accessories ........................................................ 43
Transporting and towing - recommissioning ........ 6
W
Warning of special dangers .................................. 5
Warnings and symbols ........................................ 2
Wedge rings ...................................................... 27
WORKING EQUIPMENT...................................... 7
Z
Zako-system ...................................................... 32
Welding for maintenance and repair
2 732 923.02 us
TABLE OF CONTENTS
Foreword .................................................................................................................................. 1
Safety ........................................................................................................................................ 1
1. Fundamentals
1.1 Loads on structural elements .............................................................................................................. 2
1.2 Types of loading .................................................................................................................................. 2
1.3 Material behaviour under different loads .............................................................................................. 4
1.4 Notches in components
1.4.1 Mechanical notches .............................................................................................................. 5
1.4.2 Metallurgical notches ............................................................................................................ 6
1.4.3 Shape-induced notches ........................................................................................................ 6
1.4.4 Notch effects ........................................................................................................................ 8
1.4.5 Practical experience ............................................................................................................ 9
1.5 Avoiding notches
1.5.1 Grinding drag lines ............................................................................................................ 10
1.5.2 Grinding tools .................................................................................................................... 10
1.5.3 Run-off tabs ........................................................................................................................ 11
1.5.4 Attaching auxiliary elements .............................................................................................. 12
1.5.5 Ends of ribs ........................................................................................................................ 13
1.5.6 Undisturbed flow of forces .................................................................................................. 13
1.5.7 Ribs and stiffeners .............................................................................................................. 14
1.5.8 Welding technique .............................................................................................................. 15
1.5.9 Welding of "tempering beads" ............................................................................................ 16
1.5.10 Buffering of weld edges ...................................................................................................... 16
1.5.11 Welding sequence .............................................................................................................. 17
2. Planning of repair and reinforcing work for steel components

2.1 Causes of damage ............................................................................................................................ 18
2.2 Preparatory measures ........................................................................................................................ 18
2.3 Scope of repair work
2.3.1 Scrapping of components .................................................................................................. 19
2.3.2 Temporary repair ................................................................................................................ 19
2.3.3 Permanent repair ................................................................................................................ 21
2.4 Precautionary examinations .............................................................................................................. 22
2.5 Detection of cracks and other defects
2.5.1 Examination for surface cracks with the dye-penetration test ............................................ 22
2.5.2 Examination for surface cracks with the magnetic powder test .......................................... 22
2.5.3 Ultrasonic testing ................................................................................................................ 22
3. Repair welding techniques

3.1 Gouging out and welding of cracks .................................................................................................... 23
3.2 Cracks in hub connections
3.2.1 Cracking along the center of the seam .............................................................................. 25
3.2.2 Sharp, exactly radial crack along the unchamfered edge .................................................. 26
3.3 Welding on of a metal cylinder by the back-step technique................................................................ 27
3.3.1 Working sequence .............................................................................................................. 27
3.4 Cracks in box-type sections................................................................................................................ 29
TABLE OF CONTENTS
3.4.1 Opening of box-type sections ............................................................................................ 30
3.4.2 Removing parts of a chord plate by flame-cutting .............................................................. 30
3.4.3 Backing strips .................................................................................................................... 33
3.5 Recommended groove shapes for manual welding with electrodes
3.5.1 Butt joints ............................................................................................................................ 34
3.5.2 T-joints ................................................................................................................................ 35
3.6 WORKING SEQUENCE FOR WELD SEAMS
3.6.1 Butt welds .......................................................................................................................... 36
3.6.1.1 V-butt weld........................................................................................................ 36
3.6.1.2 Double-V butt weld .......................................................................................... 36
3.6.1.3 V-butt weld with backing strip .......................................................................... 37
3.6.2 T-joint.................................................................................................................................. 37
3.6.2.1 T-joints (fig. 53), accessible from 2 sides ........................................................ 37
3.6.2.2 T-joints with backing strip (fig. 54), accessible from 1 side .............................. 37
3.7 Closing of working openings, renewal of component areas
3.7.1 Closing a working opening ................................................................................................ 38
3.7.2 Closing a web-plate opening .............................................................................................. 39
3.7.3 Replacing a chord-plate section ........................................................................................ 42
3.7.3.1 Salient chord plate ............................................................................................ 42
3.7.3.2 Recessed chord plate ...................................................................................... 45
3.7.3.3 Possible causes of damage to chord plates .................................................... 47
3.7.3.4 Repair of a boom with a salient chord .............................................................. 48
4. Reinforcing of steel components

4.1 Reinforcing plates
4.1.1 Dimensions ........................................................................................................................ 49
4.1.2 Shapes of reinforcing plates .............................................................................................. 50
4.1.3 Welding slots ...................................................................................................................... 51
4.1.4 Fitting of reinforcing plates.................................................................................................. 52
4.1.5 Weld seams of T-joints ...................................................................................................... 52
4.2 Shaping plates for repairs .................................................................................................................. 53
4.3 Reinforcing by shape improvements
4.3.1 End of ribs .......................................................................................................................... 54
4.3.2 Open sections/closed sections .......................................................................................... 54
4.3.3 Reinforcing by build-up welding .......................................................................................... 55
4.3.4 Improvement of curved sections in ribs .............................................................................. 56
5. Materials, filler metals for welding

5.1 Materials in welded components ........................................................................................................ 57
5.1.1 Component materials ........................................................................................................ 58
5.2 Filler metals for welded components depending on partner materials
and welding techniques ...................................................................................................................... 61
TABLE OF CONTENTS
6. Heat treatment of materials

6.1 Preheating for tacking, welding, gouging and flame-cutting .............................................................. 63
6.2 Hot bending of plates ........................................................................................................................ 68
6.3 Hot straightening of plates .................................................................................................................. 68
6.4 Stress-relief annealing of steel components ...................................................................................... 68
6.5 Stress-relieving of steel components
6.5.1 Warming of components .................................................................................................... 69
6.5.2 Peening of weld seams ...................................................................................................... 69
6.5.2.1 Method of peening ............................................................................................ 69
6.5.2.2 Peening tools .................................................................................................... 70
6.6 Treatment of filler metals .................................................................................................................... 71
6.7 Temperature monitoring .................................................................................................................... 71
7. Cold bending of plates .................................................................................................. 72
8. Build-up welding
8.1 Addition of missing / worn-out material
8.1.1 Build-up welding in drill holes ............................................................................................ 73
8.1.2 Build-up welding on worn-out threads ................................................................................ 74
8.2 Correcting of component shapes to improve the flow of forces .......................................................... 75
8.3 Build-up welding as a protection against wear .................................................................................. 75
9. Wear protection (hard-facing)

9.1 Fundamentals .................................................................................................................................... 76
9.2 Build-up welding of wear protection layers ........................................................................................ 76
9.2.1 Build-up welding patterns .................................................................................................. 77
9.2.2 Special hints ...................................................................................................................... 78
9.3 Filler metals
9.3.1 For buffer layers ................................................................................................................ 78
9.3.2 For hard-facing layers ........................................................................................................ 78
9.4 Repair of build-up welds
9.4.1 State of wear ...................................................................................................................... 79
9.4.2 Identification of buffer and hard-facing layers .................................................................... 80
9.5 Repair of cracks in build-up welds ...................................................................................................... 81
9.6 Welding on wear-resistant steel plates or steel strips
9.6.1 Arrangement of plates/strips .............................................................................................. 82
9.6.2 Bending of strips ................................................................................................................ 86
9.6.3 Working instructions .......................................................................................................... 86
9.6.4 Filler metals ........................................................................................................................ 86
9.7 Welding of plates or strips with wear-resistant coatings
9.8 Welding of wear-resistant studs
9.9 Welding cutting edges onto digging tools of excavators
9.9.1 Working sequence .............................................................................................................. 89
9.9.2 Welding sequence (fig. 39) and filler metals ...................................................................... 89
TABLE OF CONTENTS
10. Repair of cast-iron components by welding

10.1 Spheroidal-graphite cast iron
10.1.1 Hot welding ........................................................................................................................ 91
10.1.2 Cold welding ...................................................................................................................... 91
10.2 Flaky-graphite cast iron
10.2.1 Hot weldingn ...................................................................................................................... 92
10.2.2 Cold welding ...................................................................................................................... 92
10.2.3 Repair of components with the "interlock" technique .......................................................... 93
11. Touching up paint coatings in repair areas ................................................................ 94
Appendix
Comparison: old designation - new designation ................................................................ 95
Part nos. for filler metals........................................................................................................ 96
Conversion from foot (Fu) and inch (Zoll) to metric measure .......................................... 98
Conversion for units of length .............................................................................................. 98
Temperature units and conversion formulas ...................................................................... 99
Hardness - strength comparisen ........................................................................................ 100
GENERAL
Foreword Safety
In spite of proper design, perfect stress analysis, Always observe the accident prevention rules and
meticulous manufacturing, attentive maintenance and safety regulations.
responsible operation, damage to parts of building
machines and mobile industrial handling equipment Work on recipients containing or having con-
cannot always be completely avoided. Normal wear tained substances
in areas subject to mecanical or abrasive action must
always be reckoned with. that are combustible or susceptible to stimu-
late combustion,
Experience in the early detection of damage and the that may be the cause of explosions and
causes thereof, the choice of appropriate repair mea- which develop noxious gases, fumes, mists or
sures and consistent, workmanlike execution contri- dusts during handling
bute to a high availability of construction machines.
must only be carried out under expert supervi-
sion and by experienced and specially qualified
Before beginning with welding, gouging, hot and cold persons.
bending and heat treatments, the person in charge of
the repair must be familiar with the material of the
component. Depressurize all circuits and components (e.g.
pipelines, coolers, hydraulic oil tank, com-
pressed-air receivers) before opening them.
The present Technical Handbook has been compiled
from many useful hints supplied by welding experts
as well as from experience gathered in the field of For fitting and removing of working equipment or
welding. They contribute to the proper planning and of components thereof, or for fitting and remov-
execution of repair and reinforcing work. It is taken ing of units
for granted that the personnel in charge of this work make sure that the machine and its equipment
possesses the required expert knowledge. Moreover, are secured against unintentional and un-
it is important to take the particulars of the respective authorized starting. Place the working equip-
case of damage into consideration. ment on the ground so that it cannot move
when mechanical or hydraulical connections
This latest edition of the Technical Handbook "Weld- are opened or released.
ing for maintenance and repair" SN 2 114 500.00 is a
revised and updated version and takes account of make sure that equipment or components to
EN standards. Some sections have been supplemen- be fitted, removed or brought into another po-
ted or added. For this reason, only the instructions in sition are secured against unintentional mov-
this edition should be observed for welding work. ing, sliding or dropping by means of lifting
tackle or suitable suspensions and supports.
Persons working at a considerable height must

be equipped with a safety harness to prevent
them from falling.
If - for the execution of work - helpers, such as

marshallers, are needed, it is essential to fix the
responsibilities of the individual helpers before-
hand and to observe these responsibilities during
the work in order to avoid any conflict of com-
petence in safety matters.
Make sure that all tools, lifting appliances, sling

gear, supports and other auxiliary devices are in
a safe and reliable state of operation.
For further hints see para. 2.2 "Preparatory mea-

sures".
Page 1
FUNDAMENTALS
1. Fundamentals 1.2 Types of loading
Loads (tension and compression forces) may act

upon the structural element as static or mainly static
1.1 Loads on structural elements (fig. 2), pulsating (fig. 3) or alternating loads (fig. 4).
Pulsating and alternating loads may occur either as
Structural elements may be subject to different loads. continuous or as shock loads.
Forces practically never act as individual forces but

mostly in combination (fig. 1).
Fig. 2
O+F Tension
O-F Compression
Fig. 1
Loads on structural elements produced by forces act- Fig. 3

ing simultaneously and from different directions are
difficult to assess by computation.
Modern computing methods nevertheless permit the

determination of stress magnitudes and concentra-
tions.
Fig. 4
Page 2
FUNDAMENTALS
The following illustrations (figs. 5 and 6) give an During the "digging" cycle, the boom stretches
example of different types of loads acting on the out. The lower chord plate is subject to tension
boom of an excavator. The boom is stressed for and the upper chord plate to compression.
tension.
During the "lifting" cycle, the boom is compressed.
Now, the upper chord plate is subject to tension
and the lower chord plate to compression.
This means that the loads act alternately on the

boom.
Fig. 5
Fig. 6
Page 3
FUNDAMENTALS
1.3 Material behaviour under different loads
The mechanical stresses admissible with regard to The reason for this material behaviour lies in the
the operating safety of a structural element gradual weakening of the cohesive forces along the
(N/mm2) vary for the same material under static and grain boundaries, and, at a later stage, in the occur-
alternating loads (fig. 7). rence and increase of disturbances in the microstruc-
ture (fig. 8).
Fig. 8
1 Shows an idealized material microstructure under

alternating load. The material experiences elastic
deformation along the sliding planes at the grain
boundaries. The sliding planes present no distur-
bances.
2 Permanent elastic deformation leads to shifting
of material grains along the sliding planes where
the first disturbances appear.
3 The disturbed areas widen as the frequency of
elastic deformation increases.
Fig. 7
The admissible mechanical stresses are clearly below

the values for tensile strength indicated in the stan-
dards. The example shows a rolled steel EN 10025 -
S355J2G3, with thicknesses > _ 3 mm < _ 100 mm.
Page 4
FUNDAMENTALS
1.4 Notches in components
All areas where the ideal flow of forces in a compo- These notches may, however, also have other me-
nent is disturbed are qualified as notches. chanical causes (fig. 10 and 11), such as:
steel stamping figures, chisel marks,
From their occurrence and their effect on the compo- marking tool lines, damage by lifting
nent 3 different types of notches have to be consi- chains.
dered:
- mechanical notches
- metallurgical notches
- shape-induced notches
1.4.1 Mechanical notches
Mechanical notches may occur during welding in the

weld seam (fig. 9).
Fig. 10
Fig. 11
1 Steel stamping figures
2 Chisel marks
3 Marking tool lines
4 Notches due to lifting chains
Fig. 9
1 Undercut
2 Incomplete joint penetration
3 Porosities in the weld deposit
4 Incomplete fusion
5 Grinding drag lines
6 Drop-through at the root
7 Underbead crack
Page 5
FUNDAMENTALS
Mechanical notches lead to stress concentrations (fig. Due to their properties, these areas, however small
12). they may be, show a different behaviour under load-
ing which, in turn, leads to elongation impediments
and material constraints.
The occurrence of metallurgical notches can be kept
to an acceptably low level by applying optimized
welding and heat-treatment techniques.
The effect of existing metallurgical notches, e.g.
those produced by improper welding, can also be
mitigated by a stress-relieving and annealing proce-
dure.
1.4.3 Shape-induced notches

Shape-induced notches depend on the structural de-
sign and lead to stress concentrations caused by the
diversion of lines of forces (fig. 14).
Fig. 12 In many cases, shape-induced notches are moreover
located in heat affected zones with metallurgical
2 Inadequate penetration of root notches.
4 Incomplete fusion Shape-induced notches can be largely reduced by
choosing an appropriate design. For all practical pur-
These, in turn, lead to an enlargement of the poses, they have to be reduced to such an extent
notches. that the negative influence exerted by them on the
This procedure may repeat itself and eventually lead endurance strength of the structural element remains
to fracturing of the component. insignificant.
Mechanical notches are mainly produced during the
manufacture, but later on also during the utilization of
the machine (traces resulting from use).
Mechanical notches can be detected by visual in-
spection or by non-destructive testing and then be
repaired.
1.4.2 Metallurgical notches
Metallurgical notches are caused by thermal influence

on the material; i.e. always at or around weld depos-
its (fig. 13).
Fig. 13
Fig. 14
The heat applied by welding leads to zones present-
1 + 2 Hardness distribution curve
ing different metallurgical and mechano-technological
properties depending on their distance to the heat Shape-induced notches can be subsequently
source. eliminated by changes in shape.
Page 6
FUNDAMENTALS
Examples (fig. 15): An ideal and yet cost-saving solution for the distribu-
tion of forces is the butt-weld joint where the plate
a + b: inadequately executed butt-weld joints be- thickness difference is reduced by chamfering in a
tween structural elements of different thicknesses. 1:4 ratio (fig. 16).
c: better joint.
For relatively small thickness variations of the two

plates, the joint such as realized in example c) can
be sufficient.
Fig. 16
The forces should be able to flow as disturbance-free

as possible through the part of the structural element
that can be analysed.
Lines of forces should not, however, traverse auxil-
iary elements (fig. 17).
Fig. 15
Fig. 17
The welds used for fastening such auxiliary elements

are mostly overestimated as they cannot absorb the
forces prevailing in components
Page 7
FUNDAMENTALS
1.4.4 Notch effects
Depending on their shape, notches have different Possible notches (mechanical and metallurgical) in
notch or influencing factors. the seams of butt-weld joints:
The influence of notch factors on the fatigue strength
of a component is shown in the graph (fig. 18).
Fig. 18
For a notch factor of "O", practically the only effects
Location and shape of curves W, O, 1, 2, 3 and 4 to be expected are from metallurgical notches.
refer to:
material: EN 10025: S355J2G3
no. of load cycles: 2 10 6 (2 million)
i.e. of high fatigue strength
group of stress intensities: small, medium and high
stresses with approx. the
same frequency
Page 8
FUNDAMENTALS
1.4.5 Practical experience
In order to lower the weight of components, de-

signers often resort to materials with higher strength
values and to plates of lower thicknesses with no
changes to the shape of the component.
In this respect it should not be overlooked, however,

that the stability of the structural element only de-
pends on the geometrical dimensions and the
modulus of elasticity E of the material. E is basically
the same for an S690Q and an S355J2G3.
This means that a component consisting of thinner

plates is subject to stronger deformations and thus
loses some of its service properties. Moreover, the
effects of notches on the strength of the materials are
increased.
High-strength fine-grained structural steels such as

S690Q offer advantages over ordinary fine-grained
structural steel S355J2G3 only in cases of static or
predominantly static loading and reduced notching
(fig. 19).
With the strength of the material increasing, the sus-

ceptibility of structural steel elements to notching be-
comes greater.
For machines subject to alternating loads and

equipped with notched structural steel elements it is Fig. 19
therefore recommended to use an S355J2G3.
Location and shape of curves W, O and 4 refer to:
In this context, notches resulting from marks left by
usage have to be considered as well. material: S355J2G3, S690Q
no. of load cycles: _ 2 10 6 (2 million)
>
group of stress intensities: small, medium and high
stresses with approx. the
same frequency
Page 9
FUNDAMENTALS
1.5 Avoiding notches 1.5.2 Grinding tools
If notches in a component are avoided altogether or if Grinding wheel on angle grinder (fig. 21):
their acuity (notch factor) is reduced, the admissible
stresses (N/mm2) can be increased. Only suitable for the rough removal of material.
In such case, the service life approaches the compo- Not suitable for low-notch finish with controlled
nents fatigue strength and damage can be largely direction of drag lines.
avoided.
1.5.1 Grinding drag lines
Grinding drag lines transverse to the main direction

of load are dangerous mechanical notches.
Drag lines parallel to the direction of loading (fig. 20)

should therefore be avoided during grinding.
Fig. 21
Grinding stone (fig. 22):
Suitable for grinding of weld surfaces, weld

ends and plate edges. Should be used at least
for finishing.
Fig. 22
Fig. 20
This rule cannot be observed if grinding wheels are

used for the work. Under these circumstances, man-
ual reworking with emery paper may be required.
It is therefore recommended to use grinding stones at

least for the finishing pass.
Page 10
FUNDAMENTALS
1.5.3 Run-off tabs
Grinding stone (fig. 23): Mechanical stresses reach their highest value at the
edges of components.
Suitable for grinding in component areas of
difficult access. Defects in the weld which are caused, for instance,
by arc strikes or end-of-weld craters in edge zones
should be avoided. The welding groove must be
completely filled along the edges of components.
Fig. 23
Steel milling cutter (fig. 24):
Suitable for rounding off small radii.
Fig. 25
For this purpose, the weld seam has to be extended

by ca. 50 mm using run-off tabs (fig. 25). In this
case, arc strikes and end-of-weld craters are located
in the extended part of the groove.
The cross-section of the run-off tabs used depends

on the shape of the welding groove.
Fig. 24
After welding, the run-off sections are to be removed
by flame-cutting and the surfaces to be finished by
proper grinding.
For such work, the grinding instructions given under

1.5. 1 should be followed.
Page 11
FUNDAMENTALS
1.5.4 Attaching auxiliary elements
For the fastening of auxiliary elements no welding To protect the base element it may be required to
should be carried out in the edge zones of structural work out alternative methods of fastening (fig. 28).
elements subject to high stresses.
The welds should end at a well-defined distance from

the edge of the component.
Arc strikes and end-of-weld craters should be located
as far away from the component edge as possible
(figs. 26 und 27).
Fig. 28
Examples:
Fastening of pipe clamps on a very small base

element.
Fig. 26 Stirrups for pipes, lamps, cables and similar fix-

tures fastened without welding on the highly
stressed bottom chord.
Fig. 27
Page 12
FUNDAMENTALS
1.5.5 Ends of ribs 1.5.6 Undisturbed flow of forces
The ends of ribs on highly stressed structural ele- Auxiliary elements - in this case a crane eye - must
ments must taper off "gently" and be surrounded by a be shaped in such a way that the lines of force are
boxing weld. not disturbed or even interrupted.
Fig. 30
Interruptions in the flow of forces produce stress

concentrations and lead to cracks (fig. 31).
Fig. 29
The welder must position himself and the component

in such a way that the boxing weld can be carried
out without arc strikes and end-of-weld craters.
The weld interface areas must be absolutely free
from notches. This can only be achieved by grinding
(fig. 30).
Fig. 31
Recommendation: Cut off the eyes after assembly.

Grind the surfaces smooth and
clean.
Page 13
FUNDAMENTALS
1.5.7 Ribs and stiffeners
Ribs, stiffeners and similar parts on components must

be welded with endless seams if the components are
subject to pulsating or alternating loads (fig. 32).
Fig. 32
Interruptions in the weld seams are not recommend-

ed, even if they facilitate the assembly of the compo-
nent (fig. 33).
Tri-directional states of stresses in weld-seam cross-

ings are considerably less dangerous for the
structural elements than defective or even missing
boxing welds in the gaps. They represent potential
starting points for fatigue fractures. Too large gaps Fig. 33
may lead to damage by "softening-up" the component
corner, even if the weld is otherwise faultless.
Page 14
FUNDAMENTALS
1.5.8 Welding technique
Maximum bead or pass widths:

The effects of metallurgical notches can be consider-
ably alleviated by applying a proper handling tech- Solid wire:
nique during welding.
Wire Width
When repairing components by welding, the stringer 0,8 8,0
bead technique must be used (fig. 34). 1,0 10,0
1,2 12,0
1,6 16,0
Rod electrodes:
Rod Width
3,2 8,0
4,0 10,0
5,5 12,0
The weld start points for multipass welding must run

in terraces (fig. 35) or cascades (fig. 36). This is
essential if faults due to arc strikes or end craters are
to be avoided on one line in the various passes.
Illustrations:
Fig. 34
The advantages of the stringer bead technique are:

Reduced heat input (joule/cm) per welding bead.
The heat-affected zone (HAZ) in the base material
remains very narrow, resulting in a metallurgical
notch with minimum notch action.
Heat input: (J/cm) = I x U x 60
v
I = current intensity (A)
U = voltage (V)
v = welding velocity (cm/min)
Each welding bead is tempered by the overweld-

ing with the next bead.
The weld pool can be well controlled, with Fig. 35
- good penetration at the weld edges,
- avoidance of weld pool pre-flow (cold welding),
- avoidance of poor fusion.
Fig. 36
Page 15
FUNDAMENTALS
1.5.9 Welding of "tempering beads" 1.5.10 Buffering of weld edges
The welding of "tempering beads" provides a sub- The formation of heat-affected zones (HAZ) is vital to
stantial improvement in the mechanical-technological the durability of the weld, especially when welding
characteristics of the weld metal both in the cover materials with a high carbon equivalent.
pass and in the heat-affected zone (HAZ) close to The aim must be:
the surface.
a narrow heat-affected zone (HAZ),
a minimum reduction in the strength of the ma-

terial and of the heat-affected zone (HAZ),
a slight increase in hardness at the transition

between the heat-affected zone and the base ma-
terial.
This aim is largely achieved by so-called buffering of

the weld edges prior to weld- joining.
For buffering purposes, welding is done with the low-
est possible heat input (J/cm).
The following details must be observed when buf-
Fig. 37 fering:
Explanations of Fig. 37:
Weld the buffering with rod electrodes of the type
suited to the base material.
Beads 6 and 7 are the "tempering beads".
Diameter of rod electrodes: 3.2 mm.
The welding of beads 6 and 7 re-heats the weld
metal of beads 1 and 3 / 4 and 2 respectively.
The metal is tempered. Preheat the base material, depending on type.
In this tempered weld metal, an ideal material Weld in stringer bead technique.
structure with improved expansion and toughness
characteristics is induced with a negligible loss of Check the inter-pass temperature of the materials
strength. accordingly.
If necessary, the cover pass can be ground down. If run-off tabs are present at the weld ends: buffer
beyond the start point as far as the end of the
run-off tabs.
Clean the finished buffering thoroughly before

overwelding. (Slag residues on the contact line
from one bead to the next).
Start the weld-joining without intermediate cooling

of the component.
When 2 separate components or fragments are to be

joined by welding, buffering should be done prior to
assembly in the most favourable welding position for
both parts.
Assembly of the warm parts must be scheduled be-
fore the heating, e.g. with an appropriate device.
Page 16
FUNDAMENTALS
1.5.11 Welding sequence
Definition: When welding weld crossings, the welding sequence

Stipulating in which direction a joint is to be welded drawn below must be observed (fig. 38).
and in what sequence several joints are to be weld-
ed.
Explanation of drawing:
Presetting the welding sequence allows the following

to be determined:
The component must be kept as stress-relieved

as possible. Delays due to the effect of welding
stresses must be accepted.
The component must be kept as dimensionally

stable as possible. Intrinsic stresses in the compo-
nent, resulting from the welding, must be accept-
ed. Fig. 38
When repairing components by welding them, it will To avoid defects and thus to prevent mechanical
generally be necessary to keep the component di- notches, weld crossings in the edge zone of compo-
mensionally stable. nents must not have any arc strikes or end craters.
Page 17
PLANNING OF REPAIR AND REINFORCING WORK
2. Planning of repair and reinforcing In practice, repair, reconstruction or reinforcing
work for steel components work may only be carried out by experienced
welders. A welder holding a certificate in accor-
dance with EN 287-1 135 P BW W03 t20 PC SS
In planning the repair and reinforcement of steel mk already fulfils the basic qualification require-
components, the first step should be to determine the ments.
precise extent and the causes of damage and then to
fix and to carry out the appropriate measures. If possible, welding is to be done in a workshop
Reinforcement without planning leads to new da- which is equipped with the necessary tools and
mage. lifting gear.
If welding work has to be carried out on site, the
component must be protected against atmospher-
2.1 Causes of damage
ic influences such as rain, snow, dew, wind, etc.
This can be achieved, for example, by a tarpaulin
The causes of damage may be manifold. used as a working tent.
Dimensioning errors Cleanliness at the place of work is of utmost

importance.
Incorrect estimation of the potential stresses and
load cases. When dismantling the component, all built-on
Dimensioning and design errors. parts, particularly those with articulations, must be
Unsuitable construction materials. removed from the component.
(Example: Tri-Power pin and linkage).
Manufacturing errors
Hose and pipe connections opened in dismantling
Mechanical and metallurgical notches. the component as well as open holes and casings
Measuring errors. should be closed carefully in order to prevent the
Mixing up of materials. penetration of dirt.
Material defects.
The component to be repaired is to be cleaned
Wrong operation of the machine properly, particularly those parts of the component
on which work is to be carried out.
Wrong handling due to lack of experience.
Wrong use due to an overestimation of the ma- Weld grooves and surfaces for fillet welds must
chines capabilities. be completely cleaned down to the bare metal.
Using the machine for activities for which it is has
Paint coatings and priming coats must not be
not been designed.
welded over.
Accidents Lubricants must be completely removed from
bearings in order to prevent them from liquefying
Accidents during transport, relocation or operation,
under the effect of heat and flowing into the weld
e.g. accidents caused by falling rocks when work-
area.
ing in quarries.
Machined surfaces, pins, bearings, piston rods,
electrical components, etc. must be protected
2.2 Preparatory measures against weld splashes and grinding dust by cover-
ing them with non-combustible materials.
To restore the machines availability independent of
the cause of damage, it is essential to fix the appro- Before carrying out welding on assemblies
priate working procedure. containing electronic components, all connectors
must be unplugged.
Important prerequisites for the execution of repair and Example: In hydraulic excavators equipped with
reinforcing work: the PMS system, all connectors must be un-
plugged from the load-limit regulator (PMS box).
Repair, reconstruction or reinforcing work on Prior to welding on components remaining on the
structural steel elements of construction machines machine, the starter batteries must be disconnect-
may be supervised only by experts with sufficient ed. Disconnect first the negative and then the
experience in the design and construction of dy- positive terminal! After the work, reconnect first
namically stressed components. the positive and then the negative terminal.
In cases of doubt, please address the FIATALLIS
after-sales service which can refer the problem to Before welding, the type and the properties of the
the respective specialized departments, if re- material involved must be determined.
quired. Use only those weld filler metals that are suitable
for the base metal concerned.
Page 18
2.3 Scope of repair work 2.3.2 Temporary repair
The most suitable procedure to be followed in a case The component must be repaired immediately in or-
of damage is shown in the diagram below. der to maintain the machines availability, e.g. be-
cause the machine is used for a job with fixed time
After damage has been reported, one of the 3 follow- limits (fig. 2).
ing decisions is to be taken (fig. 1).
In spite of being a matter of urgency, temporary
repairs must nevertheless be performed carefully in
order to avoid new damage.
Fig. 1
2.3.1 Scrapping of components
The damage has reached such an advanced stage

that a proper repair is either technically no longer
feasible or linked with extremely high costs.
The limit for this decision is not a fixed one. Whereas Fig. 2
at home and in most industrialized countries the de-
cision to scrap is taken relatively early, it may be
necessary in other countries to carry out the repair
because the procurement of a new part is difficult for
various reasons and sometimes even impossible. The
reasons for this situation may lie, for example, in the
lack of foreign exchange, in high customs duties,
long delivery periods and extended standstill periods
for the machine. Relatively low wage costs can also
be a reason in favour of the repair.
Page 19
The following rules must be observed: One possibility of finding the end of a crack consists
in non-destructive testing for cracks by means of one
Cracks must be stopped by drilling when they are of the well-known methods such as ultrasonic testing,
still relatively short (fig. 3). dye-penetration test, magnetic powder test or X-ray
This measure ensures a reduction in the crack testing.
propagation speed. After drilling, the stopper hole can be examined for
It does not, however, constitute a repair. persisting cracks.
Long cracks should be immediately gouged out

and welded, even if the marginal conditions are
unfavourable.
The area of damage must be subjected to permanent

inspection. In case of a failure of the repair weld, the
measure described has to be repeated.
Do not weld reinforcing elements onto damaged

areas. They not only make no sense, but more-
over cover up the area of damage and make
permanent checking impossible.
Another possibility is that the area of damage may

widen and thus make proper repair at a later time
Fig. 3 impossible.
It is particularly important to find the actual end of the
crack.
Depending on their starting point, cracks may tra-
verse the component along curved lines (fig. 4).
Fig. 4
A + B correctly stopped by drilling
C incorrectly stopped by drilling
Page 20
2.3.3 Permanent repair - A simple examination of the material consists
in comparing its hardness to that of known
materials.
- The wall thickness of sheets, cast-steel or
forged pieces can be controlled and compared
to the dimensions contained in the drawings.
- In case of persisting doubt, the component can
be subjected to a new analysis carried out by
a neutral institution.
- In difficult cases, it is advisable to make use of
the services of a laboratory if, for example,
precise material analyses, hardness curves
and an appraisal of the materials microstruc-
ture and surface are required.
In certain cases, the expertise of an indepen-
dent laboratory may also be required in order
to clear up liability matters.
A workmanlike repair giving a high fatigue
strength expectancy must be properly planned
and carefully executed on the workshop level.
Fig. 5 In each phase of the work, all advantages at hand

should be made use of.
If a decision in favour of a permanent repair of the Even so-called "trivial matters" may be of decisive
damaged component is taken (fig. 5), the following importance for the success of a repair.
rules are to be observed: The repair work must be subject to supervision
The cause of damage must be determined and and the phases in which inspections are to take
eliminated if it can be traced back to design or place be determined beforehand.
manufacturing deficiencies. To determine the It is advisable to explain the theoretical reasons
cause of damage, the following simple measures for the repair measure to the craftsman carrying
will often be sufficient: out the work as he will then develop a feeling of
responsibility for a successful achievement of the
- Personal experience and comparison with repair.
damage patterns in similar components.
In case of damage caused by design failures or
- Visual inspection of the area of damage with overloading, it may be necessary to reinforce the
the aim of finding the causes for the crack component after the repair.
starting point, such as mechanical notches,
missing weld seams, insufficient root penetra- Important note: The reinforcement planned must
tion, etc. make sense and its positive effects be justified by
means of an analysis.
- Visual appraisal of the fractured surfaces with
the aim of finding the crack starting point by Badly planned reinforcing measures are useless,
means of the bench marks. expensive, do not offer real safety, increase the
Moreover, the structure of the fractured sur- weight of the component and may impede its
face allows conclusions to be drawn with re- functions.
gard to material quality. Moreover, they do not look very nice.
Page 21
2.4 Precautionary examinations 4. Spray white developer (P/N 73171492) onto the
area.
In the field of medical treatment, precautionary ex- Any cracks then become visible as small, red
aminations are standard practice. Doctors teach us lines on a white background. The extent of
that a disease, if discovered in its early stage, can be "bleeding" and the waiting time allow conclusions
cured by a simple operation, whereas in an advanced to be drawn as to the depth of the crack.
stage, help often comes too late.
Wipe off the developer with a cleaning cloth.
The regular inspection of construction machines, for
example, is also a kind of precautionary examination 2.5.2 Examination for surface cracks with the
and part of the VBG guideline 40. magnetic powder test
Inspection procedure and follow-up measures: The magnetic powder test is suitable for the detection
of cracks on the surface of the material and for
Cleaning of the machine. cracks not deeper than 2 mm below the surface.
Visual inspection of critical component areas. Re- The component is first magnetized and then sprayed
cording of all findings. with a liquid containing very fine iron particles (as fine
as dust). The iron particles settle along the cracks
Contacting the manufacturer for a discussion of and make them visible.
the inspection results.
2.5.3 Ultrasonic testing
Planning and execution of necessary repairs.
Stockpiling of damage-prone components. The ultrasonic test can be used for the detection of
defects inside materials of more then 10 mm thick-
Stockpiling of wearing parts. ness and in weld deposits.
Ultrasonic testing can only be performed by qualified
testers.
Qualification: Certificates U 1 and U 2 of the

2.5 Detection of cracks and other defects "Deutsche Gesellschaft zur zer-
storungsfreien
Prufung"
(DGZFP)*.
Cracks and other defects in plates, forged and cast-
steel parts can be detected with the help of test * (German Society for Non-Destructive Testing)
procedures:
2.5.1 Examination for surface cracks with the

dye-penetration test
The dye-penetration test is the simplest procedure to

detect cracks in the surface of the material.
1. Carefully clean the area to be tested.
2. Spray red penetration fluid

(P/N 73171489) onto the area and allow it to
take effect for 5 to 10 minutes.
3. Remove red penetration fluid with a special

cleaner (P/N 73171491).
Page 22
REPAIR WELDING TECHNIQUES
3. Repair welding techniques
The repair of a structural component by welding re-

quires working methods which do not have to be
applied when the steel component is manufactured.
Many of the methods represented have been deve-

loped on the basis of numerous individual exper-
iences and are field-proven.
3.1 Gouging out and welding of cracks
The method best suited for gouging out of cracks is

the so-called "ARC-AIR procedure" (fig. 1).
Fig. 2
A Visible crack
B Damage at the grain boundaries
If the crack is accessible from both sides in out-

of-position work, gouging should first start on the
lower side (fig. 3) with the depth of the groove being
approx. 1/3 of the material thickness.
Fig. 1
An arc is struck between a carbon electrode and the

material to be removed, and a jet of compressed air
directed towards the arc blows away the molten base
metal.
For part nos. of "ARC-AIR carbon electrodes" see

Appendix.
Another gouging method consists in gouging with

oxy-gas or with grooving electrodes.
It is important to start gouging at the end of the crack

and to proceed towards the edge of the component.
Proceeding in reverse order may enlarge the crack
Fig. 3
due to thermal effects.
It can be taken for granted that the crack has already Weld this side first.
progressed along the grain boundaries of the material
where it cannot yet be detected visually or by other The crack is then gouged out from the more easily
test procedures (fig. 2). accessible upper side down to the seam already
Gouging should therefore not start at the end of the welded from the lower side.
crack but shortly before the crack begins.
As a final step, the weld is finished on the upper side
For gouging, preheat the cracked area (cf. 6.1).
(fig. 4).
After thermal gouging, the weld groove is to be re-
worked by grinding.
The surfaces must be cleaned down to the bare
metal.
Page 23
If this procedure is not respected, it may happen that

areas of material between the cracks break away and
that the gaps thus produced cannot be closed.
The same applies to long cracks where gouging out

and welding should equally be done step by step.
(fig. 6).
Fig. 4
So-called "weld-pool backing strips" should not be

used if welding from both sides is possible, as a
backing strip in the root area of the weld represents
a mechanical notch (shape-induced notch).
Ramified cracks
Ramified cracks should be gouged out and welded
step by step (fig. 5).
Fig. 6
During cooling of the partial welds, the surrounding

cold areas prevent excessive welding shrinkage and
distortion of the component.
Fig. 5
Page 24
3.2 Cracks in hub connections
Fig. 7 shows the connection of a hub to a box-type A possible cause is a broken fillet-weld backing.
section which is accessible only from one side.
Counter-measures:
Gouge out the crack carefully (fig. 9).
Weld the gouged joint (fig. 10).
Gouge out the web plate (2) in the area of the
fillet-weld backing round the hub (1) and down to its
collar (fig. 10).
Weld the gouged joint (fig. 11).
Fig. 7
1 Hub
2 Web plate
3 Square-edge butt joint
4 Fillet-weld backing, welded before closing of the
box-type section. Fig. 9
The weld is characterized by a fillet-weld backing on

the outer edge and the chamfered web plate.
The following defects may occur:
3.2.1 Cracking along the center of the seam (fig.

8)
Fig. 10
Fig. 8
Fig. 11
Page 25
3.2.2 Sharp, exactly radial crack along the
unchamfered edge
A possible cause is a lack of fusion in the uncham-

fered edge of the joint (see arrow in fig. 12).
Fig. 14
Fig. 12
Counter-measures:
Gouge out the crack carefully (fig. 13).
Weld the gouged groove (fig. 14).
Fig. 13
Page 26
3.3 Welding on of a metal cylinder by the 3.3.1 Working sequence
back-step technique
1. Position and align the cylinder in accordance
with the drawing. Tack the cylinder solidly on the
The following example describes the welding of a outside and carry out a dimensional check after
machined cylinder onto an undercarriage. tacking.
Welding by the back-step technique can always be

employed where as distortion-free a weld as possible
is required.
This applies to circumferential seams as well as to
longitudinal seams.
Fig. 15 shows how to execute the weld between the

web plate of the cylinder and the base plate.
Fig. 17
2. Welding of the 1st pass from the inner side of
the cylinder (fig. 17).
For this work use rod electrode 3.20 mm.
Weld in accordance with the back-step proce-
dure,
step length: approx. 250 mm
Fig. 15 Fig. 18 shows an example for the back-step

A Outer side of cylinder technique.
B Inner side of cylinder
Welding is carried out in the normal operating posi-

tion.
Welding position: horizontal
Correct positioning of the electrodes avoids defects

from incomplete fusion (9, fig. 16) at the web plate
edges.
Fig. 18
Fig. 16
Page 27
3. Grind weld joint clean working from the cylinder 5. Complete the joint on the cylinder inside (fig. 20).
outside. Remove any slag residues from the 1st
pass and completely grind out any cracked tack Rod electrode 5th and 6th pass: 4 or 5 mm.
welds.
Weld seams as described under 4.
Do not weld over cracked tack welds!
Fig. 20
Fig. 19
6. Clean the weld seams and check for defects.
4. Weld the full seam on the cylinder outside. The
example in fig. 19 shows a cylinder wall thick- 6.1 There must be no undercuts, weld metal
ness of 15 mm. For other plate thicknesses, the pores, arc strikes, end craters, spatter par-
build-up of the weld has to be planned and ticles, slag, etc.
executed accordingly.
6.2 Carry out a dye-penetration test of the sur-
Rod electrode 2nd pass: 3.20 mm face which must be absolutely free from
Rod electrode 3rd and 4th pass: 4 or 5 mm cracks.
Weld all beads in the back-step procedure and 7. Check the dimensions. Irregularities in the plane
stagger starting and end points of each new of the cylinder flange must not be levelled by the
layer. application of heat (danger of distortion due to
weld-induced residual stresses).
Example:
Page 28
3.4 Cracks in box-type sections
Gouging and welding of cracks only from the outside

cannot be recommended.
Welding without backing strips usually leads either to
an incomplete filling of the root area or to a drop-
through at the root (fig. 21).
Fig. 21
In both cases, the mechanical notches in the root

area will lead to the formation of new cracks.
Welding on backing strips introduced through the joint
can equally not be recommended (fig. 22).
Fig. 22
The backing strips will not come to rest properly on

the base metal.
Flashes and slag residues on the under-side cannot

be removed.
The resulting mechanical notches will cause new

damage.
Page 29
3.4.1 Opening of box-type sections
If the crack is accessible only from one side, an Practical hint:
access opening has to be created from the second Ribs are often visible on the reverse side of the
side. This can be done by opening the component in plates.
areas not subject to high stresses (figs. 23 and 24). Especially on painted surfaces they are clearly visi-
ble.
Gouge out the crack first from the inside (over 1/3 of
the plate thickness) and weld. Continue on the out-
side and then reclose the box-type section.
3.4.2 Removing parts of a chord plate by

flame-cutting
Figures 25 to 30 show how a box-type section can

be opened in a way which does not affect the
remaining parts of the component.
The section (1, fig. 25) of the top chord (2) is to be

removed.
Fig. 23
Fig. 25
Cut a pilot hole in the chord plate (2, fig. 26) behind
the web (3) with a flame (4). Flame-cut in longitudinal
direction and as closely as possible to the web plate.
Cutting must be carried out without producing drag

lines in the web plate.
Fig. 24
In larger components there may also be openings

allowing access to the interior of the component. The
size of access openings is approximately 500 mm x
500 mm.
If the internal structure of the component is unknown,
it is advisable to contact the design department.
A drawing showing the location of possibly existing
stiffening ribs inside the box-type section should be
at hand.
Otherwise it may be necessary to cut out small spy-
holes in order to find out the areas in which repair
openings of sufficient size can be created.
Fig. 26
Page 30
Sever the remaining strip of the chord plate (5, fig. Cutting as in fig. 30 leads to unnecessary damage of
27) by flame-cutting from the inside. the web plate (3, fig. 30) (5 = damaged area /
flame-cut area).
Fig. 27
Fig. 30
Flame-cut the welding chamfer required for welding
the new chord plate section (fig. 28).
Welding on backing strips
Openings cut into components in order to gain ac-

cess to the under-side during the welding of cracks
must be carefully reclosed in a workmanlike manner.
Welding of the component is carried out from one
side on backing strips (fig. 31).
Fig. 28
Make the transverse cut in the chord plate by pro-

ceeding from the web plate towards the center and
not - as shown in fig. 29 - from the center towards
the web plate (3).
Fig. 31
The geometry of the weld and the welding sequence

shown are to be carefully observed. Only then can a
welding seam with a relatively low root notch factor
be expected.
It goes without saying that the root notch factor of

such a welding seam has to be compatible with the
selected component area.
This must be examined before opening the compo-
nent.
Fig. 29
Page 31
The same applies basically also to the welding of
T-joints (fig. 32).
Fig. 34
Fig. 32 If the joint is larger than required, welding should
start with a build-up weld on one of the seam edges
The same working method can also be employed if in order to avoid excessive transverse shrinkage.
plates of different thicknesses are welded (figs. 33 After depositing the build-up weld, the gap between
and 34). the seam edges can be completely closed (fig. 35).
The method shown in fig. 33 is, no doubt, the better
solution.
Chamfering of the thicker plate in a 1 : 4 ratio.
Fig. 33
The welding joint must in no case be too narrow, as

the planned welding sequence can otherwise not be
observed. Fig. 35
This applies equally to the welding of T-joints with too
large a groove.
Page 32
3.4.3 Backing strips
Backing strips are mostly made of flat steel 30 x 6 or

25 x 4 (fig. 36).
Fig. 37
Fig. 36
Backing strips for non-linear weld seams are flame-

cut out of plates with the corresponding thickness
(fig. 37) or welded together from pieces of flat steel
(fig. 38). The joints (fig. 38) must be welded and
ground from both sides.
Fig. 38
Page 33
3.5 Recommended groove shapes for manual
welding with electrodes
For repairs or welding work carried out in the field,

the following weld groove configurations should be
preferred.
These groove configurations can be employed for
plate thicknesses up to 30 mm. The dimensions
shown in the drawings are applicable up to this thick-
ness.
For gas metal-arc welding, the weld preparation an-
gle can be reduced to 45o.
For greater plate thicknesses, the weld preparation
angles must be reduced so as to leave a maximum
opening width of abt. 30 mm. Except for the sharp-
edge seam, all grooves should be gouged out, Fig. 41
ground and counter-welded, if possible.
3.5.1 Butt joints
Recommended weld groove shapes:

- V-butt weld (fig. 39)
- Double-V butt weld (fig. 40)
- Single-bevel butt weld (fig. 41)
- Double-bevel butt weld (fig. 42)
- Square-edge butt weld (fig. 43)
Fig. 42
Fig. 39
Fig. 43
Welding Symbol Opening angle

technique EN 24 063
E 111 60
MAGM 135 45
Solid wire 136 45

Fig. 40
Page 34
3.5.2 T-joints
Recommended weld groove shapes:
- Single-bevel butt weld (fig. 44)

- Double-bevel butt weld (fig. 45)
- Square-edge butt weld (fig. 46)
Fig. 45
Fig. 44
Fig. 46
Page 35
3.6 WORKING SEQUENCE FOR WELD 3.6.1.2 Double-V butt weld (fig. 49)
SEAMS Seam accessible from 2 sides
3.6.1 Butt welds

+ easily accessible side
- poorly accessible side
3.6.1.1 V-butt weld (fig. 47)
Fig. 49
A Joint prepared
B Joint welded overhead
C Root gouged out
D Seam welded
Fig. 47
A Joint prepared
B Joint welded Double-V butt weld (fig. 50). Seam accessible
from 2 sides after turning of the component
C Root gouged out from the under-side
D Root capped
V-butt weld (fig. 48). Seam accessible from 2

sides after turning of the component
Fig. 50
A Joint prepared
B Root welded
C Plate turned, root gouged out
Fig. 48
D Seam welded
A Joint prepared
B Joint welded
C Plate turned, root gouged out
D Root capped
Page 36
3.6.1.3 V-butt weld with backing strip 3.6.2 T-joints
V-butt weld with backing strip 25x4 (fig. 51). Seam 3.6.2.1 T-joints (fig. 53), accessible from 2 sides
accessible from 1 side
Fig. 51 Fig. 53
A Backing strip attached A Web and chord plates tacked
B Joint prepared and 1st root bead welded B Single-bevel weld deposited
C 2nd root bead welded C Root gouged out
D Seam welded D Seam welded
V-butt weld with backing strip 30x6 (fig. 52). Seam 3.6.2.2 T-joints with backing strip (fig. 54), acces-
accessible from 1 side sible from 1 side
Fig. 52 Fig. 54
A Weld-backing strip attached A Backing strip welded

B Joint prepared B 1st root bead welded
C Joint gouged out (grinding) C 2nd root bead welded
D Seam welded D Seam welded
Page 37
3.7 Closing of working openings, renewal of component areas
Openings (fig. 55) should be as small as possible but Weld seams [2] and [3] alternately and use the so-
as large as necessary in order to allow the unimped- called "back-step procedure" for the long seams.
ed use of tools.
Back-step welding:
Experience: Openings 300 mm long and 200 mm
high are normally sufficient.
3.7.1 Closing a working opening
Weld seam [4] in the same way as seam [1].
Fig. 55
The following example (fig. 55) is suitable for plate

thicknesses up to 25 mm.
Fig. 56 shows a backhoe stick. The diagram of mo-

ments clearly shows the areas of highest loads and
thus of greatest stresses. Seam [1] is therefore the
seam that lies in the area of high chord stresses.
Weld seam [1] from the middle outwards to the left

and right to the midpoint of the corner curvatures.
Finish upper beads or passes approximately 15 mm
before reaching the end of the underlying bead or
pass. Allow the completed weld seam to cool down
to approximately + 50oC.
Fig. 56
Page 38
3.7.2 Closing a web-plate opening
Fig. 59
Prepare backing strip (3) from flat steel 30 x 4
bent on edge or burn out of 4 mm thick plate. Do
not tack-weld backing strips from flat-steel bars
for lack of cover at the rounded corners.
4. Attach backing strip (3) to the web plate (2) by
means of screw clamps (fig. 60). Do not tack-
Fig. 57
weld but rather weld with a 3 mm fillet seam
1. At the web-plate (2, figs. 57 + 58), chamfer the running all around (fig. 61).
edges to be welded with approximately 10o.
Width b of the chamfer in reldition to the plate
thickness can be seen in fig. 70, page 42.
Fig. 60
After welding the fillet seam, clean the contact
surface for the cover plate by removing all traces
of weld spatter (arrow, fig. 61).
Fig. 58
2. Gouge out the longitudinal seams between chord

plate (1) and web plate (2) over a distance of
approximately 100 mm (fig. 58).
3. Attach backing strip (3, fig. 59), but only to the

web-plate edges.
Fig. 61
Page 39
5. Prepare cover plate (5, fig. 62) for the repair Press cover plate (5, fig. 64) against backing
opening. For this purpose, use a new plate of strip by using screw clamps. In workshops, this
the same thickness and chamfer as shown. can be done with box-type section widths of up
Width (b) can be seen in fig. 70, page 42. to 1.5 m.
Fig. 62 Fig. 64
If the use of screw clamps is not possible, the
6. Attach cover plate (5, fig. 63) and check for cover plate should be fastened by so-called
perfect weld joints. "hold-down strips" (6, fig. 65). Attach the hold-
The cover plate must be in full-face contact with down strip (6) to the web plate (2) with a fillet
the backing strip. weld. Fix the cover plate (5) by driving wedges
In case of distortions due to welding, the backing (7) between plate and strip.
strip has to be straightened.
After welding of the cover plate, remove hold-
down strips by flame-cutting.
Grind welded areas smooth and clean.
Do not knock off hold-down strips with a ham-
mer.
Fig. 63
Fig. 65
Page 40
7. Weld on cover plate (fig. 66).
Fig. 66 Fig. 67
It is essential to observe the welding sequence
shown. The symbols used have the following
meaning:
Weld seam [1] approximately to the midpoint of

the corner curvature. Place the first bead exactly
between cover plate (5) and backing strip (3).
The upper bead must end approximately 15 mm
before the end of the underlying bead. After
welding of seam [1], the cover plate may shrink.
Proceed by welding seams [2] and [3]. Make
sure that the seams interlock properly with the
ends of seam [1] (prepare by grinding). Weld the
other ends through to the chord plate. The end
of seams [2] and [3] at the chord plate are to be
ground as shown in fig. 66, so as to obtain the
same shape of the welding joint as the one
between web and cover plate.
Finish the sequence by welding seam [4]. The

ends of welds [2] and [3] must not come to lie
against interruptions or starting points of seam
[4]. If possible, weld seam [4] with continuous
stringer beads from one end to the other.
Finish by grinding the surfaces of seams [1], [2],

and [3] flush with the adjacent plates (fig. 67).
Page 41
3.7.3 Replacing a chord-plate section
3.7.3.1 Salient chord plate 1. Chamfer welding bevels at 10o. Width b (fig. 69)
In a box-type section with 2 web plates (fig. 68), a can be read from fig. 70 below.
chord-plate section is to be replaced by a new one.
PLATE THICKNESS t CHAMFER WIDTH b
8 2,0
10 2,0
12 2,5
15 3,0
20 3,5
25 4,5
30 5,5
35 6,5
40 7,0
45 8,0
50 9,0
Fig. 70
2. Work out the longitudinal seams between web

plate (2, figs. 68 + 69) and chord plate (1) over a
length of approximately 100 mm from the point
at which the new piece is to be fitted.
Fig. 68
Fig. 71
Fig. 69
Page 42
3. Attach backing strips (3, 4, figs. 72 + 73) at the 5. Weld the backing strips (3, fig. 75) with fillet
two remaining ends of the chord plate (1). Fit the seams to the web plates (2).
plates properly and without any gaps.
Fig. 75
Fig. 72
6. Tack-weld backing strips (4, fig. 76) to the outer
side of web and chord plates.
Fig. 73
For the backing strips (3,4) use flat steel 25 x 4 Fig. 76
mm. Fit backing strip (3) exactly between the
two web plates (2). Adapt external backing strips 7. Tack-weld run-off tabs (5, fig. 77) to backing
(4) to the joints of the web plates (2) and allow strips (4). Cf. also the section "Ends of butt
them to extend outwards by approximately welds".
30 mm.
4. Tack-weld backing strips (3) between the web

plates. If distortion occurs due to welding (fig.
74), the backing strips have to be straightened.
Fig. 77
Fig. 74
Page 43
8. Fit the new piece of chord plate (6, fig. 78). The 10. Weld in the new piece of chord plate by strictly
old piece of chord plate previously removed must observing the welding sequence shown (fig. 80).
not be used again. Make sure that the new piece The symbols have the following meaning:
of plate rests properly on its support.
Seam [1] - transverse seam in the area

subject to high chord-plate
stresses. Weld seam com-
pletely.
Seams [2] + [3] - weld longitudinal seams in

the direction indicated by
Fig. 78 the arrows.
9. Weld the two fillet seams (fig. 79) as shown, Seam [4] - weld transverse seam com-
without interruptions and without any tack points. pletely.
Seams [5] + [6] - weld longitudinal seams in

the direction indicated by
the arrows.
Weld seams [1] and [4] with stringer beads and

continue the weld onto the 50 mm long run-off
tabs (4). Remove the run-off tabs after welding
with a clean cut.
The surfaces of the transverse seams must be

ground clean and flush with the adjacent plates.
Work out properly the longitudinal seams in the
area of the transverse seams. The grinding drag
lines must run parallel to the longitudinal lines of
force. If possible, the transverse seams should
Fig. 79 be subsequently subjected to ultrasonic testing.
Practical hint:
In welding the longitudinal seams [2] [3] [5] and
[6] there must be no welding starts or stops in
the area of the transverse seam (backing strip).
Fig. 80
Page 44
3.7.3.2 Recessed chord plate
The following example shows how to fit a new re- 2. Work out longitudinal seams between web plate
cessed piece of chord plate by welding it into a (2, fig. 83) and chord plate (1) over a distance of
box-type section with 2 web plates (fig. 81). approximately 100 mm beyond the cutting edge
of the chord plate.
Fig. 81
Fig. 83
Working sequence:
3. Attach backing strips (3, figs. 84 + 85) to the two

remaining ends of the chord plate (1).
For the backing strip (3) use flat steel 25 x 4
mm. Fit in backing strip (3) properly and without
any gaps between the two web plates (2).
Fig. 82
1. Chamfer welding bevel at 15o. Width (b, fig. 82)

can be taken in fig. 70, page 42.
Fig. 84
Page 45
5. Weld in new piece of chord plate by strictly

observing the welding sequence shown (fig. 87).
As to the welding of the seams, cf. 10 on page
44.
Fig. 85
4. Tack backing strips (3) between the web plates

(fig. 85 + 86). If there is any distortion due to
welding, the backing strips have to be straight- Fig. 87
ened.
Fig. 86
Page 46
3.7.3.3 Possible causes of damage to chord plates
The following faults may occur in chord plates of Reason for the damage:
box-type sections: There are non-metallic inclusions from the pool (seg-
regation defects), distributed over the entire plate
1. Transverse cracking dimension, at the centre of the plate.
The chord plate may crack open transverse to the Measures:
component in the chord plate.
The plate cannot be repaired by welding.
For durable repairs, the damaged plate must be re-
placed. It is to be assumed that areas of the plate
not yet cracked open would eventually also crack
open as a result of the dynamic stress on the compo-
nent.
3. Longitudinal cracking
The chord plate may crack open in longitudinal direc-
tion of the component parallel to the edge of the
plate (fig. 90).
Fig. 88
Reason for the damage:

Expansion of the component obstructed by non-opti-
mally dimensioned or welded
component elements such as bearing blocks, ribs,
reinforcing plates etc.
Measures:
The component can almost always be repaired by
welding. For a durable repair, the component must
be opened to allow the welds in the component Fig. 90
areas subject to maximum stress to be capped.
Reason for the damage:
2. Plate parting The component is not adequately stable. The chord
The plate may crack open almost exactly at the plate is deformed under changing loads, resulting in
centre of the plate, as shown in the diagram (fig. 89). material distortions at the weld/chord plate transition.
Measures:
The chord plate cannot be repaired by welding.
For a durable repair, the plate must be replaced in
the cracked area. The new plate must be thicker than
the cracked one to reduce deformation to a tolerable
level.
Fig. 89
Page 47
3.7.3.4 Repair of a boom with a salient chord
The top chord of the boom is cracked (arrows, 3. Repair the damage inside the box-type section
fig. 91). and in the side walls.
1. Remove support eye (1, fig. 91). 4. Weld on new top chord (fig. 93). Increase plate
thickness by 5 to 10 mm.
Fig. 91
Fig. 93
2. Remove top chord in the area of damage
(fig. 92). 5. Weld support eye back in place (fig. 94).
Recommendation: Remove the curved section of Machining of the severed parts is generally not
the top chord completely. required if fitting and welding are carried out
carefully.
Fig. 92
Fig. 94
Page 48
REINFORCING OF STEEL COMPONENTS
4. Reinforcing of steel components Thickness of reinforcing plates
The thickness of reinforcing plates should be max.
The reinforcement of components by welding can be 60 % of the thickness of the plate to be reinforced
done in the following ways: (fig. 2).
Covering up a damaged area after repair by re-

inforcing plates, with the aim of reducing the me-
chanical stresses (N/mm2) in the repair area.
Eliminating deficiencies caused by changes in

shape, e.g. the problematic case of "open sec-
tions/closed sections", shape of stiffening ribs,
configuration of frame corners, etc.
Eliminating deficiencies by means of changes in

shape by build-up welding, e.g. on cast-steel
parts.
The necessity of a component reinforcement should,
if possible, have been proved by a simple analysis.
4.1 Reinforcing plates Fig. 2

An analysis shows that thicker reinforcing plates
4.1.1 Dimensions cannot be connected to the plate to be reinforced
Length of reinforcing plates as the welding seams required would be too
The ends of reinforcing plates are places where large.
metallurgical and shape-induced notches occur Thicker plates moreover lead to large shape-in-
which may lead to damage by the concentration duced notches and make the component heavier
of stresses (Part A, fig. 1). than is really necessary.
Width of reinforcing plates
In steel components, stresses are often highest
near the edges. The reinforcing plate should
therefore be as wide as the plate to be reinforced
(A, fig. 3).
Fig. 3
For practical reasons, reinforcing plates of less
than 8 mm thickness can not be chamfered. In
Fig. 1 such cases, the reinforcing plate (B, fig. 3) must
Reinforcing plates should therefore be dimen- be narrower to leave enough space for a fillet
sioned in such a way that they end in areas with weld.
low basic stresses (Part B, fig. 1). The upper edges (arrow, fig. 3) of the plate to be
reinforced and of the reinforcing plate should not
be melted away.
Page 49
4.1.2 Shapes of reinforcing plates
Reinforcing plates should, if possible, have simple Small plate strips, flat-steel or wide flat-steel bars,
shapes with straight edges (figs. 4 + 5). can be more easily fitted and bent (fig. 5).
To relieve the transverse seams of stresses, welding
slots should be provided (fig. 4).
Fig. 6
Fig. 4 Non-linear plate shapes (figs. 7 + 8) are difficult to

manufacture and do not offer any advantages with
Another possibility consists in welding on strips of regard to the distribution of forces.
plate. In this case, the longitudinal seams must be
welded continuously.
Advantages:
The edge zones, where high stresses normally prevail,
are reinforced. Another advantage is the reduction of
weight (fig. 5).
Fig. 7
Fig. 5
Page 50
Fig. 10
The welding seams in the welding slots are ideal

thrust connections between the reinforcing plate and
the plate to be reinforced.
Circular welding holes are disadvantageous (fig. 11):

Fig. 8
4.1.3 Welding slots
In addition to the welding seams along the outer

edges, the seams in welding slots are equally
intended to enhance the connection of reinforcing
plates (figs. 9 and 10).
Fig. 11
Fig. 9
The parts of the seam transverse to the lines of
Finish the ends of the slots by drilling stopper holes forces cannot bear any loads and can therefore not
(fig. 9). be considered for analysis.
Slot width = 2 x plate thickness (fig. 9). The reinforcing plates cross-section is strongly re-
duced.
The hole edges are subject to stress concentrations.
Page 51
4.1.4 Fitting of reinforcing plates After tack-welding, the welded-on stud may only be
knocked off. The area in the base metal where the
Reinforcing plates should be in full-face contact with studs have been removed must be carefully prepared
the plate to be reinforced, i.e. they should lie as by grinding before the slot is welded.
closely as possible against the base plate. The air
gap should, if possible, be nil.
For relatively small components and thin plates, the
reinforcing plates should be squeezed against the
base plate by means of screw clamps (fig. 12).
Fig. 12
For larger components and thicker plates, the
reinforcing plates should be held in place by wedges
(fig. 13).
This is, however, only possible at the edges of plates.
Welding and cutting of the wedge holders must be
done properly. Never knock off wedge holders with a
hammer.
Fig. 14
4.1.5 Weld seams of T-joints
Reinforcing plates in T-joint areas should be welded
in such a way that a connection between all 3 plates
is formed (fig. 15).
Fig. 13
The central area of plates can be pressed into position
by means of bolting (fig. 14).
This is particularly recommended for large plate
sections. The studs can be favourably placed near the
welding slots.
Fig. 15
Page 52
4.2 Shaping plates for repairs
The plates needed for repair or reinforcement pur- Rolling (Fig. 18):
poses can be shaped in different ways. cold shaping;
Problems which may arise in the different shaping no problems to be expected after shaping.
methods:
Edge folding (Fig. 16):
cold shaping;
observe minimum bending radius;
watch for longitudinal cracking in the bending
area.
Fig. 18
Multi-edge bending (Fig. 19):

cold shaping:
cracking at the lines where the tools act on the
plate edges is to be expected;
Fig. 16 chamfer plate edges approx. 2 x 2 mm at top and
bottom after multi-edge bending.
Pressing (Fig. 17):
cold or warm shaping;
with cold shaping, observe minimum bending ra-
dius and watch for longitudinal cracking in the
bending area.
Fig. 19
Fig. 17
Page 53
4.3 Reinforcing by shape improvements Areas where overlapping takes place should be
ground smooth (fig. 21).
4.3.1 End of ribs
The terminal section of ribs ending on highly stressed

parts of components is to be shaped as shown in fig.
20. This applies equally to ribs of minor importance.
Fig. 21
Make sure that the welding seam as such is not

ground off.
4.3.2 Open sections/closed sections
The moment of torsion resistance of a closed section

is approximately 500 times greater than that of an
open section of otherwise similar dimensions.
This leads to stress peaks in the zone of transition
from the opened to the closed section. These peaks
are caused by deformation impediments and con-
straints (fig. 22).
Fig. 20
t a h R e L1 L2
o
mm mm mm mm mm mm mm
6 4 6 10 60 20 30 12
8 4 6 10 60 20 30 12
10 4 6 10 80 20 30 12
12 5 8 10 100 20 40 14
15 6 9 10 120 30 50 18
20 8 12 10 160 30 60 22
26 8 12 10 180 30 70 22
30 10 15 10 200 30 70 28
Fig. 22
T Torsional moment
O Open section
G Closed section
Page 54
Therefore, it is required to have a gradual transition 4.3.3 Reinforcing by build-up welding
from the open to the closed section (fig. 23).
The effects of notches in steel components can be
eliminated or at least mitigated by build-up welding.
Such work presupposes expert planning and careful
workmanship (fig. 24).
Fig. 23
The area of transition is to be welded around
continuously.
Fig. 24
Page 55
4.3.4 Improvement of curved sections in ribs
Fig. 25 shows a rib contour with too high stresses in Subsequently, a new and better contour can be pro-
the marked area. duced by flame-cutting (fig. 27). In doing so, make
sure that the torch guidance unit is absolutely stable.
Fig. 25
Fig. 27
To improve this situation, weld on a plate of the
same thickness (fig. 26) and observe the welding 1 Flame-cut here
sequence as represented in the cross-section.
Grind flame-cut edge smooth and work out the new
contour (fig. 28).
Fig. 26
1 Weld joint prepared
2 First side welded Fig. 28
3 Back of first side gouged to sound metal 2 Grind here
4 Second side welded
5 Faces of welds ground smooth Reworking facilitates the gradual and continuous flow
of component forces.
Page 56
MATERIALS, FILLER METALS FOR WELDING
5. Materials, filler metals for welding
5.1 Materials in welded components

The material properties cannot be determined by
simple hardness measurements or even by a
Before welding, gouging, warm or cold bending and spark test. Such testing methods lead to wrong
heat treatments, the person carrying out the repair conclusions.
must be familiar with the material of the component.
After this, the filler metals suited to the materials can

At least the following information should be available: be selected. For the selection of filler metals, the
person carrying out the repair should seek advice
- strength class from the manufacturer of the machine or the supplier
- state of heat treatment of filler metals. Recommendations can also be found
- chemical analysis reference data; carbon in the catalogues of the filler metal manufacturers.
equivalent
- material thicknesses
The repair measures to be carried out depend essen-

tially on the above data.
These can be found in drawings and parts lists.
The operator of a machine can obtain the required

information from the manufacturer.
In case of scheduled repair work, the type of material

can also be determined in a materials testing labora-
tory.
Page 57
5.1.1 Component materials
Materials for welded components Plate Plate

in construction machinery and
mining equipment
Standard designation: EN 10025 - S275JRG2 (ex. St37-2) EN 10025 - S355J2G3 (ex. St52-3)
Trade name: - -
Delivery specification: - LV 2 293 157
Description of material Fine-grained structural steel Fine grained structural steel

weldable weldable
normalized normalized
killed double killed
Heat treatment state: normalized or in an equivalent state attained by normalizing rolling
Mechanical and technological

properties (reference values):
Tensile strength Rm N/mm2 340 - 470 490 - 630

Hardness B.H.N. B.H.N. 140 190
Yield strength Rel N/mm2 >
_ 265 >
_ 345
Elongation A % >
_ 26 >
_ 22
Impact energy Av Joule _ 27 J ISO-V + 20oC
> _ 27 J ISO-V - 20oC
>
Chemical composition: EN 10025, table 3
Processing characteristics:
Welding: Highly suited; cf. 1.5.8 and 6.1. Highly suited; cf. 1.5.8 and 6.1.
Warm bending: Possible at temperatures between Possible at temperatures between

400 and 850oC. 400 and 850oC.
Cold bending: Possible, but observe DIN 18800, Possible, but observe DIN 18800,
Part 1. Part 1.
Additional information about Used only for subordinate welded Abt. 95 % of the load-bearing
material; valuable for practical components. components are made of this
repairs: Not used in load-bearing material.
components.
Filler metals See page 61 See page 61
Page 58
Plate Plate Plate
DIN EN 10113-2-S460N(ex.St E460) EN 10037 - S690QL(ex.St E690) Wear plate 500 HB LV 2 270 002
Fine-grained structural steel Fine-grained high strength structural Fine-grained structural steel high
steel strength
weldable weldable weldable
normalized quenched and tempered quenched and tempered
Normalized or in an equivalent state quenched and tempered in fluid quenched and tempered in fluid
induced by normalizing rolling
550 - 720 790 - 940 1550

210 ~ 300 ~ 450 - 540
460 >
_ 690 >
_ 1300
17 >
_ 16 >
_8
_ 40 J ISO-V - 20oC
> _ 27 J ISO-V - 40oC
> _ 20 J ISO-V - 10oC
>
See DIN EN 10113-2 See EN 10037 See manufacturers instructions
Weldable; see 1.5.8 and 6.1 Readily weldable; see 1.5.8 and 6.1 Weldable as wear protection;
preheating to + 100C (212F)
Possible at temperatures between Not possible without postweld Not possible
400 and 850C (752 - 1471F) quenching and tempering
Possible, but observe DIN 18800, Possible by rolling Possible with very large radius by
Part 1 rolling (plate thickness)
Used mainly for hubs on equipment Used for wear-prone parts, e.g. Wearing plates welded onto
for construction machinery excavating tools, blades, wearing excavating tools
edges
See page 61 See page 61 See page 61
Page 59
Materials for welded components Cast steel Cast steel

in construction machinery and
mining equipment
Standard designation: SEW 685 - GS-21Mn5V(ex. GS-52.3V) DIN 17205 - GS - 25 CrMo4V II

Trade name: SEW 520 - GS - 18 NiMoCr36V
Delivery specification: LV 2 102 375 SEW 520 - GS - 22 NiMoCr56V
ESCO - cast steel
Description of material Cast steel Cast steel

weldable
quenched and tempered
Heat treatment state: quenched and tempered in fluid quenched and tempered in fluid
Mechanical and technological

properties (reference values):
Tensile strength Rm N/mm2 480 - 620 850 - 1000

Hardness B.H.N. B.H.N. ~ 180 ~ 300
Yield strength Rel N/mm2 >
_ 340 >
_ 750
Elongation A % >
_ 20 >
_ 10
Impact energy Av Joule _ 35 J ISO-V - 50oC
> _ 27 J ISO-V - 20oC
>
Chemical composition: SEW sheet See manufacturers instructions
Processing characteristics:
Welding: Readily weldable. See 1.5.8 and 6.1 Readily weldable. See 1.5.8, 1.5.9
and 6.1
Warm bending:
Cold bending:
Additional information about Together with plate St 52-3 in Adapters, corner blades; almost all
material; valuable for practical plate/cast steel composite cast wearing parts
repairs: constructions
Filler metals See page 61 See page 61.
Page 60
5.2 Filler metals for welded components depending on partner materials and welding techniques
Part nos. for filler metals are listed in the appendix.
Material 1 Material 2 Gas-shielded welding Arc welding

Designations Designations, standards EN 24063: 135 EN 24063: 111
Standard and delivery instructions Standard designations Standard designations
Delivery instruction as for Material 1 Trade names
S235JRG2 S235JRG2 EN 440: G 38 4 M G3Si1 EN 499: E 38 2 RA 22

DIN EN 10025 S355J2G3 AWS A5.18: E 70S-6 AWS A 5.1: E 6013
GS-21Mn5V EN 439: M21 (shielding gas)
(ex. St37-2) S460N (ex. DIN 8559: SG2) (ex. DIN 1913: E 4332 AR7)
S355J2G3 S355J2G3 EN 440: G42 4 M G4Si1 EN 499: E 38 4 B 42
DIN EN 10025 oder GS-21Mn5V AWS A5.18: E 70S-6 AWS A 5.1: E 7018
LV 2 293 157 S460N EN 439: M 21 (ex. DIN 1913: E 5154 B 10)
(ex. St52-3) S690QL (ex. DIN 8559: SG3)
GS-25CrMo4V II
GS-22NiMoCr56V
GS-18NiMoCr36V
ESCO cast steel, blade
Wear plate 500 HB
S460N S460N DIN 8575: SG CrMo1 DIN 8575: ECrMo1 B 20
DIN EN 10113 Part 2 S690QL AWS A5.28: ER 80S-G AWS A 5.5: E 8018-C1
(ex. StE460) GS-25CrMo4V II EN 439: M21
GS-22NiMoCr56V
GS-18NiMoCr36V
Wear plate 500 HB
S690QL S690QL EN: not standardized EN 757: E 69 5 Mn2NiCrMo B 42
DIN EN 10037 GS-25CrMo4V II Trade names: AWS A 5.5: E 110-18M
(ex. StE690) GS-22NiMoCr56V UNION NiMoCr
GS-18NiMoCr36V NiCrMo 2,5-IG
Wear plate 500 HB AWS A 5.28: ER 110S-G
EN 439: M21
GS-21Mn5V GS-21Mn5V EN 440: G 42 4 M G4Si1 EN 499: E 38 4 B 42
SEW 685 and S355J2G3 AWS A 5.18: E 70S-6 AWS A 5.1: E 7018
LV 2 102 375 S460N EN 439: M21 (ex. DIN 1913: E 5154 B10)
(ex. GS-52.3V) S690QL (ex. DIN 8559: SG3)
GS-25CrMo4V II GS-25CrMo4V II EN: not standardized EN 757: E 69 5 Mn2NiCrMo B 42
and modifications Trade names: AWS A 5.5: E 110-18 M
DIN 17205 and UNION NiMoCr
LV 262 480 NiCrMo 2,5-IG
AWS A 5.28: ER 110S-G
EN 439: M21
GS-22NiMoCr56V GS-22NiMoCr56V EN: not standardized EN 757: E 69 5 Mn2NiCrMo B 42
and modifications Trade names: AWS A 5.5: E 110-18 M
SEW 520 UNION NiMoCr
NiCrMo 2,5-IG
AWS A 5.28: ER 110S-G
EN 439: M21
GS-18NiMoCr36V GS-18NiMoCr36V EN: not standardized EN 757: E 69 5 Mn2NiCrMo B 42
SEW 520 Trade names: AWS A 5.5: E 110-18 M
UNION NiMoCr
NiCrMo 2,5-IG
AWS A 5.28: ER 110S-G
EN 439: M21
ESCO cast steel S690QL EN 440: G 42 4 M G4Si1 EN 499: E 38 4 B 42
Adapter AWS A 5.18: E 70S-6 AWS A 5.1: E 7018
EN 439: M21 (ex. DIN 1913: E 5154 B10)
(ex. DIN 8559: SG3)
ESCO cast steel S690QL EN: not standardized EN 757: E 69 5 Mn2NiCrMo B 42
Corner blade Trade names: AWS A 5.5: E 110-18 M
UNION NiMoCr
NiCrMo 2,5-IG
AWS A 5.28: ER 110S-G
EN 439: M21
Page 61
Examples of the meaning of designations of filler metals for welding:
Rod electrode
EN 499 : E 38 4 B 4 2
Design. of welding pos.; here: all positions except vertical-down weld

Code no. for type of current; here: direct current
Code letter for coating; here: basic
Code no. for minimum impact energy; here: >

_ 47 joules at - 40C (100F)
_ 380 N/mm2
Code no. for minimum yield strength; here: Rel = >
Code letter for welding technique; here: arc welding, 111
Number of European Standard
European Standard
Former designation: DIN 1913: E 5154 B 10
Welding wire
EN 440 : G 42 4 M G4Si1
Code no. for chemical composition of weld metal
Code letter for inert gas; here: mixed gas EN 439: M 21
Code no. for minimum impact energy; here: >

_ 47 joules at - 40C (100F)
_ 420 N/mm2
Code no. for minimum yield strength; here: Rel = >
Code letter for welding technique; here: metal-inert-gas (MIG) method, 135
Number of European Standard
European Standard
Former designation: DIN 8559: SG 3
Page 62
HEAT TREATMENT OF MATERIALS
6. Heat treatment of materials
The repair of steel components often requires the

use of heat. The instructions on the input of heat with
regard to the materials and working methods used
are to be observed.
6.1 Preheating for tacking, welding, gouging

and flame-cutting
Preheating for tacking, welding, joining and flame-
cutting is necessary for two main reasons:
It prevents heat from dissipating too fast from the Fig. 2
heat-affected zone. The prolonged cooling time
achieved prevents the formation of hard and brittle Butt joint (Fig. 3)
structural states.
Moisture is dried out in the welding area. The Heat dissipation two-dimensional.
penetration of detrimental hydrogen and oxygen Rapid heat dissipation due to large component cross-
via the arc into the liquid weld pool is avoided. sections.
Influence of wall thickness and of weld joint

When preheating components for welding, the quan-
tity of heat to be applied depends on the dimensions
of the component and on the weld joint.
T-joint (Fig. 1)
Heat dissipation three-dimensional.
Very rapid heat dissipation due to large component
cross-sections.
Fig. 3
Butt joint (Fig. 4)

Heat dissipation two-dimensional.
Gradual heat dissipation due to small component
cross-sections.
Fig. 1
T-joint (Fig. 2)
Heat dissipation three-dimensional.
Gradual heat dissipation due to small component
cross-sections.
Fig. 4
Page 63
Prevention of hardness peaks

The formation of structural states which are undesira- The preheating temperature depends primarily on the
ble due to being too hard and brittle is avoided by material, the shape and thickness of the component,
preheating. the welding technique and the climatic influences.
During repair work, it is absolutely essential to ob-

serve the temperatures specified in the following list.
Fig. 5
1 Hardness, non-admissible*
2 Hardness, admissible*
3 Hardness in base material, heat-affected, without
preheating
4 Hardness in base material, heat-affected, with
preheating
5 Weld metal
6 Base material, not affected by heat
7 Hardness series
HV Hardness
* depending on material
Page 64
Preheating and interpass temperatures; heating-up and cooling-down rates when repairing by welding
Non-alloyed structural steels in normalized state as per DIN EN 10025 or LV 2 293 157, such as
S355J2G3 (ex. St52-3) and S235JRG2 (ex. St37-2).
Max. heating-up rate, reference value + 50C/h (120F/h)

Min. preheating temperature for tacking and welding:
Wall thicknesses < 25 mm + 20C (70F)
Exceptions:
- Component temperature below +20C + 100C (210F)
- Ambient temperature below +10C + 100C (210F)
- Component wet, moist or dewy + 100C (210F)
Wall thicknesses >
_ 25 mm + 100C (210F)
Max. interpass temperature during welding:
All wall thicknesses + 250C (480F)
Min. preheating temperature for flame-cutting and gouging:
Wall thicknesses > _ 80 mm + 100C (210F)
Max. cooling-down rate, reference value:
All wall thicknesses + 50C/h (120F/h)
Hot-rolled products made of weldable fine-grain structural steels as per DIN EN 10113, part 2, such
as S460N (ex. StE460).

Wall thicknesses >_ 25 mm + 100C (210F)
High-strength fine-grain steels quenched and tempered in fluid as per SEW 090, part 1, such as
S690Q and S690QL (ex. StE690).

Page 65
Wear plates 500 HB as per delivery instruction 2 270 002, such as HARDOX 500, DILLIDUR 500V,
XAR 500.

Steel castings with a high impact strength at low temperature, quenched and tempered, with good
weldability as per SEW 685 and LV 2 102 375, such as GS-21Mn5V (ex. GS-52.3V).

Heat treated steel casting for castings as per DIN 17205 and LV 262 480, such as GS-25CrMo4V II
and modifications.
High-strength steel casting with good weldability as per SEW 520 and LV 943 661, such as
GS-22NiMoCr56V and modifications.
ESCO steel castings as per ESCO specifications.

Page 66
Preheating procedure: Temperature measuring
For preheating purposes, the heat must be applied at Measuring points for measuring the preheating tem-
a heating-up rate of 30 to 50C/h (90 to 120F/h). perature and the interpass temperature.
This can be done by one of the following methods:
Key:
Electric heating mats
If the fastening elements for the heating mats Tv = preheating temperature
have to be welded to the component, the
Tz = interpass temperature
welding areas must be locally preheated. After
removal of the fastening elements, the welding t = thickness of component
areas must be ground to eliminate any micro-
cracking in the component material. Preheating temperature
Measuring point: 4 x t measured from the centre of
Gas jets the weld.
Gas jets must be applied to the component in
such a way that there is no risk of the compo- Measuring time: before tacking and welding.
nent being locally overheated. It may be nec-
essary to protect the component from over- Interpass temperature
heating by using heat buffer plates.
Measuring point: 30 mm beside the centre of the
Gas burners weld or 30 mm beside the centre
Gas burners must burn with a gentle, of the last bead
low-oxygen flame. The gas flames must not
Measuring time: not less than 2 minutes after arc
contact the component because of the risk of
welding.
local overheating. The component must be
protected from overheating by using heat
buffer plates.
In all heating procedures, the component must be

covered with insulant mats to prevent excessive heat
dissipation into the environment.
The cooling-down process after welding must not be
accelerated with compressed air, draughts or water.
The weld area must cool down gradually, depending
on material (see data) at a rate of 30 to 50C/h (90
to 120F/h) to room temperature RT = 20C (70F).
For cooling-down purposes, the components must be
covered with insulant mats.
Important: For technical and economic reasons it is
advisable to carry out repair welding with a duration Fig. 6
covering more than one shift with the necessary
preheating and controlled cooling-down continuously,
i.e. in one working operation (day shift - night shift
etc.) If the welding is done only during the day shift,
for example, careful cooling-down to RT and heating-
up to the prescribed preheating temperature must be
assured.
Page 67
6.2 Hot bending of plates 6.4 Stress-relief annealing of steel components
For practical repairs, stress-relief annealing is hardly
Under the influence of heat, steel loses the mechano- ever necessary.
technological properties that it possesses in the cold
state. This characteristic can be used for hot bend- If a component is to be stress-relief annealed after
ing. repair or reinforcing, some fundamental rules are to
be observed.
The ideal hot-bending temperature lies between 800 Details of the process are to be discussed with the
and 850oC (1470 - 1560oF) when the material is in annealing workshop before annealing.
the state of red heat.
In practical repairs, only normalized plate qualities, Machined surfaces are to be measured before
such as S275JRG2, S355J2G3, can be treated by and after the annealing process. Distortion due to
hot bending. annealing is to be reworked.
Quenched and tempered steel plates can only be Machined surfaces are to be protected before
treated by cold bending or at temperatures between annealing against the formation of scale by apply-
400oC (750oF) and 550oC (1020oF). ing suitable protective coatings.
Quenched and tempered steel plates, such as
S690Q, would be overdrawn at abt. 800oC (1470oF) For pressure compensation purposes, hollow sec-
and lose their mechano-technological properties. This tions are to be provided with drill holes before
would require requenching and retempering which is annealing takes place. Hole diameter 4 mm.
hardly practicable in field repairs.
Annealing parameters:
Normalized or quenched and tempered steel plates
must by no means be treated by cold bending in a - Annealing temperature for normalized materi-
temperature range of abt. 100 to 350oC (210 - als 580oC + 20oC (1080 + 70oF)
610oF), as in this so-called blue-heat temperature
range the material is brittle and tends to the forma- - Annealing temperature for quenched and
tion of cracks in the bending area. tempered materials 30oC (90oF) below temper-
ing temperature. This value can be taken from
the relevant standards or the material certif-
6.3 Hot straightening of plates icates.
As a rule, the annealing temperature is 530 to
550 oC (990 - 1020oF).
Plates can be straightened in a cold and warm state. - Heating and cooling should take place at a
rate of around 50oC/h (120oF/h). The furnace
In cold straightening, the deforming forces required may be at a temperature of 150oC
are exerted from the outside by means of tools, such (300oF)when the component is inserted. It can
as presses or rolls. be opened after cooling when the temperature
is 150oC (300oF). Final cooling can then take
Hot straightening makes use of the interaction pro- place in calm air.
duced by the local input of heat:
- The holding time at annealing temperature in
Elongation of the material in the warmed-up area, the furnace should be 2 min. per mm of wall
upsetting of the warm material at the transition to the thickness, but not less than 1 h.
cold area, shrinkage of the warmed-up area and
straight stretching by internal stresses.
The material should be warmed up to red heat if

efficient straightening is to be achieved.
Here again the material quality is to be taken into
consideration. Only normalized plates can be bent in
a hot state without the loss of mechano-technological
properties.
In hot bending of quenched and tempered plates,
quality losses in the heated areas must be reckoned
with.
Page 68
6.5 Stress-relieving of steel components 6.5.2 Peening of weld seams
As a stress-relief annealing of repaired components Shrinkage impediments produced during cooling of

is feasible only in rare cases and as machined sur- the weld seam may lead to high internal stresses
faces may lose their dimensional accuracy in the (tensile stress) and to cracks. Unimpeded shrinking
annealing process, it is necessary to take other mea- may produce material deformations (angular shrink-
sures for the reduction of stresses. age).
Both these undesired conditions can be remedied by
6.5.1 Warming of components peening.
One means of reducing high local internal stresses, 6.5.2.1 Method of peening
which may occur, for example, after build-up welding
or weld seam repairs, consists in stress relieving of Peening is performed after completion of a weld pass
the component area concerned. which may also consist of several weld beads. Peen-
ing of individual beads of a pass is not allowed.
The area around presumed stress concentrations
must be heated up to 250 to 300C (480 to 570F). During peening, the temperature of the weld seam
Electric heating mats, gas jets or gas burners can be should be below 200oC (390F/h). Except for root and
used as sources of heat. cover passes, all weld passes are to be peened.
Before peening, all traces of slag and spatter on the
Heating up must be done at a rate of approx. 30C/h weld seam are to be removed. Inadmissible eleva-
(90F/h). tions, notches and pores are to be properly elimi-
nated.
For simply designed components with a wall thick-
ness of less than approx. 25 mm, a retaining period The peening chisel has to be run two to three times
of 3 h is sufficient. For more compact components over the same area of the weld seam at a speed of
with wall thicknesses of more than approx. 25 mm, a abt. 100cm/minute. Peening must not produce any
retaining period of 5 h is necessary. sharp notches, grooves and material overlaps. The
surface of the weld pass is to be uniformly treated by
Cooling-down must be done at a rate of approx. peening.
30C/h (90F/h).
The component must be covered with insulant mats

throughout the heating-up process.
The temperature differential in the component, e.g.
between high-volume and compact areas and thin-
walled, ribbed areas must not exceed 50C (120F).
Page 69
6.5.2.2 Peening tools
Peening is to be carried out by means of com-

pressed-air operated riveting hammers and flat
chisels with suitably shaped cutting edges.
The riveting hammers must be of handy shape and

equipped with a throttle valve to reduce the impact
rate.
The hammers must be equipped with a chisel guide

in the direction of impact.
The edges of chisels should have shapes such as

shown in fig. 7 and be hardened.
Fig. 7
Material Chisel Riveting hammers
Yield strength Width of No. of strokes Length Piston Stroke Air con- Pressure Impact
of weld cutting edge per min. without length sumption force
material b tool
N/mm2 mm mm mm mm l/min. bar N
450 to 530 23 1700 +

_ 10 % 270 25 50 350 6 300
to to to to
600 to 700 18 325 30 100 550
Table 1: Technical data of suitable riveting hammers. The width of chisels depends on the yield strength of
the weld metal.
Page 70
6.6 Treatment of filler metals
Filler metals, such as rod electrodes, welding wire Rust, a chemical compound of iron and oxygen, intro-
coils, welding powder and welding rods, must be duces unwanted amounts of oxygen into the weld
stored so as to prevent them from deteriorating. metal, with the result that the material gets brittle.
This is only possible in heated rooms at abt. 30C
Corroded welding wire contaminates the wire guide
(90F) and a relative humidity of below 50 %.
tubes. This leads to an earlier wear of these ele-
ments.
The packages must remain closed until the material
is used. Unused filler metals must be repacked and Corroded welding wires and welding rods therefore
brought back into the storage room. have to be discarded.
6.7 Temperature monitoring

Why is this necessary?
For temperature monitoring during heat treatment
Coatings of rod electrodes or welding powders processes, the following equipment is recommended:
used for submerged-arc welding are hygroscopic,
i.e. they absorb ambient humidity. Without protec-
Electrical temperature probes:
tion, these materials get moist or even wet. Dur-
ing welding, the hydrogen and oxygen contained These are easy to handle and provide an exact
in the water penetrate into the weld metal and temperature reading on an analog or a digital
make it brittle. display.
Rod electrodes from new or already opened pack-
ages must be redried and stored in a heated box Manufacturers of rod electrodes issue instructions for
until they are used. redrying.
Manufacturers of rod electrodes issue instructions for
redrying. Adherent thermometers:
Reference values for electrodes with coating type B: Thermometers with an analog display, which are
attached with magnets to the component.
2h at 350C (660F)
3h at 250C (480F)
4h at 200C (390F) Temperature-indicating crayons:
There is often a failure to take this tiresome but These crayons are used to make a mark on the
necessary action. component to be heated. When the desired tem-
perature range is reached, the colour of the mark
Assistance is now offered by the manufacturers of changes.
rod electrodes.
In principle, this procedure is very simple.
The rod electrodes are supplied in site-resistant,
It requires, however, some experience with the
moisture-impermeable special packs.
crayons to perceive the changing of the colour.
Redrying and keeping warm are no longer necessary
if the rod electrodes are used within 8 hours (1
working shift) of the pack being opened. Hydrogen
content < 5 ml/100 g weld metal.
One box (package) therefore contains a number of
individual packs suitable for use by one welder. The
rod electrodes are vacuum-packed firmly together in
shrink film.
Single rods must not be movable if the packaging is
intact. Prior to opening the pack, it must have been
brought to the ambient temperature at the application
site.
Wet rod electrodes must be destroyed. In spite of
redrying they can never again be used for welding.
Wet welding wires or welding rods are subject to

corrosion. The copper coating offers only a
temporary protection against corrosion.
Page 71
COLD BENDING OF PLATES
7. Cold bending of plates
Plates can also be treated by cold bending. They depend on the thickness of the plate and the
direction of rolling. The minimum bend radii trans-
In cold bending, it is important to observe the mini- verse to the direction of rolling are more favourable
mum admissible bend radii in order to avoid cracks at than those in the direction of rolling.
the edges of the bending areas.
The minimum bend radius is also influenced by the
The bend radii can be taken from the relevant stan- welding suitability in the bending area. Due to grain
dards for the different plate materials. coarsening and the ensuing embrittlement of the ma-
terial during heating after excessive cold bending, the
minimum bend radii in accordance with DIN 18800,
Part 4, must be observed.
Page 72
BUILD-UP WELDING
8. Build-up welding
The purposes for which build-up welding can be used The welding sequence depends on the hole diameter
are manifold. Build-up welding constitutes an impor- and the possibility of handling the component (figs. 2
tant aid in repair practice. and 3).
8.1 Addition of missing / worn-out material
The addition of material may be necessary due to

wear, deformation, distortion or handling errors during
machining.
Like any other welding, build-up welding, too, re-

quires proper planning of the welding technique and
meticulous execution of the practical work.
The mechano-technological properties of the weld

metal are to be adapted to the requirements of the
base metal.
8.1.1 Build-up welding in drill holes
Before carrying out build-up welding, the worn-out

drill hole is to be enlarged by approximately 4 mm (2
mm cutting depth) either on a horizontal boring ma-
chine or by manual grinding.
This is necessary if the new surface of the drill hole
is to coincide after build-up welding and machining
Fig. 2
with the homogeneous weld metal deposit and not
with the relatively hard heat-affected zone.
The build-up weld must have a sufficient thickness so
as to obtain a "clean" drill hole surface.
Fig. 3
For smaller diameters it is common practice to weld

the beads parallel to the holes longitudinal axis. In
Fig. 1
large holes, the weld metal can be deposited as a
The individual working steps are shown in fig. 1: continuous, spiral-welded bead.
1 worn-out hole
2 hole enlarged by drilling
3 steel rings tacked to component as run-off tabs
4 build-up weld
5 run-off tabs removed and hole machined to fi-
nished size
Page 73
BUILD-UP WELDING
Fig. 4 demonstrates the recommended welding se- 8.1.2 Build-up welding on worn-out threads
quence by means of a practical example. Hole (B) of (fig. 5)
a shovel stick is to receive a new surface by build-up
welding. After welding the lower half of the hole, the
stick is turned over.
Fig. 5
Before carrying out build-up welding, the worn-out

damaged thread must be cut away on a lathe. The
Fig. 4 diameter of the shank is to be abt. 4 mm less than
the core diameter.
Run-out grooves are to be provided in order to en-
sure that the new contours are located in the homo-
geneous area of the weld metal.
The shank has to be prolonged with a backing strip
on which the individual weld beads are to end.
If possible, build-up welding is to be performed on a
device with which the component can be rotated.
The shank can be produced by machining.
Page 74
BUILD-UP WELDING
8.2 Correcting of component shapes to 8.3 Build-up welding as a protection against
improve the flow of forces wear
Shape-induced notches detected in steel components Component surfaces subject to heavy wear can be
can be removed by build-up welding. protected by welding on wear-resistant materials. For
details see chapter 9 "Wear protection".
This requires particularly careful work in order not to
produce even more detrimental metallurgical notches
removing the shape-induced notches.
Example:
Taper between thick and thin plate in the edge zones
of the component (fig. 6).
Fig. 6
The surfaces must be ground absolutely smooth and

clean, and all grinding drag lines must run parallel to
the lines of force.
Page 75
WEAR PROTECTION
9. Wear protection (hard-facing ) 9.2 Build-up welding of wear protection layers
9.1 Fundamentals Wear-prone areas are protected by the application of

a wear-resistant weld overlay.
Component surfaces subject to strong wear can be
given a protection by welding wear-resistant material
onto these surfaces. Depending on the conditions of use, the choice is
between a weld metal of high toughness and good
The need to provide wear-protection should be impact resistance on the one hand and greater sur-
known before the machine is put into operation. face hardness on the other.
If the component is to be hard-faced after putting into Another important factor to be considered for rework-
operation, the wear-protection must be applied in ing is the materials suitability for being welded out of
time, i.e. before the base material itself begins to position.
show signs of wear. A component with worn load-
bearing elements can no longer be protected properly
against wear. An excellent weld metal for this purpose is one con-
taining chromium, tungsten and niobium carbides em-
The wear protection is not durable, but is also subject bedded in a tough matrix and offering at the same
to wear and tear. Due to the particular metallurgical time good resistance to abrasive wear and sufficient
properties of the hard-facing materials, the rate of resistance to impact.
wear is, however, considerably reduced.
Such weld metal has a cumulative hardness of abt.
The wear protection system must be regularly in- 59 to 61 HRC. For higher values of impact strength,
spected and carefully maintained. it is advisable to choose another weld metal with a
It is therefore advisable to provide for regular rework- lower hardness of abt. 54 to 56 HRC.
ing during machine standstill periods or for a timely
replacement of worn-out components. The hard and not very tough weld metal tends to
form hairline cracks on its surface which are pro-
Reworking of used components can then be per- duced by surface stresses (fig. 1).
formed in a workshop where more time is available.
An attentive and well-trained repair staff can contri-

bute considerably towards achieving high machine
availability.
In the following chapters several wear protection sys-

tems are discussed. The question of which system is
to be applied can be answered only by taking the
specific conditions of use into account. A good de-
cision can be taken only by weighing up and evaluat-
ing the advantages and disadvantages of the sys-
tems.
Fig. 1
In order to prevent the cracks from running through

into the base material, a so-called buffer layer must
be provided for in case of components subject to
alternating or pulsating loads.
Areas subject to particularly high stresses, such as

the side cutting edges of excavating tools, should
even be protected by 2 buffer layers (fig. 2).
Page 76
WEAR PROTECTION
As to the arrangement of the welding spots, it is

important to take account of the direction of flow of
the medium causing the wear (fig. 5).
Fig. 2
The hard-facing build-up weld must always lie exactly

on the buffer layer in order to avoid the risk of cracks
Fig. 5
in the base metal (fig. 2).
Incorrect placing of the spots may lead to scoring

between the rows of spots.
Criss-cross pattern. The criss-cross pattern is to be

applied on smaller surfaces subject to high wear.
On a criss-cross pattern, soft loading material can be

deposited in the intermediate spaces and thus pro-
vide an extra wear protection for the base metal
(fig. 6).
Fig. 3
9.2.1 Build-up welding patterns
Spot pattern. The spot pattern is suitable for large

areas which are subject to a relatively low risk of
wear (fig. 4).
Fig. 6
Fig. 4
Page 77
WEAR PROTECTION
Full-face build-up welding 9.3.2 For hard-facing layers
Only for gravity position welding, e.g. original

Relatively small areas subject to heavy wear are hard-facing in the workshop:
hard-faced by a full-face build-up weld.
This ensures full-face protection of the base material
Wire electrodes:
(fig. 7).
DIN 8555 : MF 10 - GF - 60 - RT
filler wire 2 mm
P/N 73171549
Reference analysis:
C Cr Nb Si Mn
5.0 22.0 7.0 0.5 0.7 %
Rod electrode
DIN 8555 : E 10 - UM - 60 GRZ
5 mm x 450 mm
P/N 73171538
Reference analysis:
Fig. 7 C Cr Nb V Mo W
9.2.2 Special hints 5.0 22.0 8.0 1.5 8.0 2.5 %
Before carrying out build-up welding, the base

materials are to be preheated depending on their For out-of-position welding, e.g. subsequent hard-
material properties. facing in the field:
During welding, the interpass temperature is to be
kept below 250oC (480oF). Rod electrode:
DIN 8555 - E 6 - UM - 60 P
basic-type coating
Build-up welding should be used only for the pro- alloyed core wire
tection of base materials with a hardness not P/N 73171539
exceeding a B.H.N. of abt. 300. Trade name: EA 600 Kb : VALCO Dusseldorf

Due to the welding heat introduced, build-up weld-
ing on base materials of greater hardness causes Reference analysis:
microstructural transformations in zones of the
material close to the surface, with the result that C Cr Si Mn
hardness diminishes considerably.
0.5 6.0 1.3 1.3 %
Another consequence is the formation of high internal
stresses in the base material.
Only tough base materials can deal with these inter- Key:
nal stresses, such as materials with a max. B.H.N. of
300 . R = rust-proof
Z = heat-resistant
9.3 Filler metals P = impact-resistant
UM = coated
9.3.1 For buffer layers MF = metal-arc welding with filler wire
GF = flux-filled
Rod electrodes: T = high-temperature resistant
EN 499: E 38 2 RA 22 G = abrasion-resistant
AWS 5.1: E 6013
Wire electrodes:
EN 440: G 3 Si 1
AWS 5.18: ER 70 S-6
Page 78
WEAR PROTECTION
9.4 Repair of build-up welds State of wear 2 (fig. 9)
Worn-out build-up welds must be repaired by reweld-

ing, if required.
Rewelding should be performed as long as remaining

parts of the buffer layer are still visible.
Before rewelding, a surface crack test has to be

carried out.
It is absolutely essential to gouge out any cracks in
the base metal or the buffer layer before welding is
performed. Cracks should never be overwelded!
9.4.1 State of wear

Fig. 9
The repair measures to be taken depend on the
materials state of wear.
The hard-facing layer is completely worn out.
State of wear 1 (fig. 8) The buffer layer is almost worn out.
Repair measure: Weld 1 new buffer layer and 2 new

hard-facing layers.
State of wear 3 (fig. 10)
Fig. 8
The hard-facing layer is almost worn out.
The buffer layer is still fully intact.

Fig. 10
Repair measure: Weld 2 new hard-facing layers.
Hard-facing and buffer layers have been com-
pletely abraded down to the base metal.
Repair measure: Weld 1 new buffer layer and 2 new

hard-facing layers.
Page 79
WEAR PROTECTION
State of wear 4 (fig. 11) 9.4.2 Identification of buffer and hard-facing
layers
The following are hints to identify the individual layers

of build-up welds:
The existence of remaining parts of the hard-facing

can be identified by grinding (fig. 12).
Fig. 11
Hard-facing and buffer layers are partly worn out

or broken off.
Repair measure: The remainders of hard-facing have

to be removed by ARC-AIR gouging (cf. page 23).
Fig. 12
The sparks produced by grinding a hard-facing layer

Never knock off remaining parts of the hard-fac- are dark red. They fly away in a linear path and
ing layer. Flying fragments may cause injury! almost without branching.
The gouged-out area is to be ground smooth and A buffer layer consisting of an austenitic, i.e. corro-
clean before welding 1 new buffer layer and 2 new sion-resistant, weld material can be recognized by
hard-facing layers onto the base metal. the bright colour of the grinding sparks.
If the buffer layer consists of a ferritic weld metal, the

grinding sparks are light red. They branch out and
spatter (fig. 13).
Fig. 13
Page 80
WEAR PROTECTION
9.5 Repair of cracks in build-up welds
Damage configuration: The crack in the component Gouge out the crack in the base metal properly and
lies in the area of the build-up weld (fig. 14). in accordance with standard practice (cf. page 23)
and weld (fig. 16).
Fig. 14 Fig. 16
1 Crack 5 Run-off tab
2 Hard-facing
Restore the cover over the repair zone by welding
3 Base metal the buffer and hard-facing layers (fig. 17).
4 Cracked zone
First, remove the hard-facing in the cracked area

completely (fig. 15).
The hard-facing layer can be removed only by the
ARC-AIR procedure.
Fig. 17
Fig. 15
Page 81
WEAR PROTECTION
9.6 Welding on wear-resistant steel plates or steel strips
Wear-resistant plates or strips with Brinell hardness For welding onto curved surfaces with very great
numbers of up to 500C an be welded onto the radii, the strips should be abt. 100 x 400 mm and
surfaces to be protected. equally arranged in a staggered pattern (fig. 19).
9.6.1 Arrangement of plates/strips
For welding onto plane surfaces, the wear plates

should have a size of abt. 200 x 300 mm and be
arranged in a staggered pattern (fig. 18).
Fig. 19
The strips must not be deformed. The gap caused by

the curvature of the underlying metal should, if possi-
ble, be the same on both sides (fig. 20).
Fig. 18
The plates must be in perfect contact (i.e. without

any gap, if possible) with the surfaces to be protect-
ed.
If the plates are greater than recommended and if

their contact with the surface is insufficient, they are
susceptible to cracking or fracturing under compres-
sive or impact loads.
The stresses produced by pressing the plates against

the surface may lead to the formation of cracks in the
weld seams. Fig. 20
Observation of the recommended plate size moreover The spacing between the plates or strips should not
allows partially worn-out areas to be repaired more be too large (fig. 21), so that loading material can fill
easily. the spaces between the plates, thus protecting the
weld seams against wear.
Page 82
WEAR PROTECTION
For a spacing of the plates as a function of the plate
thickness see fig. 21.
Fig. 21
t = 10 mm a = 6 mm b = 20 mm
15 mm 8 mm 25 mm
20 mm 10 mm 30 mm
The welds in the flow direction of the medium wear

substantially faster than welds positioned transverse
to them (fig. 22).
Fig. 23
The side blades of bucket front sections and back-
hoes can be protectd with wear strips.
These strips must be made in one piece. They must
end in an area with low working stresses (Fig. 24).
Fig. 22
Narrow areas, e.g. at side walls (arrow, figs. 22 and
23) of bucket fronts and backhoes should therefore
be fitted with interrupted strips.
Transverse joins or slots are filled in with the
medium, forming a self-protection for the welds.
The slipping of the medium is interrupted by the
joins or slots. The medium rolls, reducing the
wear.
Circular weld openings should be avoided, as exper- Fig. 24
ience shows that the opening fail to fill in. Make long, tapering build-up welding at the ends of
Large parts of the weld and of the plate metal are the wear strip.
subject to wear. Grind transitions from weld metal to base material
notch-free.
Page 83
WEAR PROTECTION
The welds in longitudinal direction of the strips must 3. The welds are optimally protected.
be protected in their layout. Possible layouts: The layout of the wear strips is recommended
(fig. 27).
1. The welds are severely susceptible to wear. The
layout is not recommended (fig. 25).
Fig. 27
Fig. 25 4. This layout is recommended only if the side walls

are also fitted with wear plates.
2. The welds are susceptible to wear as the ex- The welds are then protected from wear (fig. 28).
cavating device moves back. The cutting edge is
substantially widened. The penetration resistance
is increased (fig. 26).
Fig. 28
Fig. 26
Page 84
WEAR PROTECTION
The gaps between the plates of the 1st row must be The welds for fixing the plates and strips consist of
closed by build-up welding. soft weld metal which is not resistant to wear. This is
If this is not done, the wear plates in the 2nd row necessary due to the types of material used in the
behind the gaps may close (become joined up). base body and the wear plates.
Welds positioned in flow direction in particular should
therefore be given a "hard" cover to protect them
from excessively rapid wear.
Fig. 29
Explanations of fig. 29:
1 Direction of flow of medium
2 Fillet welds
3 Hard-faced deposit
Fig. 30
Explanations of fig. 30:
1 Metal plate, base material, e.g. S690Q
2 Wear plate, hardness: ca. 500 HB
3 Wear plate, hard layer on soft carrier material
4 Weld metal, soft
5 Weld metal, soft, buffer pass
6 Weld metal, hard, hard-faced deposit
Page 85
WEAR PROTECTION
9.6.2 Bending of strips 9.6.3 Working instructions
Strips of a material with a B.H.N. of max. 400 can be
worked by cold bending and adapted to curved sur- Plates with Brinell hardness numbers exceeding
faces (fig. 31). 300 must not be treated by hot bending or hot
straightening.
Plates and strips must not be welded onto highly

stressed component edges.
Plates and strips must be fastened to the base

material with a continuous fillet weld running all
around. Tack-welding is not sufficient.
"Soft" filler metals are used for welding. This ap-

plies also to the top pass of the fillet weld.
The base material must be preheated in accor-

dance with the material qualities, at least, how-
ever, to abt. 100oC (210oF).
For thicknesses up to 20 mm, the wear plates

must be preheated to at least 100oC (210oF). For
thicknesses of 40 mm, a preheating temperature
of 200oC (300oF) is required.
The interpass temperature during welding must

Fig. 31 not exceed 250oC (480oF).
However, bending must be done on a bending roll 9.6.4 Filler metals

and not on an edging press.
Due to bending radii and spring action, bending by
Rod electrodes:
gradual edging would lead to cracks on the side of
EN 499: E 38 4 B 42
the wear plate subject to tension.
AWS 5.1: E 7018
Worn-out plates and strips must always be replaced
in time. Wire electrodes:
Remaining pieces of the wear plate may not be EN 440: G4 Si 1
removed by wedging (fig. 32), unless a notch is AWS 5.18: ER 70S-6
ground into the weld seam in order to create a
predetermined breaking point.
The cutting areas must be ground smooth and clean
and be free from cracks.
Fig. 32
Page 86
WEAR PROTECTION
9.7 Welding of plates or strips with wear-resistant coatings
Plates or strips of S275JRG2/S355J2G3 with a pre-
viously welded wear-resistant coating with a hardness
of up to 58 HRC may also be welded onto the
surfaces to be protected.
The plate thickness depends on the size of the ex-
cavating tool.
If the recommended plate thicknesses are used, the
spacing between the plates should be 15 mm
(fig. 33).
Fig. 35
9.7.1 Working instructions

Fig. 33
The strips must be attached by continuous fillet
Plate thicknesses: e.g. welds of a = 6 mm thickness running all around.
A B C "Soft" filler metals are used for welding (cf. 9.6.4).
This applies also to the top pass of the fillet weld.
13 8 5
19 13 6 Strips must not be welded onto highly stressed
25 19 6 component edges.
The plates or strips should be abt. 100 x 400 mm The base material must be preheated in accor-
and arranged in a staggered pattern (fig. 34). dance with the material qualities, at least, how-
ever, up to abt. 100oC (210oF).
The strips are normally not preheated.
Exceptions: Component and ambient tempera-
tures are below 20oC (70oF) and the strips are
moist.
With regard to the base metal, the interpass tem-
perature during welding must not exceed 250oC
(480oF).
Worn-out strips must be replaced in time.
Remaining pieces of the strips may not be re-
moved by wedging, unless the weld seams are
notched by grinding in order to create predeter-
mined breaking points. Cf. also fig. 32.
The cutting areas must be ground smooth and
Fig. 34 clean and be free from cracks before new strips
are welded on.
The strips must not be bent. They can nevertheless
be welded onto curved surfaces with large radii if The prefabricated strips can be cut with a plasma
their central part rests on the base metal and if the torch. If this is not possible, the base material
gap at the long sides of the strips is relatively small must be cut by grinding or gouging, and the hard
and of equal size on the right and left sides (fig. 35). layer be broken.
Page 87
WEAR PROTECTION
9.8 Welding of wear-resistant studs Process desription (fig. 36)
Studs of wear-resistant materials can be welded onto The studs are fastened to the welding device
the surfaces to be protected. together with the ceramic weld backing. The ce-
ramic backing ring confines the weld pool and
Studs of different sizes, shapes and hardness are protects it against external influence.
available from dealers specializing in these articles.
The arc is ignited by pulling the stud away from
Welding procedure: the component surface, whereby parts of the stud
Initial contact capacitor-discharge stud-welding and of the base metal are melted.
The stud is pressed into the liquid weld pool. After

This type of welding requires high-current power sup-
cooling the stud is completely welded to the base
plies.
metal.
Before welding it must be checked whether the 9.8.1 Working instructions

power supply available on site has sufficient ca-
pacity for weld finishing. The studs should be placed as closely together as
possible. The distance between studs is deter-
mined by the size of the ceramic backing ring.
Close spacing of the studs ensures that forces
acting on the studs are distributed more evenly to
an as large number of studs as possible, thus
reducing the danger of stud fracturing.
Depending on the material quality, the base metal

must be correspondingly preheated, at least, how-
ever, to 100 oC (210oF).
Studs must not be welded onto component edges

or component radii.
For instructions on the procedure as well as on studs

and tools, the user is advised to contact specialist
firms.
Stud welding has proved a successful wear protec-
tion procedure worldwide.
Rewelding of single studs broken out of the base

material cannot be recommended.
In most cases, the breaking point in the base metal
cannot be ground as smooth as required.
Fig. 36
Page 88
WEAR PROTECTION
9.9 Welding cutting edges onto digging tools of excavators
Prefabricated cutting edges (1, fig. 37) of high- To facilitate fastening and welding, the excavating
strength, tempered steel can be welded to the ex- tool should be placed with its blade in a vertical
cavating tool (2) as a wear-protection material with position.
good cutting capability. For welding, preheat blade cutting-edge and
replacing part to 150oC (300oF).
9.9.2 Welding sequence (fig. 39) and filler

metals
Fig. 37
9.9.1 Working sequence

Fig. 39
The contour of the worn-out cutting segment is to
be cut straight by means of a flame torch. Before Weld first the root and 1 interpass from one side using
flame-cutting, preheat to 50oC (120oF). Grind soft filler metals.
flame-cut edges down to the bare metal.
Make a replacing part with the help of a template.
Filler metals (soft) for root and 1st interpass
Material: wear-resistant tempered steel; pre-
shaped, available e.g. from the FIATALLIS spare-
Rod electrodes
parts service.
EN 499: E 38 4 B 42
For cutting out the contour and for chamfering the AWS 5.1: E 7018
weld grooves, preheat the material to 50 o C
(120oF). Wire electrodes
Grind the weld groove surfaces smooth down to EN 440: G4 Si 1
the bare metal. AWS 5.18: ER 70S-6
Attach replacing part (fig. 38). Grind out the root pass from the other side and weld
2 layers as on the other side.
Finish the remaining weld with filler metals adapted

to the material of the cutting edge (cf. page 86).
Weld stringer beads; interpass welding temperature
max. 250oC (480oF).
Work alternately on both sides in order to avoid

distortion of the replacing part.
Fig. 38
Page 89
WEAR PROTECTION
Filler metals (hard) for interpasses and cover
passes
Rod electrodes
EN 757: E 69 5 Mn2NiCrMo B 42
AWS 5.5: E 11018 - M
Trade names
Thyssen: SH Ni 2 K 100
Kjellberg-Esab: OK 75,75
Oerlikon: Tenacito 75
Wire electrodes
not yet standardized
Trade names
Thyssen: Union Ni Mo Cr
Boehler: Ni Cr Mo 2,5 - IG
The seam ends at the transition to the tooth holders

must be ground smooth and clean (arrows, fig. 40).
Fig. 40
The entire welding area must be allowed to cool
down slowly after completion of the weld. Cover up
with glass wool. Never cool with water or jets of
compressed air.
Page 90
REPAIR OF CAST-IRON COMPONENTS
10. Repair of cast-iron components by
welding
10.1 Spheroidal-graphite cast iron 10.1.2 Cold welding
Basically 2 methods requiring different amounts of Welding is carried out with filler metals of different
work can be applied. Though requiring the greater compositions to the base metal. If the work is carried
amount of work, hot welding mostly yields the better out in a workmanlike manner, the weld metal ob-
results. tained corresponds to the B-quality level in accor-
dance with the VDG Code of Practice N 60. The
weld differs in its mechano-technological properties
from the unwelded material, although in most cases
10.1.1 Hot welding the weld fulfils the requirements for a given use.
Such requirements have to be defined for each spe-
cial case.
Welding is carried out with the filler metal of the
same composition as the base. If the work is carried
out in a workmanlike manner, the weld metal ob- Welding recommendations:
tained corresponds to the A-quality level in accor-
dance with the VDG Code of Practice N 60. The Keep the welding current as low as possible, so
mechano-technological properties of the weld deposit that the heat-affected zone remains extremely
are identical to those of the unwelded material. narrow.
For welding, it is required to preheat the workpiece to Preheating temperatures of up to 400oC (750oF)
600oC (1100oF). After welding, the component must have a strengthening effect on the welded joint.
be subjected to normalizing at 900oC (1650oF).
The welding areas must be clean down to the
Because of this requirement, the procedure can be bare metal.
virtually excluded for field repairs.
Rod electrodes:
DIN 8573 - Typ E NiFe - 1 - BG 23
Moreover, the component is subjected to great AWS 5.15: E NiFe - C1
amounts of heat, so that the dimensional accuracy of Electrodes - 3.20 mm
machined surfaces can no longer be guaranteed. P/N 73171541
For repairs requiring this type of welding, it is always Weld short stringer beads and provide for inter-
advisable to contact a company specializing in this pass cooling.
field of welding repair, because only these companies
have the necessary equipment for preheating and
normalizing as well as for handling hot components. Normalization after welding is not required.
After grinding, the welded area should be checked for

cracks by means of the dye-penetration test.
Cold welding by inexperienced welders may yield

poor results. It is therefore advisable to contact spe-
cialized companies for this work as well.
Page 91
10.2 Flaky-graphite cast iron
Here again, 2 methods requiring different amounts of Therefore, it is not possible to restore all the compo-
work can be applied. Though requiring the greater nents original material properties.
amount of work, hot welding mostly yields the better
results. Microstructural changes in the edge zones and high
internal stresses cannot be avoided. Due to inevitably
high structural hardening, microcracking cannot be
excluded.
10.2.1 Hot welding
Welding recommendations:
Welding is carried out with a filler metal of the same
composition as the base metal. If the weld is carried Keep the welding current as low as possible in
out in a workmanlike manner, the weld deposit ob- order to keep heat application to a minimum.
tained corresponds in its mechano-technological
properties to those of the unwelded material.
The temperature in the workpiece should not ex-
ceed 70oC (160oF)in an area directly adjacent to
For welding, the component must be partly or com- the weld.
pletely preheated to 650oC (1200oF). As the fluidity of
the weld metal is very high, the welding area as such Rod electrodes:
must be confined by backing devices. DIN 8573 - type E NiFe
AWS 5.15: E NiFe - C1
Because of this requirement, the procedure can be Electrodes - 2.5 mm.
virtually excluded for field repairs. P/N 73171540
Moreover, the component is subjected to great Always weld short stringer beads in a staggered
amounts of heat, so that the dimensional accuracy of pattern.
machined surfaces can no longer be guaranteed.
In order to reduce shrinkage and thus internal
For repairs requiring this type of welding, it is always stresses in the component, the beads should be
advisable to contact a company specializing in this slightly extended before cooling by hammering.
field of welding repair, because only these companies
have the necessary equipment for preheating and Cold welding should only be carried out on flaky-
normalizing as well as for handling hot components. graphite cast-iron components if it is absolutely in-
dispensable.
It is advisable to contact specialized companies to
carry out this work.
10.2.2 Cold welding
Alternative recommendation:
Welding is carried out with weld filler metals of dif-
ferent compositions to the base metal. If the weld is For the repair of flaky-graphite cast-iron components
carried out in a workmanlike manner, the weld metal another procedure can be successfully applied, i.e.
obtained differs in its composition from the base ma- the so-called "interlock" method.
terial and possesses other mechano-technological
properties than the latter. A homogeneous welded
Repair by means of the "interlock" method can be
joint between base metal and filler material cannot be
carried out only by special firms.
expected.
For details see paragraph 10.2.3.
Page 92
10.2.3 Repair of components with the "interlock" technique
The repair of cast-iron components by welding is The holes are drilled by means of a template. The
often not possible if the repaired area is subject to remaining metal between the drill-holes is re-
the action of forces. moved by chipping.
For this reason, a technique has been developed So-called "interlocking bars" are then inserted into
where cracks or fractures are repaired by "interlock- these joints (fig. 2).
ing". Such repair is carried out by means of mechani-
cal tools only and requires no welding.
This procedure represents nevertheless a useful

complementary technique to welding.
Interlocking can be used to join fragments or, if re-

quired, newly made replacing pieces of another ma-
terial, e.g. of cast steel or plate steel.
Process description:
The component is prepared by drilling rows of

holes on both sides and across the fracture line
(fig. 1).
Fig. 2
These bars are made of a steel material which

can be deformed and solidified by hammering.
The bars are inserted into the joints in layers, with

every single layer being hammered in place. In
the process, the interlocking bars are moulded
exactly to the shape of the joints.
This ensures that also the rear areas contribute to
the load-bearing capability of the bars.
The substitute cross-section, i.e. the number of

bars, can be calculated from the ratio of the ma-
terial strength values of grey cast-iron and steel.
Fig. 1
Page 93
TOUCHING UP OF PAINT COATINGS IN REPAIR AREAS
11. Touching up paint coatings in repair
areas
All damaged or partly removed coatings of the com-

ponent must be touched up after completion of the
weld. This applies to areas in which
- welding has been carried out,

- additional reinforcing plates have been fitted or
inserted,
- coatings have been damaged by thermal (e.g.
straightening, preheating) or mechanical (e.g. lift-
ing gear) action.
The damaged areas of the component are to be

cleaned by mechanical procedures, such as brushing,
grinding or scraping.
Surface purity: St 3 in acc. with DIN 55 928, Part 4,

supplement 1.
The degree of purity required by this standard can be
achieved only by thorough cleaning.
The repaired area is then to be touched up with 2

coats of paint, a priming and a finishing coat.
The priming coat must ensure that the metal surface

is covered up with a sufficient overlap. In the same
way, the finishing coat has to sufficiently overlap the
priming coat.
Page 94
APPENDIX
Comparison
Old designation New designation
Materials
DIN 17100: St37-2 EN 10025: S275JRG2

DIN17100; St52-3 EN 10025: S355J2G3
DASt-directive 011: StE690 SEW 690 Part 1: S690Q
LV 976752: GS-52.3V LV 2102375; GS-21 Mn5V (as per SEW 685)
Swedish Steel: HARDOX 500 LV 2270002: wear plate 500HB
Filler metals for welding
DIN 1913: E4332AR7 EN 499: E38 2 RA 22

DIN 1913: E5154B10 EN 499: E38 4 B 42
DIN 8559: SG2 EN 440: G3Si1
DIN 8559: SG3 EN 440: G4Si1
DIN 8529: EY6975Mn2NiCrMoB EN 757: E69 5 Mn2NiCrMoB 42
Page 95
APPENDIX
Part nos. for filler metals
The filler metals listed below can be obtained from the FIATALLIS spare-parts service.
For orders, please quote part no., quantity and designation of the filler metal required.
Rod electrodes
Standard designation Dimensions Part no. Remarks
(mm) for 1 pack
EN 499: 4.0 x 450 73171529

E 38 2 RA 22 5.0 x 350 73171530
EN 499; 2.5 x 250 73171531

E 38 4 B 42 3.2 x 450 73171532
4.0 x 450 73171533
5.0 x 450 73171534
EN 757: 3.2 x 350 73171535

E 69 5 Mn2NiCrMoB42 4.0 x 450 73171536
5.0 x 450 73171537
DIN 8555-E10-UM-60 GRZ 5.0 x 450 73171538

DIN 8555-E6-UM-60 P 3.20 x 450 73171539
DIN 8573 2.5 x 250 73171540

E NiFe 1 BG 23 3.2 x 350 73171541
DIN 8575 3.2 x 350 73171542

E CrMo1B 26 4.0 x 350 73171543
5.0 x 350 73171544
2. Rod electrodes, vacuum-packed

(mm) for 1 vacuum pack
EN 499 2.5 x 250 73171545

E 38 4B 42 3.2 x 450 73171546
4.0 x 450 73171547
5.0 x 450 73171548
Page 96
APPENDIX
3. Wire electrodes
Standard designation Dimensions P/N for Remarks
(mm) 15 kg coil
DIN 8555-MF 10-GF 60-RT 2.0 73171549

EN 440: G3 Si 1 1.2 73171550
EN 440: G4 Si 1 1.2 73171551
DIN 8575: SGCrMo1 1.2 73171552
Wire electrode 1.2 73171553 Fa. Thyssen: Union NiMoCr
(not yet standardized) oder
Fa. Bohler:
NiMoCr 2.5-IG
4. Carbon electrodes for "ARC-AIR Procedure"

(mm) for 1 pack
Carbon electrode 5.0 x 300 73171554

6.0 x 300 73171555
8.0 x 300 73171556
Page 97
APPENDIX
Umrechnung von foot (Fu) und inch (Zoll) in Meter
Conversion from foot (Fu) and inch (Zoll) to metric measure
1 in (inch) = 25,4 mm (genau) 1 ft (foot) = 12 in = 304,8 mm Beispiel: 4 ft 2 in = 1,27 m

1 in (inch) = 25,4 mm (exact) Example: 4 ft 2 in = 1,27 m
in
+0 +1 +2 +3 +4 +5 +6 +7 +8 +9 +10 +11
ft
m m m m m m m m m m m m
0 0.0254 0.0508 0.0762 0,1016 0,1270 0,1524 0,1778 0, 2032 0,2286 0,2540 0,2794
1 0,3048 0,3302 0,3556 0,3810 0,4064 0,4318 0,4572 0,4826 0.5080 0.5334 0.5588 0.5842
2 0,6096 0,6350 0,6604 0,6858 0,7112 0,7366 0,7620 0,7874 0,8128 0,8382 0,8636 0,8890
3 0,9144 0,9398 0,9652 0,9906 1.0160 1.0414 1.0668 1.0922 1,1176 1,1430 1,1684 1,1938
4 1,2192 1,2446 1,2700 1,2954 1,3208 1,3462 1,3716 1,3970 1,4224 1,4478 1,4732 1,4986
5 1.5240 1.5494 1.5748 1,6002 1,6256 1,6510 1,6764 1,7018 1,7272 1,7526 1,7780 1,8034
6 1,8288 1,8542 1,8796 1,9050 1,9304 1,9558 1,9812 2.0066 2.0320 2.0574 2.0828 2,1082
7 2,1336 2,1590 2,1844 2,2098 2,2352 2,2606 2,2860 2,3114 2,3368 2,3622 2,3876 2,4130
8 2,4384 2,4638 2,4892 2.5146 2.5400 2.5654 2.5908 2,6162 2,6416 2,6670 2,6924 2,7178
9 2,7432 2,7686 2,7940 2,8194 2,8448 2,8702 2,8956 2,9210 2,9464 2,9718 2,9972 3.0226
10 3.0480 3.0734 3.0988 3,1242 3,1496 3,1750 3,2004 3,2258 3,2512 3,2766 3,3020 3,3274
11 3,3528 3,3782 3,4036 3,4290 3,4544 3,4798 3.5052 3.5306 3.5560 3.5814 3,6068 3,6322
12 3,6576 3,6830 3,70 3,7338 3,7592 3,7846 3,8100 3,8354 3,8608 3,8862 3,9116 3,9370
Umrechnung von Langen

- Maen
Conversion for units of length
Lange
in ft yd mile UK cm m
Length n mile
1 inch (Zoll) 1 0,0833 0,0278 2,54 0,0254
1 foot (Fu) 12 1 0,3333 0,00019 0,00016 30,48 0,3048
1 yard 36 3 1 0,00057 0,00049 91,44 0,9144
1 statute mile (Landmeile) 63 360 5 280 1 760 1 0,86842 1609,3
1 UK nautical mile 72 960 6 080 2 026,7 1,15151 1 1 853,2

(engl. Seemeile)
1 cm 0,3937 0,0328 0,0109 1 0,01
1m 39,370 3,2808 1,0936 0,00062 0,00054 100 1
Page 98
APPENDIX
Temperatur - Einheiten und Umrechnungsformeln
Temperature units and conversion formulas
Einheiten Umrechnung in
Units Conversion into
Benennung
o o o
Nomenclature K C R F
Kurzzeichen
Symbol
Kelvin K 1 (K-273.16o) 4/5 (K-273.16o) 9/5 (K-273.16o)+32o

o o
Celsius C C+273.16o 1 4/5 oC 9/5 oC+32o
o
Reaumur
R 5/4 oR+273.16o 5/4 oR 1 9/4 oR+32o
o
Fahrenheit F 5/9 (oF-32o)+ 273.16o 5/9 (oF-32o) 4/9 (oF -32o) 1
Beispiel: Umrechnung von o

R in oC : oC = 4/5 oR
Example: Conversion from
Die Grundeinheit der Temperatur ist Kelvin (K).

The fundamental temperature unit is the Kelvin (K).
Als Formelzeichen wird T verwandt.

The symbol used is the T.
o
Die ebenfalls benutzte absolute Temperatur degree (Grad) Rankin errechnet sich zu Rank = 9/5 K.
The likewise used Rankine temperature scale for absolute temperatures is related to K
as follows:
Page 99
APPENDIX
Hardness - strength comparisen

Vickers- Brinell- Tensile- Rockwell- Vickers- Brinell- Tensile- Rockwell-
hardness hardness strength hardness hardness hardness strength hardness
HV HB HRB HRC HV HB HRB HRC
kp/mm2 kp/mm2 N/mm2 kp/mm2 kp/mm2 N/mm2
80 80 270 36.4 360 359 1210 37.0

85 85 290 42.4 370 368 1240 38.0
90 90 310 47.4 380 376 1270 38.9
95 95 320 52.0 390 385 1290 39.8
100 100 340 56.4 400 392 1330 40.7
105 105 360 60.0 410 400 1360 41.5
110 110 380 63.4 420 408 1390 42.4
115 115 390 66.4 430 415 1410 43.2
120 120 410 69.4 440 423 1440 44.0
125 125 430 72.0 450 430 1470 44.8
130 130 440 74.4 460 45.5
135 135 460 76.4 470 46.3
140 140 480 78.4 480 47.0
145 145 490 80.4 490 47.7
150 150 500 82.2 500 48.3
155 155 520 83.8 510 49.0
160 160 540 85.4 520 49.6
165 165 550 86.8 530 50.3
170 170 570 88.2 540 50.9
175 175 590 89.6 550 51.5
180 180 610 90.8 560 52.1
185 185 620 91.8 570 52.7
190 190 640 93.0 580 53.3
195 195 660 94.0 590 53.8
200 200 680 95.0 600 54.5
205 205 690 95.8 610 54.9
210 210 710 96.6 620 55.4
215 215 730 97.6 630 55.9
220 220 750 98.2 640 56.4
225 225 760 99.0 650 56.9
230 230 770 19.2 660 57.4
235 235 790 20.2 670 57.9
240 240 810 21.2 680 58.4
245 245 830 22.1 690 58.9
250 250 840 23.0 700 59.3
255 255 850 23.8 720 60.2
260 260 870 24.6 740 61.1
265 265 880 25.4 760 61.9
270 270 900 26.2 780 62.7
275 275 920 26.9 800 63.5
280 280 940 27.6 820 64.3
285 285 960 28.3 840 65.0
290 290 980 29.0 860 65.7
295 295 990 29.6 880 66.3
300 300 1010 30.3 900 66.9
310 310 1050 31.5 920 67.5
320 320 1080 32.7 940 68.0
330 330 1120 33.8
340 340 1150 34.9
350 350 1180 36.0
Page 100
NOTES
Page 101
NOTES
Page 102
Sealing, protective, testing and
cleaning agents
2 796 730.00 en
INTRODUCTION ........................................................................................................................................ 1
FUNDAMENTAL SAFETY INSTRUCTIONS ............................................................................................ 1
Safety Instructions.................................................................................................................................... 2
PRESERVATION OF GEARBOXES
Rust inhibitor .......................................................................................................................................... 4
Application to gearboxes and axles without oil filling .............................................................................. 4
Preservation period ................................................................................................................................ 4
Gearboxes and axles with oil filling ........................................................................................................ 4
Protective finishes .................................................................................................................................. 4
PRESERVATION OF CYLINDER PISTON RODS

Corrosion inhibitor .................................................................................................................................. 5
Consumption of inhibitor.......................................................................................................................... 5
Application of inhibitor ............................................................................................................................ 5
Removing the inhibitor ............................................................................................................................ 5
Renewing the inhibitor ............................................................................................................................ 5
Corrosion protection for pins and bearings (bushings and hubs)

Part nos. for Voler A.C............................................................................................................................. 6
Application of Voler A.C. ........................................................................................................................ 6
S0LUTION 1 CORROSION INHIBITOR FOR CYLINDER ROD THREADS.............................................. 7
RIVOLTA W.S.X, NU CORROSION INHIBITOR FOR ELECTRICAL SYSTEMS .................................... 7
SURFACE SEALING AGENTS

WKT black - H ........................................................................................................................................ 8
Loctite 573 (proprietary brand from Loctite Ltd.,) .................................................................................... 8
HYLOMAR SQ 32/M SEALING AGENT (THREAD SEALER) .................................................................. 9
LIQUID THREAD ADHESIVES .................................................................................................................. 9
METAL ADHESIVES ................................................................................................................................ 10
ADHESIVES FOR PLASTICS

Acrylic cyanide (Loctite IS 414) ............................................................................................................ 11
ADHESIVE FOR O-RINGS ...................................................................................................................... 11
LUBRICANTS
Solid lubricating paste .......................................................................................................................... 12
Solid lubricant paste spray .................................................................................................................... 12
Compound spray .................................................................................................................................. 12
Mineral-based lubricating paste ............................................................................................................ 13
Lithium soap grease .............................................................................................................................. 13
SOLID LUBRICANT FOR MOLYCOTE-COATED BOLTS ...................................................................... 14
SILICON-CORUNDUM POWDER (REDURIT) ........................................................................................ 14
P3 COLD CLEANER ................................................................................................................................ 15
SURFACE CRACK CHECKING AGENT (METAL-CHECK) .................................................................. 16

SEALING, PROTECTIVE, TESTING AND CLEANING AGENTS
INTRODUCTION 2801914 FUNDAMENTAL SAFETY
This Technical Handbook (THB) provides a com-
INSTRUCTIONS 2801915
pilation of the directions for using recommended

sealing, protective, testing and cleaning agents. Warnings and symbols
All of these agents are necessary for various The following signs are used in the manual to
assembly procedures. designate instructions of particular importance:
The agents can all be ordered from this Spare

Parts Service.
Precautionary rules and measures de-
Products from other manufacturers are only to be signed to protect the machine operator
used when they possess the same characteristics and other persons from life-threatening
and qualities as those of the agents stated. danger or injuries and to prevent exten-
sive damage.
If in doubt, ask the After-Sales Service.
Further descriptions and directions (over and

above those given here) are to be found in the
relevant manufacturers instructions and literature. Information and precautionary measures
designed to prevent damage to the ma-
chine or other property.
2 796 730.00 en 1
Safety Instructions
Personnel Tools and auxiliaries

The machine must not be started by un- Tools, hoists, slings, jackstands and other
authorized persons. devices must be in a reliable, safe con-
It must therefore be secured. dition.
Observe the accident prevention regula- Metal splinters may cause injury when at-
tions. tachment bolts are being driven in or out.
The machine may be operated, serviced A brass or copper punch should therefore
or repaired only by specially trained and be used for this purpose, and safety
authorized personnel with the appropriate glasses must be worn.
technical know-how. For climbing onto or off the machine, use
If such know-how is lacking, meticulous only the ladders, steps, platforms and
instruction must be given by experienced handrails provided for this purpose.
personnel. Always keep ladders, steps and platforms
The personnel must have read and under- in a non-slip condition.
stood the operating instructions and in Remove any oil, grease, dirt, clay, snow,
particular the chapter ice and other foreign material immediate-
"Fundamental Safety Instructions". ly.
chine during assembly work in order to
Securing the working equipment
attachments may give rise to life- Before carrying out assembly work, the
threatening situations. machine and the attachments must be
secured against inadvertent and un-
During all works, always observe the
authorized starting, e.g. by placing chocks
start-up and shut-down procedures pre-
under the wheels or tracks and by resting
scribed in the operating instructions.
the working equipment on the ground.
Rest the working equipment on the
ground in such a way that no movements
can be made when mechanical or hydrau-
lic connections are detached.
Personnel Secure any equipment or component
Personal protective gear and working which is to be mounted or dismantled or
clothing: whose position is to be changed using
hoists or appropriate slinging/supporting
Wear a safety helmet, safety footwear, devices to prevent them from moving,
gloves and safety glasses. slipping or falling inadvertently.
Wear closely fitting working clothing Systems and units (e.g. pipes, accumula-
when working on the machine. tors, etc.) must be properly depressurized
Loose, wide garments may catch on ma- before being opened.
chine parts and result in injury. Protective devices on moving machine
If the work to be carried out requires aux- parts may be opened or removed only
iliaries, e.g. foreman, the duties of each when the drive unit is stationary and pro-
individual helper must be clearly defined tected against inadvertent starting.
beforehand. Before recommissioning, all protective de-
The individual responsibilities must be vices must be refitted.
meticulously observed to avoid misunder-
standing and unsafe activity.
2 2 796 730.00 en
Sealing, protective, testing and Conversions or modifications to the

cleaning agents machine
The safety instructions contained in this Unauthorized conversions or modifica-
Technicel Handbook with respect to tions of the machine are forbidden for
accident prevention and those set out on reasons of safety.
the packing of the above-mentioned The nominal pressure of pressure relief
agents must be observed. valves must not be modified.
Do not remove the lead seals from pres-
sure-relief valves and pressure accumula-
Hydraulic and lubricating system tors.
Always observe the safety regulations ap-
plicable to the product when handling
oils, greases and other chemical sub-
stances.
Unused but open containers, pipelines
and hose connections must be closed in
Recommissioning
a pressure- tight manner.
Refill collected hydraulic oil back into the Prior to recommissioning:
hydraulic system only through the return- - Grease all lubricating points.
flow filters. - Check all oil levels and make the nec-
Dispose of waste oil without polluting the essary corrections.
environment. - Carry out function checks of all
Observe the correct working sequence repaired components.
when fitting or replacing components or - Check all functions of the machine in-
equipment. cluding the brakes during a test run.
The working sequence has been specified Release the machine for recommission-
and tested by qualified experts. ing only after all functions have been
found to work perfectly.
Replace defective, mechanically prestres-
sed units (e.g. nitrogen accumulators)
only as an entirety. Never open them.
In exceptional cases, open only when the
system and the operating sequence are
precisely known. The Technical Manual
contains no information on such work.
scalding.
eyes and the skin.
liquids.
ted lighting.
easily.
2 796 730.00 en 3
PRESERVATION OF GEARBOXES
Scope Preservation period
The following specifications apply to the internal The preservation measures protect against rust
protection of gearboxes and axles that are to be for
stored individually without oil in them, or that are
installed in machines (and therefore filled with oil) 2 years when stored indoors
that are to be decommissioned for a long period 1 year when stored in the open
of lay-up.
Whatever the type of storage, gearboxes and
axles must be protected against dampness and
Rust inhibitor dirt.
A thin, solvent-based product, soluble in mineral-
oil based lube oils and as specified in Part No. Gearboxes and axles with oil filling
73171464 is to be used.
Upon installation of the gearboxes into machines,
Such an inhibitor contains: 55% solids a trial run of the machine, and therefore of the
45% solvent gearbox/axle, is to be carried out. The gear oil
then flushes the rust inhibitor off the internal
The solids content (which increases on account parts. Because the gear oil remains in the gear-
of solvent evaporation) must not exceed 75% as box/axle during the lay-up, those components and
rust inhibition is then no longer ensured. surfaces lying above the oil level do not have any
protection against rust.
The solids content can be determined by carrying
out an evaporation test in a measuring beaker. For this reason, the machine is to be moved
every 3 - 4 weeks. This coats all of the gear-
Such a test can be carried out by the manufac- box/axle components with fresh oil and provides
turer using approx. 0.5 litres of the rust inhibitor. temporary protection for all motors and hydraulic
components.
Application to gearboxes and axles
without oil filling Protective finishes
The internal surfaces of gearboxes and axle
1. Clean the gearbox or axle externally using housings are given a rust protection in our works.
diesel fuel or cold cleaner. This protection is reached by:
2. Drain gear oil while still warm following a trial
run. 1. sand blasting the housing sections before
Allow the gearbox to cool down to 68 - 77F. assembly
3. Fill rust inhibitor up to oil-level marker. 2. priming the housing sections before
4. Run the gearbox load free to circulate the assembly
inhibitor through all internal chambers and 3. coating the assembled components with an
channels. oil- and acidresistant synthetic resin paint
5. Drain off the rust inhibitor. The inhibitor can - yellow RAL 1009 or
be used again. - yellow RAL 1017 Part No. 73171465
6. Allow the gearbox to dry off for approx. 30
minutes. Check the paint finish during any re-
pair/overhauling work. Before touching up the
7. Carefully seal up all openings on the gearbox paint finish, remove any rust or oil/grease from
using oil paper, plastic plugs or other suitable the areas to be painted. Apply paint with a brush
materials. to give a complete cover coat.
8. Brush or spray rust inhibitor onto all blank
external surfaces of the gearbox. Choose a colour that agrees with the originally
applied primer coating so that it does not "show
9. When commissioning the gearbox, do not re-
through". Carry out a trial application if necessary.
move the film of rust inhibitor. Only fill the
gearbox with the prescribed gear oil.
4 2 796 730.00 en
PRESERVATION OF CYLINDER PISTON RODS
Scope Preservation period
The following specifications apply to all machines. The inhibitor protects piston rods against corro-
Preservation should be carried out to protect ex- sion for:
posed piston rods against fret corrosion and ag-
gressive environmental influences both before 12 months when stored indoors
storage and before dispatch of a machine for sea 6 months when stored in the open
transport.
Removing the inhibitor
Corrosion inhibitor The inhibitor is scraped off by the cylinder wiper
rings when the piston rod is retracted - special
For piston rods of machines in storage and be-
procedures are not necessary.
fore the shipment - exception sea transport - a
special long-term lubricating grease acc. to part Any inhibitor that should get into the cylinder(s) is
no. 73176179 is to be used. absolutely harmless to the hydraulic system.
For sea transport a product which is viscous, Renewing the inhibitor
contains solvent and is soluble in hydraulic oils,
danger class II, parts no. 73171466 is to be used When machines are stored in the open air, the
as coorosion preventive. protective coating of inhibitor is to be renewed at
the latest after 6 months. The piston rods must
The inhibitor can be removed with diesel fuel, be cleaned beforehand.
petrol, petroleum and the like.
The inhibitor coating must also be renewed if the
Consumption of inhibitor cylinder/s has/have been actuated.
The amount required depends upon the type (and
therefore size) of the machine.
Example: approx. 20 g are needed to coat the Do NOT put machines into stock without a
exposed rod ends on the machine. coating of inhibitor on their piston rods.
Application of inhibitor
1. Retract all cylinder piston rods as far as pos-

sible.
2. Allow the exposed rod ends to cool to am-
bient temperature and then clean them with a
fiber-free cloth. Remove any fret corrosion.
3. Apply the rust inhibitor with a soft brush.
2 796 730.00 en 5
Corrosion protection for pins and bearings (bushings and hubs) 2801916
Application of Voler A.C.
Clean off grease, oil, dirt and corrosion protec-

Use Voler A.C. anti-corrosive agent only. tion agents from pins and bearings using white
Other agents are not approved. spirit or diesel fuel.
Rust patches must be thoroughly removed, if
any.
All pins and bearings (bushings and hubs) of the
working equipment or in equipment components All parts must present a dry, bright metal sur-
must be treated with Voler A.C. anti-corrosive face.
agent before fitting. Apply a thin layer of Voler A.C. on pins and all
bearings using a brush or a spray can. Pin
Voler A.C.:
shafts and bearings must be completely co-
permits easy fitting and dismantling vered by the protective layer.
protects against rust, oxidation and similar wear If the protective layer of a pin already treated
with Voler A.C. is damaged, these areas must
prevents seizing and fretting corrosion in non- be touched up before fitting the part.
moving parts of bearings.
Fitting and securing of pins
This is achieved by aluminium and copper par- If the pin is too heavy to be fitted manually,
ticles forming a protective layer on the metal. This apply Voler A.C. at first only on abt. a quarter
layer removes surface irregularities and does not of the pins length
sweat, seize or harden.
Then position pin by means of a lifting gear
Part nos. for Voler A.C. ready for fitting.
Apply Voler A.C. on the remaining length of pin
P/N 73171461 - 0,5 l spray can (CFC-free) shaft, fit pin and secure.
P/N 73171462 - 0,5 kg tin
P/N 73171463 - 4,5 kg bucket
Available from the Spare-Parts Service.
6 2 796 730.00 en
S0LUTION 1 CORROSION RIVOLTA W.S.X, NU CORROSION
INHIBITOR FOR CYLINDER ROD INHIBITOR FOR ELECTRICAL
THREADS SYSTEMS
Part No.: 73171467 Part No.: 73171468
To prevent corrosion, e.g. between bearing eye To prevent corrosion in/on electrical systems and
and piston rod of hydraulic cylinders components. Prevents failure due to corrosion
and leakage currents following moisture ingres-
Properties: sion.
Prevents corrosion, especially fret corrosion,

where different types of materials are mated.
Not to be used on computers and millivolt
Application:
contacts.
Apply with brush, roller or spray.
On hydraulic cylinders, for example, apply to
threaded end of piston rod, thread run-out, heads Application:
and exposed ends of bearing eye clamping bolts.
On "split" eyes, also into the "split" itself. Thoroughly clean the parts to be treated.
Apply inhibitor with a spray pistol or brush.
Binder:
Flash point:
Bitumen
+117F
Solvent:
Storage stability:
Petroleum spirits, aromatics
Unlimited storage when in tightly sealed
Flash point:
containers
+100F
Drying time:
Flash point +117F.
Dust dry in 40 to 50 min. at 68F Containers are therefore to be stored cool
and tightly sealed.
Removal:
Smoking forbidden during application.
Can be washed off with a cleaner Care is to be taken in small, enclosed
rooms where evaporation fumes could
Storage stability: displace the oxygen supply.
Unlimited storage when in tightly sealed Splashes in the eyes are to be flushed out
containers of the eyes, then rinsed in abundant wa-
ter.
If high fume concentrations are inhaled,
adequate fresh air must be obtained im-
Flash point of solvent is +100F. mediately.
Containers are therefore to be stored cool
and tightly sealed.
Smoking, naked lights and fire are forbid-
den during application.
Residues must not be allowed to get into
the ground water or into the sewerage.
2 796 730.00 en 7
SURFACE SEALING AGENTS
WKT black - H Loctite 573 (proprietary brand from
Loctite Ltd.,)
Part No.: 73171469
Part No.: 73171469
Application:
Application:
To seal gearbox housing sections.
as above WKT black - H.
Application:
Application :
Clean the surfaces to be sealed using a grease
solvent. Allow solvent to evaporate fully and then Clean the surfaces to be sealed using a grease
apply an approx. 1 mm thick layer of WKT black- solvent. Allow solvent to evaporate fully and then
H to one of the surfaces. apply adequate Loctite 573 to one of the sur-
When using a pistol, apply a cord of the sealer. faces. Apply with a foam or short-pile roller, with
The sealer then spreads itself out when the two a brush or directly from the tube.
surfaces are pressed together. When using a roller, pour sufficient (e.g. as much
as is needed in one day) into a plastic tray and
Consumption: then apply with the slightly moist roller.
Prevent dirt getting into the Loctite 573.
approx. 3 ml/150 sq.cm. of surface
Do NOT pour unused Loctite 573 back into the
Re-using: container.
Possible, providing the surface is free of dirt and Consumption:

grease. Points at which the sealer has crumbled
approx. 1 m1/150 sq.cm. of surfaces.
away can be covered with fresh sealer. The
sealer vulcanizes itself with the older, hardened Hardening time:
sealing agent without any kind of treatment being
necessary. Sealing effect is immediate on level surfaces.
Final hardness reached after 12 - 24 hours.
Removal:
Re-using:
When vulcanized (hardened), the film of sealing
agent can be pulled off the surface. Hardened Loctite 573 does not need to be re-
moved from surfaces after disassembly. Before
re-assembly, clean the sealing surfaces with a
grease colvent. The solvent must be allowed to
evaporate completely.
Apply a small quantity of Loctite 573 evenly to
one of the two sealing surfaces.
8 2 796 730.00 en
HYLOMAR SQ 32/M SEALING LIQUID THREAD ADHESIVES
AGENT (THREAD SEALER) The following products are approved for securing
Part No.: 73171471 (medium tight) and sealing threaded connections:
Application: 1. Loctite 242 / P/No. 73171473

2. Omnifit Rapid 100 M / P/No. 73171473
For permanently elastic sealing of threads, IC
engines, gearboxes etc., Threaded connections treated with these securing
adhesives are resistant against vibrations al-
Properties: though they can still be loosened.
Elastic at temperatures between -122F and Application:

+572F. Prevents element formation between dif-
fering metal surfaces. Is not flammable, non-toxic 1. Screws and bolts can be used in the
and is a bad conductor of heat. condition in which they are delivered.
Resistance:
2. Very dirty threads are to be cleaned with a
Resistant to all oils and lubricants, all fuels, air, grease solvent.
water, gases, water/glycol and water/methanol The solvent must be allowed to evaporate
mixtures, and to continuous vibration. completely.
Application: 3. a) For screws and bolts, apply a ring of the

adhesive to the first three thread pitches.
Brush or spread onto cleaned, oil-free surfaces.
Wait approx. 10 minutes between application and b) For blind-end threaded holes, coat the in-
assembly to allow the solvent content time to ternal thread.
evaporate. c) For threaded through-holes, apply the ad-
hesive to the screw/bolt thread.
Re-using:
Possible, provided that sealing surface is free of 4. Tighten the screw/bolt to the prescribed
dirt and grease. torque.
Points at which sealing film has broken away can
be re-sealed with fresh sealer. Hardening:
Fresh sealer vulcanizes with older sealer without
any special treatment being necessary. When using Loctite 242 to secure threaded com-
ponents, following hardening times can be as-
Removal: sumed:
- hand tight after 15 - 30 minutes
Hylomar is alcohol-soluble and can therefore be
removed by, for example, using a cloth saturated - final hardness after 3 hours
in methylated spirits.
If shorter hardening times are required, activator
"T" is to be used. First apply activator "T" to the
screws/bolts and allow it to dry completely. Then
apply Loctite 242 to the threads.
Hardening time is shortened to 20 minutes. Ac-
tivator "TN" P/No. 73171475.
Resecuring a threaded connection:
Remove hardened thread adhesive with com-

pressed air or a wire brush. Apply fresh adhesive
as described under "Application".
2 796 730.00 en 9
METAL ADHESIVES
The following products are approved: Tighten the bolts within 30-45 minutes.
Hardening begins after adhesive has been ap-
Omnifit Rapid 200 H / P/No. 73171476 plied and has contact to the air.
Application: Re-tighten the bolts after 50-60 operating hours
and in the intervals given in the machines Servic-
Swing bearing and track pad mountings. ing and Inspection Instructions.
Application: Disassembly:
Clean all traces of paint and grease from all Before lifting off a swing bearing, loosen it at
contact surfaces using AK-PHTH-thinner DV 2404 several points using a crowbar.
(P/No. 73171477). On small swing bearings, it is usually sufficient to
Apply a continuous strip, approx. 1 mm thick, in a hit the undercarriage or superstructure mounting
ring around each bolt hole. Keep the ring a slight surfaces with a hammer. Large swing bearings
distance away from the bolt hole to prevent the can be lifted off as soon as the bolts have been
adhesive from being squeezed into the thread loosened.
when the bolts are tightened up. Once the bolts have been removed, the small
fissures in the adhesive film (due to unevenness)
increase in size and cause the adhesive to crum-
ble away.
Fig. 1
10 2 796 730.00 en
ADHESIVES FOR PLASTICS ADHESIVE FOR O-RINGS
Acrylic cyanide (Loctite IS 414) Part No.: 73171480
Part No.: 73171478 Application:
Application: As an adhesive to form endless rubber piping (as

supplied) into O-rings.
Plastic to plastic
Plastic to rubber Application:
The adhesive contains acrylic cyanide ester
which brings about an instantaneous adhesion. 1. Place the rubber piping into the groove and
Humidity should be between 50 and 60% during cut off slightly longer than required.
application.
Hardening time: 2 - 5 seconds 2. Cut one end at a right angle (do not cham-
fer it) by pulling a sharp, clean, grease-free
Temperature range: blade through it.
-140 to +176F 3. Cut the other end to length with a straight

cut. Cut the rubber material 1 - 2 mm shorter
Storage stability:
than needed so that the O-ring lies with light
6 months at +72F. tension in the groove and does not fall out.
Storage in a refrigerator (+41F) lengthens the Greater tension of the ring twisting in its
storage life. Fresh adhesive can be freeze stored. groove during installation causing leakages.
Solubility: 4. Glue the two ends together in a butt joint.

Push the two ends together (with the hands)
In acetone, methylene-chloride, nitro-methane for at last 20 seconds
Avoid any contact with skin and eyes. The adhesive must NOT be allowed to
Keep working areas well ventilated. come into contact with the skin as it can
lead to the skin flaking away.
2 796 730.00 en 11
LUBRICANTS
Solid lubricating paste Compound spray
Part No.: 73171481 Part No.: 73171483
Application: Special lubricant, grease and bitumen free, with

EP additives and an especially high viscosity.
High-perfomance lubricant for reducing friction
and wear, among others for fitting and trouble- Application:
free removal of ball/roller bearings, bushings etc.,
Lubricant for swing bearings, exposed gear
Solid lubricant: wheels, racks, guides etc.,
Molybdenum disulphide Solid constituent:
Method of application: Graphite
Brush Adhesion and plasticity:
Temperature range: Very tough, no fracture formation
-77 to +113F Temperature range:
Solid lubricant paste spray -59 to +149F
Part No.: 73171482 Method of application:
Application: Spray
High-perfomance lubricant for reducing friction

and wear where low coefficients of friction are
encounted, among others for fitting and removal Do NOT inhale solvents. Keep work-places
of bearings, bushings etc., and for badly acces- well ventilated. Do NOT spray into open
sible points. flames.
Store spray cans at temperatures below
Method of application: +122F.
Spray
Composition
Molybdenum disulphide and other solid lubricants.
Temperature range:
-95 to +113F
Skin contact:
no objections
12 2 796 730.00 en
Mineral-based lubricating paste Lithium soap grease

Part No.: 73171484 Part No.: 73171485
Assembly paste for reduction of friction and fret Lithium soap grease with solid constituent (e.g.
corrosion on press and bearing seatings, pins, Molycote multi-purpose grease), resistant to wa-
splines, V-rollers etc., ter, consistency 2 for highly stressed plain and
roller/ball bearings.
Compatibility to seal rings:
Method of application:
good
Brush, grease gun
Method of application:
Temperature range:
Brush
-86 to +266F
Temperature range:
-86 to +302F
Skin contact:
No objection, except in cases of allergy
2 796 730.00 en 13
SOLID LUBRICANT FOR SILICON-CORUNDUM POWDER
MOLYCOTE-COATED BOLTS (REDURIT)
Part No.: 73171486 Part No.: 73171487
In series assembly, Molycote-coated bolts are Application:

use for all bolt sizes of M 36 and above. The
Molycote coating lowers the coefficient of friction Track pads of crawler excavators
and therfore the necessary tightening torque.
Application:
Before re-inserting such a bolt, coat the thread
and the turning seating (bolt head or nut) with Sand down the contact surfaces between chain
Molycote, P/No. 73171486. link and track pad.
The contact surface of the chain link must have a
smooth finish.
Brush a light film of petroleum onto the track pad

and scatter a thin coating of silicon-corundum
powered (grain size 150 - 250) onto it.
Fit and tighten up track pad.
Tighten up track pad bolts after 50 - 60 operating

hours.
14 2 796 730.00 en
P3 COLD CLEANER
Part No.: 73171488 Using P 3:
Application: P 3 is first to be diluted with petroleum or diesel

(fuel) oil. The concentration of the resulting solu-
P 3 cold cleaner is a concentrated cleaning liquid tion depends upon the degree of dirt to be re-
that is used (at room temperature) diluted with moved. It is usually sufficient to dilute with 2 to 4
either petroleum or diesel (fuel) oil. parts of petroleum.
If the degree of dirt is low, a seven-to-one dilution
P 3 cold cleaner has a neutral characteristic so with diesel (fuel) oil is sufficient.
that all metal and alloys can be treated without
being endangered by corrosion formation. The part to be cleaned is usually placed into the
solution. After a suitable cleaning time, it is then
P 3 cold cleaner is suitable for cleaning grease taken out of the solution and washed down with a
and oil from dirty and oiled machine and engine strong water jet.
components. Flash point approx. 140F. The cleaning solution itself must not come into
contact with water as this affects the cleaning
characteristics.
Cleaning is always carried out cold. The time for
cleaning depends upon the amount of dirt to be
removed. 20 to 30 minutes are usually adequate.
Very dirty, encrusted parts should be left in the
solution over night.
To clean large or fixed components, the cold
cleaner can be sprayed on. P 3 cold cleaner is to
be diluted and sprayed onto the component. If a
spray pistol is not available, the P 3 solution can
be applied with a brush. After the cleaning period,
the component is to be washed down with a
water jet.
P 3 cleaner must NOT come into contact with

sensitive lacquer/paint finishes.
Gloves should be worn for continuous use, resp.

when spraying or brushing on the P 3 cold clean-
er.
2 796 730.00 en 15
SURFACE CRACK CHECKING AGENT (METAL-CHECK)
Cracks and other faults in metal plates, forged Checking:
and cast steel parts can be localized using a
dye-penetration check. This is the simplestmethod 1. Clean the area to be checked.
of testing.
Further tests, e.g. magnaflux (magnetic-powder) 2. Spray on the red penetration fluid and allow
or ultra-sonic testing, require specialist knowledge 5 - 10 minutes for it to penetrate.
and special apparatus.
3. Remove the red penetration fluid using the
The dye-penetration (metal-check) test requires special cleaner.
only the following:
red penetration fluid - P/No. 73171489 4. Spray on the white developer.

Any cracks/faults show up as red "veins"
special cleaner - P/No. 73171491 against the white background. The extent of
the "veining" and the time allowed for devel-
white developer fluid - P/No. 73171492 opment provide indications as to the depth of
the cracks/faults.
Wipe off the developer with a cloth.
16 2 796 730.00 en
M
A METAL ADHESIVES .......................................... 10
Acrylic cyanide (Loctite IS 414) .......................... 11 Mineral-based lubricating paste .......................... 13
ADHESIVE FOR O-RINGS ................................ 11

P
ADHESIVES FOR PLASTICS ............................ 11
P3 COLD CLEANER .......................................... 15
Application of inhibitor .......................................... 5
Part nos. for Voler A.C. ........................................ 6
Application of Voler A.C. ...................................... 6
PRESERVATION OF CYLINDER PISTON
Application to gearboxes and axles without oil
RODS .................................................................. 5
filling .................................................................... 4
PRESERVATION OF GEARBOXES .................... 4
C Preservation period .............................................. 4
Compound spray ................................................ 12 Protective finishes ................................................ 4
Consumption of inhibitor ...................................... 5

R
Corrosion inhibitor ................................................ 5
Removing the inhibitor .......................................... 5
Corrosion protection for pins and bearings
(bushings and hubs) ............................................ 6 Renewing the inhibitor .......................................... 5
RIVOLTA W.S.X, NU CORROSION INHIBI-

F TOR FOR ELECTRICAL SYSTEMS .................... 7
FUNDAMENTAL SAFETY INSTRUCTIONS ........ 1 Rust inhibitor ........................................................ 4
G S
Gearboxes and axles with oil filling ...................... 4 S0LUTION 1 CORROSION INHIBITOR FOR
CYLINDER ROD THREADS ................................ 7
H Safety Instructions ................................................ 2
HYLOMAR SQ 32/M SEALING AGENT SILICON-CORUNDUM POWDER (REDURIT) .. 14

(THREAD SEALER) ............................................ 9
SOLID LUBRICANT FOR MOLYCOTE-COAT-
ED BOLTS .......................................................... 14
I Solid lubricant paste spray ................................ 12
INTRODUCTION .................................................. 1 Solid lubricating paste ........................................ 12
SURFACE CRACK CHECKING AGENT

L (METAL-CHECK) .............................................. 16
LIQUID THREAD ADHESIVES ............................ 9 SURFACE SEALING AGENTS ............................ 8
Lithium soap grease .......................................... 13
Loctite 573 (proprietary brand from Loctite W

Ltd.,) .................................................................... 8 Warnings and symbols ........................................ 1
LUBRICANTS .................................................... 12 WKT black - H ...................................................... 8

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FOREWORD

Using the Technical Handbook .............................................................................................................. 1

Warnings and symbols ............................................................................................................................ 2

Danger in the event of non-obser-vance of the safety instructions .................................................... 2

Organizational measures ........................................................................................................................ 3

Selection and qualification of personnel - basic responsibilities ........................................................ 4

Safety instructions governing specific operational phases

Warning of special dangers

Transporting and towing - recommissioning ........................................................................................ 7

California, Proposition 65 Warning ........................................................................................................ 7

Repair work - safety instructions ............................................................................................................ 8

Accumulators, safety instructions .......................................................................................................... 9

Engine, repair instructions .................................................................................................................... 10

Assisted starting (with jump-leads) - safety instructions .................................................................. 10

WELDING OPERATIONS ........................................................................................................................ 11

Welding operations - safety instructions.............................................................................................. 11

The main table of contents allows to find the

For the sake of clarity, the illustrations have been

Warnings and symbols 2732729 Danger in the event of non-obser-

This hydraulic excavator has been built in

Organizational measures 2261965

Use protective equipment wherever required by

Selection and qualification of per- Safety instructions governing

Before setting the machine in motion, make sure

Before starting work or travelling with the ma-

Before setting the machine in motion always

When travelling on public roads, ways and places

If the machine is completely shut down for main-

Carry out maintenance and repair work only if the

To avoid the risk of accidents, individual parts

The fastening of loads and the instructing of

After cleaning, examine all fuel, lubricant, and

Hydraulic and pneumatic equipment Transporting and towing - recom-

Oil, grease and other chemical sub-

Be careful when handling hot consumables (risk

Operating instructions Pressurized or spring loaded units

Accumulators are installed in the hydraulic

Engine, repair instructions Assisted starting

Read and observe: "Repair, safety instruc-

C Special work in conjunction with utilization of

Standard operation .............................................. 4

Engine, repair instructions .................................. 10 W

G Welding operations - safety instructions ............ 11

Gas, dust, steam and smoke ................................ 6

Service Data General

2 801 850.00 de/us

SI - AND ADDITIONAL UNITS

Die "Service Daten" enthalten Angaben, die fur

Betriebsanleitung Operating manual

Ersatzteilliste Spare parts list

Zur Dokumentation im weiteren Sinne gehoren

Data regarding auxiliary units for operating ancillary

Die in den Kapiteln aufgefuhrten

2 801 850.00 de/us 1

2 2 801 850.00 de/us

SI - AND ADDITIONAL UNITS

Quantity Symbol alt old neu new Fur

SI-Einheit Auswahl (2 % Unge-

Volumen V, Vn mm3, cm3, dm3, m3 mm3, cm3, dm3,

Masse m g, mg, g, kg, kg g, mg, g

Dichte g/cm3, kg/dm3, kg/m3 g/cm3, kg/dm3

Spezifisches Volumen v m3/kg, m3/t m3/kg m3/Mg

2 801 850.00 de/us 3