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Operating Instructions

Mobile Excavator HML 42

AUSGABE • EDITION

2003-07 GÜLTIG AB FZ-ID.NR. • VALID FROM SERIAL NO. • A PARTIR DU NO. DE SERIE

004200/0099 > 0218 SCHAEFF-TEREX GmbH & CO. KG • D-74595 LANGENBURG

Hauptverwaltung/Verkauf

Kundendienst

Ersatzteile

Direction générale/Vente

Service après-vente

Pièces de rechange

Headquarters / Sales

Service department

Spare parts

Schaeff-Terex GmbH & Co KG

Schaeff-Terex GmbH & Co KG

Schaeff-Terex Ersatzteile-Service

Postfach 61 • D-74595 Langenburg

Postfach 12 64 • D-91534 Rothenburg

Postfach 12 64 • D-91534 Rothenburg

Schaeffstr. 8 • D-74595 Langenburg

Erlbacher Str. 115 • D-91541 Rothenburg

Erlbacher Str. 115 • D-91541 Rothenburg

Phone

+49 (0) 7905/58-0

Phone

+49 (0) 9861/972-451

Phone

+49 (0) 9861/972-0

Fax

+49 (0) 7905/58-114

Fax

+49 (0) 9861/972-460

Fax

+ 49 (0) 9861/972-410

GmbH & Co KG

Order no.:

5 780 140 012

Table of Contents 1 Introduction.....................................................................................................................1 1.1 General.................................................................................................................................. 1 1.2 Warranty and Maintenance .................................................................................................... 2 1.3 Notes on using the instruction book ....................................................................................... 2 1.4 Environmental requirements .................................................................................................. 3 1.5 Pictograms............................................................................................................................. 3 1.6 Copyright ............................................................................................................................... 5

2 Safety and Prevention of Accidents..............................................................................7 2.1 Introductory remarks .............................................................................................................. 7 2.2 Proper use ............................................................................................................................. 7 2.3 General safety notes.............................................................................................................. 8 2.4 Operation............................................................................................................................... 8 2.5 Danger zone .......................................................................................................................... 9 2.6 Transport of persons.............................................................................................................. 9 2.7 Stability .................................................................................................................................. 9 2.8 Travel operation................................................................................................................... 10 2.9 Operation............................................................................................................................. 10 2.10 Guides ............................................................................................................................... 11 2.11 Danger of falling objects..................................................................................................... 11 2.12 Working in the vicinity of underground power lines............................................................. 11 2.13 Working in the vicinity of overhead power lines.................................................................. 12 2.14 Operation in closed rooms ................................................................................................. 12 2.15 Work stoppages................................................................................................................. 12 2.16 Load hook applications ...................................................................................................... 13 2.17 Change of work attachments, maintenance, repair ............................................................ 13 2.18 Recovery, loading, transportation....................................................................................... 14 2.19 Monitoring and inspections ................................................................................................ 15 2.20 Fire protection.................................................................................................................... 15 2.21 Emergency exit .................................................................................................................. 15 2.22 Other dangers.................................................................................................................... 15

3 Technical Data ..............................................................................................................17 3.1 Views ................................................................................................................................... 17 3.2 Engine ................................................................................................................................. 20 3.3 Electrical system.................................................................................................................. 20 3.4 Travel drive .......................................................................................................................... 20 3.5 Brakes ................................................................................................................................. 21 3.6 Hydraulic system ................................................................................................................. 22 3.7 Axles.................................................................................................................................... 23 3.8 Tires .................................................................................................................................... 24 3.9 Lubricants ............................................................................................................................ 24 3.9.1 Filling quantities............................................................................................................. 24 3.9.2 Fuel, lubricant and coolant specifications....................................................................... 25 3.10 Permissible loads in accordance with local regulations ...................................................... 26 3.11 Sound level values, vibration ............................................................................................. 26 3.12 Dimensions and weights .................................................................................................... 26 3.13 Excavator installation ......................................................................................................... 27 3.14 Carrying capacity ............................................................................................................... 27 3.15 Work attachments .............................................................................................................. 28 3.16 Stabilizers / Support blade ................................................................................................. 29 3.17 Optional accessories.......................................................................................................... 29

HML 42

Table of Contents 4 Operation.......................................................................................................................30 4.1 Operator controls ................................................................................................................. 30 4.2 Engine ................................................................................................................................. 34 4.2.1 Starting the engine......................................................................................................... 34 4.2.2 Monitoring during operation ........................................................................................... 35 4.2.3 Switching off the engine................................................................................................. 36 4.3 Driver’s seat, height and tilt adjustment of steering wheel .................................................... 37 4.4 Heating / Ventilation / Air conditioning.................................................................................. 38 4.5 Light switch .......................................................................................................................... 39 4.6 Front window ....................................................................................................................... 39 4.7 Travel operation................................................................................................................... 40 4.7.1 Driving ........................................................................................................................... 40 4.7.2 Steering ......................................................................................................................... 42 4.7.3 Brakes ........................................................................................................................... 44 4.7.4 Driving on roads............................................................................................................. 44 4.8 Parking the machine ............................................................................................................ 46

5 Working Operation........................................................................................................47 5.1 General................................................................................................................................ 47 5.2 Moving the excavator at high engine speed ......................................................................... 48 5.3 Operation of work functions ................................................................................................. 49 5.3.1 Operation of work equipment ......................................................................................... 49 5.3.2 Operation — intermediate boom/ articulation ................................................................. 50 5.3.3 Operation — Stabilizers / Support blade ........................................................................ 50 5.3.4 Operation — Front dozer blade (option)......................................................................... 51 5.3.5 Operation — Additional control circuit ............................................................................ 52 5.3.6 Operation of oscillating axle lock.................................................................................... 52 5.4 Changing work attachments................................................................................................. 53 5.4.1 General.......................................................................................................................... 53 5.4.2 Assembly of work attachments ...................................................................................... 54 5.4.3 Clamshell grab............................................................................................................... 55 5.4.4 Hydraulic rock breaker ................................................................................................... 56 5.4.5 Using the machine for load hook applications ................................................................ 57

6 Towing and Transport of the Machine ........................................................................59 6.1 Towing the machine............................................................................................................. 59 6.2 Loading the machine using a crane ..................................................................................... 61 6.3 Transporting the machine .................................................................................................... 62

7 Maintenance and Service .............................................................................................63 7.1 General................................................................................................................................ 63 7.2 Intervals ............................................................................................................................... 63 7.3 Regular oil analyses............................................................................................................. 64 7.4 Warranty .............................................................................................................................. 64 7.5 Inspection parts and aids ..................................................................................................... 65 7.6 Care and cleaning................................................................................................................ 66 7.7 Notes for use in winter ......................................................................................................... 66 7.8 Checking, maintenance and inspection plans ...................................................................... 68 7.8.1 Initial inspection (delivery/ handing-over inspection) ...................................................... 68 7.8.2 Daily and weekly tasks................................................................................................... 70 7.8.3 Overview of lubricating points ........................................................................................ 72 7.8.4 Inspection plan .............................................................................................................. 74

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Table of Contents 7.9 Inspection and maintenance work........................................................................................ 76 7.9.1 Engine oil....................................................................................................................... 76 7.9.2 Engine oil filter ............................................................................................................... 77 7.9.3 Cooling system — Combined hydraulic oil-water cooler................................................. 78 7.9.4 Fuel system ................................................................................................................... 80 7.9.5 Air filter, air intake .......................................................................................................... 82 7.9.6 V-belts ........................................................................................................................... 86 7.9.7 Checking the valve lash ................................................................................................. 87 7.9.8 Hydraulic oil tank ........................................................................................................... 88 7.9.9 Hydraulic oil return filter ................................................................................................. 89 7.9.10 Hydraulic oil suction filter ............................................................................................. 90 7.9.11 Hydraulic oil tank breather ........................................................................................... 91 7.9.12 Venting the plunger cylinders....................................................................................... 92 7.9.13 Line-rupture valves for stabilizers................................................................................. 92 7.9.14 Axles............................................................................................................................ 93 7.9.15 Brakes ......................................................................................................................... 97 7.9.16 Wheels ........................................................................................................................ 99 7.9.17 Swing gear................................................................................................................. 100 7.9.18 Swing bearing ............................................................................................................ 100 7.9.19 Cab ventilation dust filter............................................................................................ 102 7.9.20 Windshield washer system......................................................................................... 102 7.9.21 Electrical equipment................................................................................................... 103 7.10 Shutdown......................................................................................................................... 104 7.10.1 Preservation (temporary shutdown) ........................................................................... 104 7.10.2 During shutdown........................................................................................................ 104 7.10.3 After shutdown........................................................................................................... 104

8 Trouble-Shooting ........................................................................................................105 8.1 Generalities........................................................................................................................ 105 8.2 Engine ............................................................................................................................... 105 8.3 No steering movement....................................................................................................... 105 8.4 Insufficient performance of service brake........................................................................... 105 8.5 Parking brake without function ........................................................................................... 105 8.6 Insufficient braking power of swing brake........................................................................... 105 8.7 No zero position of travel direction ..................................................................................... 106 8.8 Hydraulic oil exceeds max. admissible temperature........................................................... 106 8.9 Sluggish acceleration and deceleration, too little propulsive power .................................... 106 8.10 Transmission works in one direction only......................................................................... 107 8.11 Transmission works in neither direction ........................................................................... 107 8.12 Excavator installation is not working................................................................................. 108 8.13 Decrease in machine’s performance ................................................................................ 108 8.14 Machine is working too slowly and hydraulic oil is becoming hot...................................... 108 8.15 Superstructure slews too far ............................................................................................ 109 8.16 Working cylinders are not working satisfactorily ............................................................... 109 8.17 Plunger cylinders fail to lock or lock insufficiently ............................................................. 109 8.18 Overload warning device malfunctions............................................................................. 109 8.19 Trouble in the electrical system........................................................................................ 110

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Table of Contents 9 Appendix .....................................................................................................................111 9.1 Electrical system................................................................................................................ 111 9.2 Hydraulic system ............................................................................................................... 124 9.3 Immobilizer ........................................................................................................................ 126 9.3.1 Activating the system ................................................................................................... 126 9.3.2 Deactivating the system............................................................................................... 126 9.3.3 Operating malfunctions ................................................................................................ 127

HML 42

Introduction 1 1 Introduction 1.1 General You decided to buy the SCHAEFF-TEREX HML 42 Mobile Excavator. The confidence placed in this model will be rewarded by the efficient and economical performance of the machine.

Please state the vehicle type and the vehicle identification number when making inquiries or orders, and in all written correspondence. The vehicle identification number of the machine is stamped on the type label (1/1).

These operating instructions contain all information necessary for the correct use of the machine. Please read them carefully before putting the machine into operation and make sure that they are kept at hand at all times. If you require additional information or if any point is unclear, please contact your dealer immediately.

FH ARZ U E GT Y P u .S E IR E NBEE Z IC H U NNG

XX XX

Z I.- E F D N .T N R.

XXX /XX XX

Z U .G L ESM A T GE WI C H T k( g)

AUA B J HR

Z U .V L ORE DRAH CSA L S T (kg )

U L .H IN T R Z EAH CSL S A T k( g)

MO T O R L IE S T UG N (kW )

T SA NDAD RBER T IE S G W E IC H T k( g)

MA D E IN G E R M N AY

Special equipment and attachments are not included in these operating instructions. We reserve the right to make improvements on the machine within the scope of impending technical developments, without incurring any obligation to change these operating instructions.

1 HM32-001

Fig. 1 – Type label

Any modifications of SCHAEFFTEREX products and their equipment, including additional equipment and work attachments, which are not included in our product range, are subject to our written approval. If omitted, our warranty as well as our product liability for possibly caused damage will expire.

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1

1 Introduction 1.2 Warranty and Maintenance The warranty period covers 1,000 operating hours, not exceeding a maximum of twelve months, whichever comes first, beginning with the day the machine is handed over or put into operation. Safe working conditions and good working order of the machine are prerequisites for efficient work. Your SCHAEFF-TEREX mobile excavator fulfills these requirements when correctly handled and when serviced and maintained as specified. Careful observation of the machine whilst in function and the use of the specified lubricants will prevent malfunction. Trained specialist personnel are responsible for any servicing of the machine which requires expert knowledge. Inspections and repairs must therefore be carried out by your dealer’s customer service. In respect of possible claims for damages during the warranty period, all work specified in the maintenance and inspection plan must be carried out at the specified intervals. After the warranty period, too, regular maintenance must be performed in order to ensure that the machine is constantly in good working order and enjoys a reasonable service life. Insist that only original SCHAEFF-TEREX spare parts are used in the event of any repair work. In this way, you will have a product of lasting high quality, thereby ensuring that your machine maintains its original condition.

2

1.3 Notes on using the instruction book References to pictures and items The references to pictures and items contained in the text, such as "Figure 12/4" mean Figure 12, Item 4 (Fig. = Figure). The figures instructions equipment.

shown partly

in these operating contain additional

“DANGER” symbol This symbol is employed for a high risk of injury to persons. It is essential that the safety notes are observed.

“WARNING” symbol This symbol is employed for information whose non-compliance may lead to severe material damage. It is essential that the safety notes are observed.

“ATTENTION” symbol This symbol is employed for information containing important notes about the correct use and / or how to proceed. Non-compliance may lead to malfunction.

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Introduction 1 1.4 Environmental requirements

1.5 Pictograms

Applicable environmental requirements must be observed for all tasks performed on and with the machine.

The following table explains the meaning of the pictograms which may be attached to your machine.

During installation, repair and maintenance tasks, particular care must be taken that substances that would damage the environment such as

Symbol

• Lubricating grease and oil

Description Danger

• Hydraulic oil

In Operating Instructions: Warning

• Fuel • Coolants • Cleaning fluids containing solvents

On machine: Caution — Safety distance

are not allowed to come in contact with the soil or the water system.

Attention

These substances must be stored in suitable containers and must be properly transported, collected and disposed of.

Battery charge indicator

If the substances listed above do reach the soil, the leak or outlet must be stopped immediately and the fluid must be cleaned up with a suitable absorbent material. If necessary, the soil involved must be removed. Absorbent materials and removed soil must be disposed of properly. Applicable environmental requirements must be observed.

Pre-heating Engine oil pressure Coolant temperature Air filter

Fuel / Fuel level Fan / Heater / Ventilation Air conditioning Windshield wash/ wipe system Horn

R

HML 42

Travel motion alarm

3

1 Introduction

Symbol

Description Hydraulic oil / Hydraulic oil level

Symbol

!

Description Brake accumulator pressure monitor

Hydraulic oil filter clogging indicator

Parking brake

Mode of operation

Oscillating axle lock

Operating hours Hazard warning system

Dozer blade

Direction indicator, left/ right

Hydraulic rock breaker

Light, low beam

Overload warning indicator

High beam indicator lamp

Lashing points

Working floodlights

Suspension points for loading by crane

Rotating beacon

First-aid kit

Rear fog lamp

Fire extinguisher

V

Travel, forward / reverse

Danger of crushing

Travel speed, fast

Danger of injury

Travel speed, slow

Observe notes in Operating Instructions

R

Accelerator pedal for "Sensitive" travel

Grease gun Lubricating point

Steering change-over Working hydraulics cut-off Engine speed control

4

HML 42

Introduction 1 1.6 Copyright This instruction book is intended for use by personnel responsible for operation, maintenance, repair and supervision of the machine. These operating instructions are copyrighted and shall not, either in whole or in part, be reproduced, transmitted or used for the purpose of competition without our prior written permission.

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5

1 Introduction

6

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Safety and Prevention of Accidents 2 2 Safety and Prevention of Accidents

2.2 Proper use

2.1 Introductory remarks

The earth-moving machine with standard bucket equipment is intended solely for work which is suitable for the function of the machine and its work implements.

Before putting the earth-moving machine into operation, read these operating instructions carefully and strictly observe the indicated references for safe operation. National safety regulations - e.g. the Accident Prevention Regulations, “Earth-Moving Machinery” (VBG 40) and “Vehicles” (VBG 12) in the Federal Republic of Germany must also be complied with when operating the earth-moving machine. In addition to the operating instructions, legal regulations governing road traffic and road safety measures must also be observed. Such requirements could also apply in respect of handling hazardous goods or the wearing of personal safety gear, for example. Furthermore, safety laws governing work in particular locations (tunnels, adits, quarries, pontoons, contaminated areas, etc.) must likewise be observed.

Such work involves loosening, taking up, transporting and dumping soil, rock or other materials as well as loading these materials on trucks, conveyor belts or other means of transport. The assembly of special work implements such as clamshell grab, hydraulic rock breaker, etc. allows the machine to perform above mentioned work. Any usage above and beyond that specified here, e.g. the transport of persons or the transport of loading material and any noncompliance with the manufacturer’s instructions is regarded as improper use. The manufacturer shall not be liable for damage resulting from improper use. This risk is borne solely by the plant operator. Compliance with the operating and maintenance instructions, the performance of maintenance work as specified and adherence to replacement intervals all form part of the concept of proper use.

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2 Safety and Prevention of Accidents 2.3 General safety notes

2.4 Operation

It is important to refrain from any working methods which impair safety.

Earth-moving machines are only to be independently operated and serviced by persons who

The earth-moving machine is only to be used when it is in a safe, operational condition. The manufacturer’s instructions must be complied with for operation, maintenance, repair, assembly and transportation. The plant operator must provide additional special safety instructions, wherever necessary, for specific local conditions. The operating instructions and any information pertaining to safety must be carefully kept in the operator’s cab.

• are physically and mentally suitable • have been instructed in the operation or maintenance of earth-moving machines and have demonstrated this ability to the plant operator • can be expected to perform their allocated duties reliably All such persons must be of the legal minimum age.

The operating instructions and safety notes must be complete and fully readable.

They must be designated by the plant operator to operate or service the earthmoving machine.

Safety devices on earth-moving machines are not to be deactivated or removed.

Operating equipment is only to be operated from the driver's seat.

Protective work clothing must be worn during operation. Rings, scarves and unbuttoned jackets are to be avoided. Protective goggles, protective boots, helmets, gloves, reflecting jackets, ear-muffs, etc. may be required.

The earth-moving machine is only to be ascended and entered using the entrances and surfaces intended for this purpose.

Before commencing work, information must be obtained on first aid and possible means of rescue (ambulance, fire brigade, helicopters).

It is the driver’s responsibility to ensure that the operator’s stand, entrances and other surfaces of the earth-moving machine which have to be stepped on are free of dirt, grease, oil, ice and snow.

A check must be carried out to ensure that the first aid box is at hand and that its contents comply with regulations. Personnel must be aware of the location and method of operation of the fire extinguishers on the earth-moving machine as well as onsite fire-warning and fire-fighting equipment. Loose parts such as tools or other accessories must be secured to the earthmoving machine. Open doors, windows, covers, flaps, etc. must be closed or secured so that they cannot slam shut.

8

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Safety and Prevention of Accidents 2 2.5 Danger zone

2.6 Transport of persons

•

The transport of persons on the machine is forbidden.

No one is to enter the danger zone of earth-moving machines. The danger zone encompasses the area around the earth-moving machine in which persons may be injured by movements of the earthmoving machine during operation, its work implements and attachments, or by swinging out or falling loads.

•

•

2.7 Stability •

The machine operator is only to work the earth-moving machine when the danger zone is free of personnel.

The earth-moving machine must be used, driven and operated in such a manner that its stability against overturning is ensured at all times.

•

The machine operator must give a warning signal to persons who may be in danger.

The machine operator must drive at speeds which are suitable for local conditions.

•

The permitted payload of the earthmoving machine is not to be exceeded.

•

The machine operator shall stop work with the earth-moving machine if anyone remains in the danger zone despite the warning.

•

The earth-moving machine must remain at a sufficient distance from the edges of quarries, pits, mounds and slopes to ensure there is no risk of falling.

•

To ensure no danger of crushing, a sufficient safety distance (min. 0.5 m) must be kept from solid objects, e.g. buildings, excavation slopes, scaffolding, other machines, etc.

•

Earth-moving machines must be secured so that they cannot roll or slip when in the vicinity of excavations, shafts, ditches, pits and slopes.

•

If the above safety distance cannot be maintained, the area between solid objects and the working zone of the earthmoving machine must be blocked off.

•

If conditions are such that the machine operator’s view of the driving and working zone is restricted, he must be guided or the driving and working zone must be marked by a solid barricade.

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2 Safety and Prevention of Accidents 2.8 Travel operation

2.9 Operation

Before putting the earth-moving machine into operation, the driver's seat, mirrors and operator's controls must be adjusted so as to ensure safe working.

Daily before commencing work and after every change of work attachments, the machine operator must check the correct fastening of the work attachments as well as the correct lock of the quick-mount hitch. Work attachments are to be carefully moved at low height. During this check no one is to be in the danger zone of earth-moving machines.

A safety belt (seat belt), if installed, must always be fastened. The windows must be clean and free of ice. Driving tracks must be designed so as to ensure smooth, safe operation, i.e. they must be sufficiently wide, on ground which has as few slopes as possible and sufficient carrying capacity. Downhill tracks must be set out in such a way that earth-moving machines can be safely braked. Before driving downhill, the appropriate gear for the terrain must be selected and the gear lever is not to be moved during downhill travel (on-road or cross-country gear). On steep drops and uphill gradients, the load must be carried on the uphill side, if possible, in order to increase stability. The carrying capacity of bridges, cellar roofs, vaults, etc. must be verified before the earthmoving machine can drive over them.

The machine operator is only to swing the work equipment over occupied drivers' seats, operator consoles and workplaces of other machines when these are protected by canopies (FOPS). If a cab does not have the required protection, the driver of this vehicle must leave the operator’s stand when the work equipment has to be slewed overhead. The vehicles must be loaded in such a manner as to ensure that there is no overloading and no material can be lost during travel. The vehicle must be loaded from the lowest possible height. At dumping points, earth-moving machines are only to be operated when suitable measures have been taken to prevent rolling or falling.

The internal dimensions of constructions must be noted before entering underground passages, tunnels, etc. It is the plant operator's responsibility to ensure that equipment such as first-aid box, warning triangle, hazard lights are kept with the machine in compliance with the traffic regulations valid in the user’s country (e.g. in Germany "StVZO"), and that the driver has the appropriate license as required by the national traffic laws of the country in question. Outside areas covered by general traffic regulations, e.g. on construction sites, traffic regulations should be applied in the proper manner. This should also apply with regard to drivers’ licenses.

10

HML 42

Safety and Prevention of Accidents 2 2.10 Guides Guides must be easily recognizable, e.g. by means of reflective clothing. They must remain within the machine operator’s field of vision. While guiding the machine, guides are not to be given other jobs which may distract them from their task.

2.12 Working in the underground power lines

vicinity

of

Before commencing excavating work using earth-moving machines, it must be determined whether any underground power lines are present in the intended working zone which may present a danger to persons.

2.11 Danger of falling objects

If underground power lines are present, their exact position and course must be determined in consultation with the proprietor or operator of the lines, and the necessary safety precautions decided and implemented.

Earth-moving machines are only to be used where there is a danger of falling objects when the operator’s stand has a canopy (FOPS). A front rock guard must be employed if there is a risk of materials breaking into the cab.

The course of power lines in the work area must be clearly marked, under supervision, before commencing any excavation work. If the position of lines cannot be determined, search ditches must be dug - manually, if needed.

In front of walls e.g. of stacked materials, earth-moving machines must be positioned and operated in such a way that the driver's seat and entry to the driver's seat are not situated on the side facing the wall.

If underground power lines are encountered unexpectedly or they or their protective covers are damaged, the machine operator must discontinue work immediately and notify the supervisor.

Demolition work is only to be performed by earth-moving machines where there is no danger to persons and if the machine is equipped with canopy, front rock guard mounted on cab and the appropriate work implement. See regulations book “Demolition work” (ZH 1/614) published by the TiefbauBerufsgenossenschaft (the employer’s liability insurance association).

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2 Safety and Prevention of Accidents 2.13 Working in the vicinity of overhead power lines

Such measures could be, e.g. •

Switching off the current

When the earth-moving machine is being used in the vicinity of overhead power lines and trolley wires, a safety distance which varies depending upon the nominal voltage of the overhead line must be maintained between the lines and the earth-moving machine and its work equipment, in order to prevent current overspill.

•

Re-routing the overhead line

•

Cabling, or

•

Limiting the work zone of earth-moving machines.

This also applies to the distance between these lines and attached implements or loads. The safety distances specified below must be complied with: Nominal voltage in Volt

Safety distance in meters

- 1000 V

1.0 m

over 1 kV - 110 kV

3.0 m

over 110 kV - 220 kV

4.0 m

over 220 kV - 380 kV

5.0 m

nom. voltage unknown

5.0 m

In the observation of safety distances, all working movements of earth-moving machines, e.g. positions of the work equipment and the dimensions of attached loads must be taken into consideration. Uneven ground which would cause the earthmoving machine to be inclined and thus nearer to overhead lines must also be taken into account. During work in windy conditions, both overhead lines and work equipment may swing out, thus reducing the safety distance. If it is impossible to maintain sufficient distance from overhead power lines and trolley wires, the plant operator must consult with the proprietor or operator of the overhead lines to find other safety precautions to prevent current overspill.

12

2.14 Operation in closed rooms If earth-moving machines are to be used in closed rooms, these areas must be sufficiently ventilated and the special regulations observed. 2.15 Work stoppages Before rest periods and at the end of the working day, the driver of the earth-moving machine must park the machine on ground which has sufficient carrying capacity and is as level as possible, and must secure it against unintended movement. Before rest periods and at the end of the working day, the driver must lower the work equipment onto the ground or secure it so that it cannot move. The driver is not to leave the earth-moving machine if the work equipment has not been lowered to the ground or secured. Earth-moving machines are only to be parked in places where they do not present an obstacle to others, e.g. on the construction site or to plant traffic. Warning devices, e.g. triangles, warning cordons, flashing or hazard lights are to be used if necessary. Before leaving the operator stand, the driver must bring all operating equipment into home position, switch off the working hydraulics and apply the brakes. If the driver is leaving the earth-moving machine unattended, he must first turn off the engine and ensure that it cannot be started up by unauthorized persons (e.g. removing ignition keys).

HML 42

Safety and Prevention of Accidents 2 2.16 Load hook applications Load hook applications are the hoisting, transporting and lowering of loads with the aid of a fixing device (rope, chain, etc.), whereby the assistance of personnel is required to attach and release the load. Such work covers e.g. the lifting and lowering of pipes, tubbing rings or containers. Earth-moving machines are only to be used for load hook applications if they are equipped in the proper manner and if they have the approval to this purpose. For load hook applications, the earth-moving machine must be equipped with the following safety devices which have to be in proper working condition: • Secure attachment of loading implements • Table of carrying capacity • Overload warning device • Line rupture valve in boom cylinder When earth-moving machines are used for load hook applications, personnel attaching loads are only to approach the boom from the side and with the machine operator’s permission. The machine operator is only to give his permission if the earth-moving machine is standing still and the work equipment is not in motion. Personnel guiding the machine and attaching loads are never to leave the machine operator’s field of sight. Do not use fixing devices (ropes, chains, shackles) which are damaged or of inadequate dimensions. Protective gloves must always be worn when working with fixing devices. Only loads not exceeding the carrying capacity of the machine and the hoisting appliance are to be used. Attach loads only at the load hook intended for this purpose. Loads must be attached in such a way that they cannot slip or fall out. Do not guide loads above persons. The machine operator must carry loads as close to the ground as possible and prevent them from swinging.

HML 42

Earth-moving machines are only to travel with an attached load if the path of travel is fairly level and if there is sufficient overview of the path of travel.

2.17 Change of work maintenance, repair

attachments,

Earth-moving machines are only to be converted, maintained or serviced under the guidance of a suitable person designated by the plant operator and following the manufacturer’s operating instructions. After every change of work attachments, the driver must convince himself that the quickmount hitch is correctly fastened and locked. Work on e.g. • braking, • steering, • hydraulic and • electric systems of the machine is only to be carried out by expert personnel specially trained in these areas. Stability must be ensured during all type of work on the machine at all times. The work equipment must be secured against movement by lowering it to the ground or equivalent measures, e.g. cylinder supports, trestles. With the engine running, the unprotected articulation range of articulated loaders is not to be entered. When jacking up earth-moving machines, jacking devices must be positioned so that they cannot slip. Jacks must be positioned and applied absolutely straight, without tilting. Raised earth-moving machines must be supported by suitable structures such as crosswise stacks of planks, square timbers or steel trusses. Earth-moving machines which are raised with work equipment must be stabilized by a supporting structure immediately after lifting. Work under machines which are only supported by their hydraulics is forbidden.

13

2 Safety and Prevention of Accidents The engine/motor must be turned off prior to all maintenance and repair work. These requirements are only to be ignored in the case of maintenance or repair work which cannot be performed without the engine/motor running. When performing maintenance and repair work on the hydraulic system, the system must be relieved of pressure. With the engine turned off, lower the work equipment to the ground and actuate all hydraulic control levers until there is no pressure in the hydraulic system. Before working on the electrics or when performing arc-welding on the machine, the connection to the battery must be disconnected. When disconnecting the battery, first the negative pole then the positive pole must be disconnected. The battery must be reconnected in reverse order. During repair work around the battery, the battery must be covered with insulating material; tools should never be placed on or near the battery. Protective devices of moving machine parts are only to be opened or removed when the drive has been switched off and cannot be switched on again by unauthorized persons. Protective devices are e.g. engine/motor covers, doors, protective grating, trim. Upon completion of assembly, maintenance or repair work, all protective devices must once more be attached in the proper manner. Load-bearing parts of loading machines are only to be welded following consultation with the manufacturer and in accordance with recognized welding principles. Protective structures (ROPS, FOPS) are not to be welded or drilled in any way.

Swallowing lubricants, or long and repeated skin contact, can be hazardous to health. When used properly, there is no particular danger to health. The safety specification sheets from the mineral companies must be observed. Only the hoses specified by the manufacturer are to be used. Hydraulic hoses must be routed assembled by expert personnel.

and

In the vicinity of fuel or batteries, smoking and naked flames are prohibited.

2.18 Recovery, loading, transportation Earth-moving machines are only to be loaded onto recovery vehicles when adequate towing vehicles are used. The tow fixing points specified by the manufacturer must be employed. For loading and transportation, earth-moving machines and all necessary auxiliary equipment must be secured against unwanted movement. The traveling gear and track-laying gear of earth-moving machines must be sufficiently cleaned of mud, snow and ice to ensure that ramps can be driven up without risk of slipping. When transporting the earth-moving machine on trucks, flatbed trailers, or by rail, it must be sufficiently secured with chocks and by attachment to the lashing points. Before setting off, the route to be taken must be examined to determine whether the roads are wide enough, entrances and passages under bridges are large enough and that roads and bridges have sufficient carrying capacity.

Alterations, such as welding of the hydraulic system, are only to be undertaken with the manufacturer’s permission. Before commencing work on the hydraulic system, the operating pressure, pilot pressure, back pressure and pressure inside the tank must be let off.

14

HML 42

Safety and Prevention of Accidents 2 2.19 Monitoring and inspections The machine must be submitted to a general inspection in compliance with the existing UVV-regulations (Accident Prevention Regulations). This inspection must be carried out by an expert (e.g. machine engineer or machine foreman): • before the machine is put into operation for the first time and before the machine is again put into operation after essential modifications have been made • at least once a year

The machine operator must advise the supervisor immediately and his replacement, if there is a change of operator with regard to any shortcomings. In the event of shortcomings which jeopardize the operating safety of the earth-moving machine, it is not to be used until these have been eliminated.

2.20 Fire protection The fire extinguisher must be kept in the cab. The fire extinguisher symbol must be attached.

• in the meantime, in compliance with operating conditions and local environments The results of this inspection have to be recorded in writing and this record has to be kept until the next inspection takes place. Prior to every work shift, the machine operator must check the earth-moving machine in compliance with the inspection and maintenance plan. Hydraulic hoses must be replaced as soon as the following damage is recognized: • Damage to the outer layer which reaches the intermediate layer

MTK115002

2.21 Emergency exit The windshield acts as an emergency exit. If a front rock guard is fitted or this exit can no longer be used for any other reason, an emergency hammer must be affixed in an easily accessible place inside the operator’s cab.

• Embrittled patches on the outer layer • Deformations when under pressure or without pressure which differ from the original shape of the installed hose

2.22 Other dangers

• Leaks

Failure of the hydraulic system

• Damage or deformation to hose fittings or to the connection between the fitting and the hose

If the hydraulic system fails because the diesel engine is not running, the hydraulic pump is damaged or hydraulic oil has been lost, only the EMERGENCY functions

The coolant level is only to be checked after the engine has cooled down; the cap must be turned carefully in order to bleed excess pressure.

• manual steering assistance) and

Prior to operations, the machine operator must check the function of the safety devices.

HML 42

(without

power

• lower work equipment (only if ignition is switched on) can be performed.

15

2 Safety and Prevention of Accidents

16

HML 42

Technical Data 3 3 Technical Data 3.1 Views • Two-piece articulated boom "TPA" with dipperstick, 2,000 mm

3

4

5

3

4

5

6040

2

1

0

1

2

3

4

5

6

7

8

9

9

8

7

6

5

4

8300

3

2

1

0

HM42-003

3975 2990

3665 4315

4980

2

1

0

1

2

3

4

5

6

7

8

9

9

8

7

6

5

4

8010 Ausladung Greifer

3

2

7140 8240

5530

Fig. 3 Digging envelope

HML 42

17

3 Technical Data • Two-piece articulated boom "TPA" with special dipperstick, 1,850 mm, for Atlas-tools 9

8

7

6

8215

5

5843

4

2990 3975

2891

3

2

1 0 9

8

7

6

5

4

3

2

1

0

HM42-004

3498

4263

1

2

3

4

5

8145 Fig. 4 Digging envelope

18

HML 42

1600

3000

Technical Data 3

HM42-008

Fig. 8 Slew circle

Slew circle 1,600

360° slew circle

3,000

490

761

2500

1030

221

180° slew circle

HM42-009

Fig. 9 Parallel side shift

HML 42

19

3 Technical Data 3.2 Engine Make:....................................................

Deutz

Type: ....................................................

BF 4 M 2012

Design: .................................................

Four-stroke diesel engine with direct injection, turbocharger

Cooling: ................................................

Water-antifreeze mixture

Displacement: .......................................

4,040 cm³

Power to DIN 70020:.............................

67 kW at n = 2,000 rpm

Max. torque:..........................................

371 Nm at n = 1,500 rpm

Specific fuel consumption: ....................

208 g/kWh

Max. inclined position:...........................

30° on all sides

Heating: ................................................

Water-heat exchanger

3.3 Electrical system Operating voltage: ................................

12 V

Battery: .................................................

12 V 135 Ah 600 A

Generator: ............................................

14 V

Starter:..................................................

3.1 kW

Starting aid: ..........................................

Glow plugs

Lighting system:....................................

in compliance with German Motor Vehicle Construction and Use Regulation (StVZO) and Euronorm

70 A

3.4 Travel drive Travel drive:..........................................

Variable displacement pump flanged directly onto the diesel engine, two-stage variable displacement motor with power shift on the front axle reduction gear. Suction filter in the form of a fixed tank filter.

Travel speeds: .......................................... Forward - reverse HML 42, HML 42 AL

HML 42 S

(all-wheel steering)

(high-speed) Speed I

20

Speed II

Driving mode "Work":

0 - 6 km/h

0 – 5.2 km/h

0 – 12 km/h

Driving mode "Road"

0 - 20 km/h

0 – 15 km/h

0 - 36 km/h

HML 42

Technical Data 3

Power transmission:..............................

Hydrostatic travel drive with automatic adjustment of propulsive force and speed over the entire driving speed range through variable speed motor. Twin-stage transmission with power shift and infinitely variable speed control, forward and in reverse.

Max. operating pressure "Travel": .........

Operation using accelerator pedal, four-wheel drive from front axle transmission over propeller shaft to rear axle. 440 bar

3.5 Brakes Service brake:........................................... Hydraulic dual-circuit accumulator-aided brake HML 42, HML 42 S (high-speed version) Oil-immersed multi-disc brake in front axle center housing and on rear axle wheel hub. HML 42 AL (all-wheel steering) Oil-immersed multi-disc brakes in front and rear axle center housings. Excavator brake: ....................................... Locking device on service brake acting on all four wheels. Parking brake:........................................... Inboard hydraulic spring-loaded brake acting on the multi-disc brake in front axle, electrically operated. Auxiliary brake: ......................................... The hydrostatic travel drive in the closed circuit acts as an additional wear-free auxiliary brake. Swing brake: ............................................. The hydrostatic swing motor acts as a wear-free swing brake. Automatic lock through transmission-integrated hydraulically releasable spring-loaded multi-disc brake.

HML 42

21

3 Technical Data 3.6 Hydraulic system Hydraulic pumps Hydraulic circuit 1: ................................

Work functions: Boom, dipperstick, bucket, intermediate boom, rock breaker / additional control circuit Axial piston variable-capacity pump with flow adjustment and pressure cut-off. Flanged onto the flywheel side. Max. capacity: Max. pressure:

Hydraulic circuit 2: ...............................

200 l/min 280 bar

Work functions: Slewing and all positioning functions Pumps sections 1, 2, and 3 of the triple gear pump flanged onto the power take-off. Twin-stage power switch at a system pressure of 110 bar. Max. capacity: Max. pressure:

Servo control: .......................................

Braking system: .......................................

Pressure removal displacement pump Pressure:

39 + 26 + 11 l/min 230 bar at

travel

drive

variable

approx. 35 bar

Pump section 3 of triple gear pump Max. capacity: Max. pressure:

11 l/min 150 bar

Priority valve: ...........................................

Priority supply of hydraulic oil to steering

Actuation:.................................................

Hydraulic pilot-operated excavator valves for all functions.

Hydraulic cylinders:..................................

Double-acting working cylinders, partially with end position damping.

Swing drive: .............................................

Hydrostatic with reduction gear and drive pinion on internally toothed ring gear of swing bearing. Slewing range: 360° unlimited Slewing speed: 0 -10 rpm

Hydraulic oil filters:...................................

Suction filter in tank for “Travel” hydraulic circuit. Return filter in tank for "Working System" hydraulic circuit.

Hydraulic oil cooler: .................................

Thermostatically controlled Operating range 50 °C — 45 °C

Knickmatik® boom control: .......................

Bend mechanism for the lateral parallel adjustment of the boom axle at total digging depth. Lateral adjustment to the right: 1,030 mm Lateral adjustment to the left: 760 mm

22

HML 42

Technical Data 3

Steering, HML 42, HML 42 S: ..................

Fully hydraulic proportional steering of front axle by means of steering control unit and one steering cylinder integrated in the axle.

Steering, HML 42 AL:...............................

Electric preselection of steering mode Fully hydraulic proportional steering of front and rear axles by means of steering control unit and one steering cylinder integrated in the axles. Due to the two steerable axles the following steering modes are possible:

standard steering standard steering for on-road and operations — only front axle is moved

standard

all-wheel steering "round": steering to reduce the turning radius. Counterrotating movement of the two axles. all-wheel steering "crab": steering for diagonal-sideway displacement. The two axles steer in the same direction. Max. wheel lock: ......................................

30°

3.7 Axles Front axle:...................................................

HML 42, HML 42 AL planetary steering axle, oscillating along with transmission, with two oil-immersed multi-disc brakes in the center housing and integrated steering cylinder. oscillating angle ± 6.5° HML 42 S planetary steering axle, oscillating along with 2stage transmission, with two oil-immersed multidisc brakes in the center housing and integrated steering cylinder. oscillating angle ± 6.5°

Rear axle: ...................................................

HML 42, HML 42 S planetary axle with two oil-immersed multi-disc brakes in the wheel hub. HML 42 AL planetary steering axle, with two oil-immersed multi-disc brakes in the center housing and integrated steering cylinder.

HML 42

23

3 Technical Data

3.8 Tires Tire size

Type

Profile

Remark

Tire pressure

Tire pressure

front in bar

rear in bar

9.00-20

14 PR

cleat profile

Twin tires

7.0

7.0

600/40-22.5

Special

J 331

"Super" widebase tires

5.0

5.0

3.9 Lubricants 3.9.1 Filling quantities Fuel:............................................................ Engine oil: ...................................................

approx. approx.

240.0 l 10.0 l

Diesel HD-oil (first filling)

Hydraulic oil, tank and system:....................

approx.

190.0 l

Hydraulic oil

Hydraulic oil tank:........................................

approx.

125.0 l

Steering front axle, HML 42, HML 42 AL..... center housing: ...........................................

approx.

7.2 l

Hydraulic oil (change quantity) Transmission oil

Steering front axle , HML 42 S .................... center housing: ...........................................

approx.

6.8 l

Transmission oil

Steering front axle, HML 42, HML 42 AL..... transmission................................................

approx.

0.9 l

Transmission oil

Steering front axle -, HML 42 S ................... transmission, shiftable ................................

approx.

1.9 l

Transmission oil

Steering front axle, HML 42, HML 42 AL,.... HML 42 S, wheel hub..................................

each approx. approx.

0.8 l

Transmission oil

8.0 l

Transmission oil

Steering rear axle, HML 42 AL .................... center housing: ...........................................

approx.

7.3 l

Transmission oil

Rear axle, HML 42, HML 42 S wheel hub ...

each approx.

2.1 l

Transmission oil

Steering rear axle, HML 42 AL, wheel hub..

each approx.

0.8 l

Transmission oil

Rear axle, HML 42, HML 42 S .................... center housing: ...........................................

Swing gear:.................................................

circulating lubrication supplied by hydraulic system

Service brake:.............................................

supplied by hydraulic system

Engine coolant: ...........................................

approx.

12.0 l

water with anticorrosion agent and antifreeze

All values stated are approximate values. The filling level indications should always be used as a guide.

24

HML 42

Technical Data 3 3.9.2 Fuel, lubricant and coolant specifications Prescribed fuels, lubricants and coolants for Central Europe

Engine

Designation Code designation 1) to Bi -Diesel fuel

Engine

EO 1540 A

Cooling for engine

SP-C

Hydraulic system

HYD 1040

Application

BIO-E-HYD-HEES

Axles, Transmission (s)

GO 90 LS

Lubricating points

MPG-A

1)

Specification, Standards, Quality DIN 51601 ASTM D975 1-D / 2-D

Engine oil

Remarks

Before using RME-fuels (rape oil methyl ester), it is essential to consult your responsible SCHAEFF-TEREX dealer for further details. See also engine manufacturer’s instructions

SAE 15W-40 API CF4 Coolant Antifreeze based on See also engine manufacturer’s ethylene glycol instructions The following viscosity limit Hydraulic oil or HVLP D 68 values must be kept (in multi-grade or compliance with ASTM 445) engine oil SAE 10W-40 2 at 100 °C min. 10 mm /s (cSt) at minus 10 °C approx. 1,500 mm 2 /s (cSt) Biodegradable Filling in compliance The same viscosity specifications hydraulic oil on with customer apply as for mineral hydraulic oils. synthetic ester specifications. base Brand label on When changing from machine. mineral to biodegradable hydraulic oils, the tank and Do not mix hydraulic system must be biodegradable oils of completely drained, cleaned and flushed. different suppliers. For further details before changing oils, please consult your responsible SCHAEFFTEREX dealer. Transmission SAE 80W-90LS Alternative recommendations oil API-GL 5 SAE 90LS SAE 85W-90LS Multi-purpose, K2K-30 lithium-soap DIN 51825 based grease

In conformity with the regulation lubricants of the Main Association of the German Building Industry e.V.

Alternative recommendation for other temperature ranges Engine oil

Hydraulic oil

in compliance with API CG 4 or CF 4 and in compliance with ACEA E3 or E2

in compliance with DIN 51524.T3 HVLP

HML 42

25

3 Technical Data 3.10 Permissible loads in accordance with local regulations (e.g. in Germany, StVZO - Regulations Authorizing the Use of Vehicles for Road Traffic) Permissible gross weight ................................................ Permissible axle load, front ............................................. Permissible axle load, rear..............................................

ðsee nameplate or ð General Operating License

3.11 Sound level values, vibration Sound level values in compliance with directive 2000/14/EC and EN 474 Guaranteed sound power level: ......................

LW(A) =

99 dB (A)

Sound pressure level: .....................................

LP(A) =

71 dB (A)

Vibration values in compliance with directive 98/37/EEC and EN 474 Weighted r.m.s. value of acceleration is below ...............

0.5 m/s2

for entire body

and .................................................................................

2.5 m/s2

for upper limbs

3.12 Dimensions and weights (with 9.00-20 14 PR twin tires) Operating weight:

approx.

kg

10,990

Total width (at outside edge of tires):

mm

2,500

Total length in travel position:

mm

5,400

Total height in travel position:

mm

3,980

Total height up to cab:

mm

2,990

Uppercarriage tail swing:

mm

1,600

Ground clearance beneath propeller shaft:

mm

approx.

440

Wheel base:

mm

2,570

Tread width:

mm

1,942

Smallest turning radius (at outside edge of tires) — HML 42, HML 42 S, HML 42 AL-standard steering

mm

Smallest turning radius (at outside edge of tires) — HML 42 AL featuring all-wheel steering "Round"

mm

7,400 5,100

All dimensions and weights refer to standard equipment. Weight including 600-mm bucket, stabilizers (blade +100 kg), driver 75 kg, twin tires (single tires – 440 kg)

26

HML 42

Technical Data 3 3.13 Excavator installation Dipperstick 2,000 mm

Dipperstick 1,850 mm

Digging depth

mm

4,315

4,263

Max. dumping height

mm

6,040

5,843

Max. height of bucket hinge point

mm

7,140

7,017

Max. reach

mm

8,300

8,145

Bucket angle of rotation

°

187

* Ripping force

N

58,500

58,300

* Breakout force

N

72,000

68,100

quick-mounting

directly attached

177.4

192.5

* Values are theoretical in compliance with DIN 24086

3.14 Carrying capacity The carrying capacities indicated in tons (t) were determined in compliance with ISO 10567 and include a stability factor of 1.33 or 87% of the hydraulic lifting capacity. The weight of the work attachment must be deducted from the payload indicated (weight see type label). Table of carrying capacity, machine with the following equipment: • without bucket • 9.00-20 14 PR twin tires with intermediate rings • full fuel tank, with driver A = supported by blade Height of hook

V = traveling Load radius from center of ring gear 4m 5m 6m

3m

along* across*

7m

along*

across*

along*

across*

along*

across*

along*

across*

3.0

A

-

-

3.11

2.63

2.44

1.91

2.39

1.31

1.98

0.92

m

V

-

-

2.56

2.40

1.76

1.71

1.28

1.18

0.92

0.83

1.5

A

4.91

3.87

3.11

2.51

2.72

1.79

2.71

1.25

1.94

0.89

m

V

3.88

3.54

2.51

2.30

1.77

1.62

1.20

1.13

0.83

0.78

0

A

6.50

3.60

3.88

2.36

3.00

1.68

2.57

1.22

1.79

0.88

m

V

3.65

3.31

2.35

2.21

1.65

1.54

1.18

1.12

0.84

0.79

-0.9

A

7.26

3.43

4.25

2.16

3.34

1.50

2.51

1.11

1.77

0.86

m

V

3.43

3.25

2.27

2.04

1.59

1.43

1.15

1.03

0.87

0.81

* across / along undercarriage

HML 42

27

3 Technical Data 3.15 Work attachments (based on 9,00-20 14PR twin tires) for dipperstick, 2,000 mm Width (mm)

Capacity (m

for dipperstick, 1,850 mm 3)

Density (t/m3)

Buckets 350 ejector

0.145

1.8

450 ejector

0.200

1.8

350 conical

0.130

1.8

450 conical

0.175

1.8

600

0.250

1.8

750

0.330

1.8

900*

0.410

1.6

Ditch-cleaning bucket 1500*

0.300

1.8

Swing bucket 1500*

0.260

1.8

Clamshell grabs type GS 3 325

0.135

1.8

400

0.170

1.8

500

0.220

1.8

600

0.260

1.8

800

0.355

1.6

* = These attachments are not licensed for use on the road!

Capacity m3

Density t/m3

300

0.200

1.8

300 SW

0.200

1.8

400

0.285

1.8**

400

0.260

1.8

400 SW

0.260

1.8

500

0.350

1.8**

500

0.230

1.8

500 SW

0.230

1.8

600

0.300

1.8

1500*

0.260

1.8

1500 SW*

0.260

1.8**

0.170

1.8**

Width (mm) (SW=quickmounting) Drainage buckets

Clay buckets

Rock buckets

Ditching buckets

Grab Type E15 300

* = These attachments are not licensed for use on the road! ** = with additional rear weight

- Further work attachments available on request -

28

HML 42

Technical Data 3 3.16 Stabilizers / Support blade Rear stabilizers for attaching diverse support pads: Support width:...............................................

2,320 mm - 2,400 mm

Distance below level surface:........................

230 mm - 290 mm

Pad sizes for the different types: ...................

flat

550 mm x 573 mm

rough terrain 550 mm x 570 mm rubber

485 mm x 540 mm

Rear support blade: Width: ...........................................................

2,500 mm

Distance below level surface:........................

250 mm

3.17 Optional accessories • Load hook, quick-mounting • Load hook for bucket rod (bolted) • Boom height limitation • Adapter for rock breaker attachment • Hydraulic rock breaker SMS 140 • Open return • Supplementary heating • Immobilizer • Electrical refueling pump • Air conditioning - Further optional accessories available on request!Any modifications of SCHAEFF-TEREX products and their equipment, including additional equipment and work attachments, which are not included in our product range, are subject to our written approval. If omitted, our warranty as well as our product liability for possibly caused damage will expire.

HML 42

29

4 Operation 4 Operation 4.1 Operator controls This picture contains non-standard equipment!

9

10

11

12 13

23

8 7 14

6 5

15

4 25

3

16 2 17 21

1

22 18

HM32-0101 010831

19 20 24

Fig. 10.1 Operation

30

HML 42

Operation 4

Description of cab

HML 42

1

Windshield washer tank

2

Stabilizer, left

3

Stabilizer, right

4

Door release

5

Control lever — excavator installation

6

Working hydraulics cut-off (raise panel)

7

Steering column — tilt and height adjustment

8

Turning indicator

9

Sensitive travel

10

Operation of intermediate boom / articulation

11

Excavator brake release

12

Service brake / excavator brake

13

Accelerator pedal

14

Control lever — excavator installation

15

Travel direction pre-selector — forward / neutral / reverse

16

Engine speed control (manual throttle)

17

Heater temperature control

18

Battery main switch

19

Socket

20

Refueling pump (option)

21

Superstructure slewing lock

22

Radio

23

Socket

24

Service ladder (cover)

25

Choice fresh air — re-circulating air

31

4 Operation

26 27 28 29 30 31

40 41

32 33

,

! 0

4/4

42 43

P

35 37 39 34 36 38

68 44

69

49 70

45

46

47

48

50 51 52 53 54 55 56 57

HM42-0102-N

71 72 73

15

HML42AL P

P

64

59 60 61 62 63 58

I II

58

HML42

59 65 66

59 60 61 62 63

HML42S P

67

62 63

Fig. 10.2 Instruments and operation

32

HML 42

Operation 4

Description of instrument panel 15

Preselection of travel direction — Forward/Neutral/Reverse

53

Rock breaker / additional control circuit

26

RED — battery charge indicator lamp

54

Overload warning device ON/OFF

55

Operation of additional control circuit I; e.g. grab rotation, rock breaker

56

Horn

57

Button — change-over intermediate boom / articulation

27

YELLOW — pre-heating monitor

28

RED — engine oil pressure

29

YELLOW — air filter indicator

30

RED — hydraulic oil return filter clogging indicator

58

Fast — slow

59

Sensitive travel

31

RED — hydraulic oil level

60

Travel motion alarm cut-off

32

GREEN — turn signals

61

Front dozer blade

33

BLUE — high beam

62

Oscillating axle lock

34

GREEN — rear axle straight-ahead

63

Parking brake

35

GREEN — front axle straight-ahead

64

36

GREEN — travel direction, reverse

Travel speed and steering mode switch

37

GREEN — travel direction, forward

65

High-speed change-over switch

38

RED — parking brake

39

RED — brake accumulator pressure indicator

Only press when machine is standing still and service brake is applied! If the red indicator lamp in the switch lights up, no gear is engaged (idle-running position). The manual transmission is in an intermediate position. The machine is not ready for operation! This can be remedied by brief steering movements to be performed until the transmission engages.

40

Overload warning device

41

Coolant temperature

42

Operating hour meter

43

Fuel gauge

44

Light switch

45

Rotating beacon

66

Indicator — Speed II

46

Working floodlights

67

Indicator — Speed I

47

Hazard warning switch

68

Operation of additional control circuit II

48

Pre-heat/ starter switch

69

Hydrostatic additional swing brake

49

Heater fan switch

70

Boom-mounted working floodlight

50

Air conditioning

71

Fog lamp

51

Windshield wiper - wash/wipe system

72

Steering change-over

73

not assigned

52

HML 42

Working hydraulics cut-off

33

4 Operation 4.2 Engine

26 27 28 29

4.2.1 Starting the engine Each time before putting the machine into operation, the inspections in compliance with Chapter 7.8 must be carried out.

,

! 0

4/4

P

Before switching on the engine, ensure that no one is in the immediate vicinity of the machine or in the danger zone.

48

• All levers must be put into neutral position. • Press parking brake switch (11/63); set direction-of-travel pre-selector (11/15) to “O”. • Insert ignition key in pre-heat/ starter switch (11/48). • Turn clockwise to “1”, the indicator lamps (11/26; 11/28) light up. • Pre-heating starts; (11/27) lights up.

the indicator

lamp

• Press down accelerator pedal (11/13) to half-throttle position.

P

• After the pre-heating indicator lamp (11/27) has gone out, turn the pre-heat/ starter switch to “2”. As soon as the engine is running, turn the key back to “1” and decrease the revs to low idle speed. The indicator lamps should go out.

63 13

• If the engine has not started after max. 15 seconds, turn the ignition key to “1” or “0”, and pause for at least 1 minute before trying again. Repeat the start-up procedure.

15

Do not drive the engine at full throttle straight away. Drive with restraint until the engine reaches operating temperature. HM32-011

Fig. 11 Operation

34

HML 42

Operation 4 4.2.2 Monitoring during operation The machine is equipped with a warning buzzer emitting an interval signal if the following malfunctions occur: Þ Battery charge indicator (12/26)

26 28 29 30 31

41 ,

Þ Engine oil pressure (12/28)

! 0

4/4

P

Þ Air filter service indicator (12/29) Þ Hydraulic oil indicator (12/30) Þ Insufficient (12/31)

filter

hydraulic

39

clogging

48

oil

level

Þ Coolant temperature (12/41) Þ Insufficient fuel level (12/43) If the engine and the machine are put into operation without prior remedy of the damage, severe damage to the engine may result!

HM32-012

Fig. 12 Operation

As soon as the warning buzzer comes up check which indicator lamp is activated and which indicator has reached the critical area and proceed accordingly. • If the battery charge indicator lamp (12/26) or the engine oil pressure lamp (12/28) light up, switch off the engine immediately and determine the cause and, if necessary, call for service personnel. • If the hydraulic oil filter clogging indicator (10/31) of the return filter lights up, perform the necessary maintenance work and, if necessary, determine the cause of clogging. If the hydraulic oil filter clogging indicator is disregarded, this may result in damage to the hydraulic system. If the hydraulic oil is cold, the hydraulic oil filter clogging indicator may light up briefly. It will go out once the operating temperature is reached. • If the air filter service indicator (12/29) lights up, perform the necessary air filter maintenance work.

HML 42

35

4 Operation • If the hydraulic oil deficiency indicator (12/31) lights up, discontinue work immediately and switch off the engine. Top up hydraulic oil and, if necessary, determine the cause. • If the permitted coolant temperature (12/41) is exceeded, stop work, open the engine hood and keep the engine running at idle speed to allow it to cool down. Once the engine has cooled down, turn it off and determine the cause, or call for service personnel.

26 28 29 30 31

41 ,

! 0

4/4

P

39 48

• If the fuel reserve limit (12/43) is reached, a residual fuel quantity of approx. 15 l is left in the tank. There is a brief acoustic warning. Replenish fuel. • If the brake accumulator pressure indicator (12/39) lights up, switch off the engine and determine the cause.

HM32-012

Fig. 12 Operation

The machine is never to be operated with insufficient brake accumulator pressure. Danger of accident! No braking power!

4.2.3 Switching off the engine Do not switch off the engine when at full throttle, but allow it to run for a short time at no load. • Turn the ignition key (12/48) to “0”. • The engine stops automatically.

36

HML 42

Operation 4 4.3 Driver’s seat, height and tilt adjustment of steering wheel Driver's seat

5

The comfort seat is spring-mounted with oilpressure-operated shock absorbers. The seat meets international quality and safety standards (Fig. 13). 1. Horizontal adjustment of seat 2. Horizontal adjustment of seat console 3. Weight adjustment 4. Seat back adjustment 5. Lumbar support 6. Height adjustment

4

1 3 2 1

Raising seat: Raise seat until it clicks audibly into place. Lowering seat:

3

HM32-013 020717

Fig. 13 Driver's seat

Raise seat as far as the stop; it then sinks to the lowest position. Tilt adjustment of steering wheel • Press down lever (14/7). • Adjust the steering wheel tilt-wise.

49 50

• Release lever (14/7). Height adjustment of steering wheel • Lift lever (14/7).

7

• Adjust the steering wheel height-wise. • Release lever (14/7).

25

17

HM32-014 010831

Fig. 14 Operation

HML 42

37

4 Operation 4.4 Heating / Ventilation / Air conditioning How to achieve efficient cooling power:

Heating and air conditioning can only be operated with the diesel engine running.

•

After switching on the air conditioning system, open the window(s) 2 – 3 min to allow the hot air (stored heat) to escape.

•

Keep window(s) closed.

•

We recommend reducing the interior temperature by no more than 6 °C to 8 °C below exterior temperature.

Heating • The heater is connected to the coolant circuit and operated using the control (14/17). • The fan is operated using the switch (14/49) and may be operated using fresh air or re-circulating air. • For recirculating air operation, open aspirating holes (14/25) (pull out slide control).

and

door(s)

• The air is distributed by adjusting the aspirating holes. Ventilation • In ventilating mode, the control for the heater (14/17) remains in the "COLD" position.

49 50

• The fan is operated using the switch (14/49). 7

Air conditioning (option) The air conditioning system has to be switched on for approx. 5 min at least once a month to lubricate the compressor seals.

25

17

• Select "Recirculation Mode" and open the aspirating holes (14/25). • Control (14/17) in "COLD" position. • Switch on the air conditioning system using the switch (14/50).

HM32-014 010831

Fig. 14 Operation of heater

• Switch on the fan (14/49)

38

HML 42

Operation 4 4.5 Light switch The excavator lighting is switched on using the light switch (15/44). Setting 0 = Light off

,

33

Setting 1 = Parking light

! 0

4/4

P

Setting 2 = Driving headlamps (low beam high beam)

44

Switch from one to the other by lifting the turning indicator (15/8); the indicator lamp (15/33) lights up.

4.6 Front window

8

• To open the window, release the two levers (16/1). • Pull the window back and up at the same time. • Lock the window in the upper position with the levers (16/1).

HM32-015

Fig. 15 Operation of lighting

Ventilation position • Release the two levers (16/1). • Pull the window back approx. 10 cm. • Lock the levers in the support.

1

vue vers l’avant view to the front

Ansicht nach vorn Ansicht nach oben view to the top vue vers le haut

1

HR32-015

Fig. 16 Front window

HML 42

39

4 Operation 4.7 Travel operation When driving on public roads, the mobile excavator — as a selfpropelled vehicle — is subject to the traffic regulations valid in the user’s country.

• Travel speed is controlled using the accelerator pedal (17/13). • The direction of travel may be changed quickly using the travel direction preselector switch (17/15).

HML 42 AL: When driving on roads, all-wheel steering has to be deactivated. See Chapter 4.7.2 ,

! 0

4/4

P

4.7.1 Driving

37 36 38

4.7.1.1 Driving using the accelerator pedal When driving the mobile excavator using the accelerator pedal (17/13), the manual throttle (17/16) must always be set to neutral position. Non-compliance with the above may result in uncontrolled movements during driving.

52

HML42AL

Driving off The direction of travel always refers to the undercarriage (steering axle to the front). • Direction position.

15

P

pre-selector

(17/15)

in

62 63

64 HML42S I II

P

P

“0”58

65 66

62 63

67 62 63 58 13

• Start the engine. • Manual throttle (17/16) in neutral position. • Raise stabilizers (support blade). • Engage working gear or road gear (17/58; 17/64).

15

• HML 42 S: Select speed range I or II (17/65). Observe indicator lamps (17/66, 17/67).

16

• Release the parking brake (17/63). The indicator lamp (17/38) is OFF. • Oscillating axle lock (17/62) "OFF". • Adjust the desired direction of travel using the selector switch (17/15) (travel direction arrows 17/36 or 17/37 light up) and press the accelerator pedal (17/13).

40

HM42-017-N

Fig. 17 Operation

HML 42

Operation 4 Coming to a halt • Speed is reduced by accelerator pedal (18/13).

releasing

the

• The hydrostatic travel drive acts as wearresistant auxiliary brake. See also Chapter 4.7.3, “Brakes”. 52

4.7.1.2 Sensitive travel using the rocker accelerator pedal When performing work where the work equipment of the excavator requires maximum hydraulic power and, at the same time, where the excavator should (must) be moved with great sensitivity, the “additional accelerator pedal for sensitive travel” is used. In this case, the direction of travel and travel speed are controlled by operating the rocker foot pedal.

HML42AL 15

P

64 59 HML42S I II

58 59

P

65

67 9

P

58 59 13

With the working hydraulics switched off, the “additional accelerator pedal” is without function. • Switch on the working hydraulics (18/52).

15

• HML 42, HML 42 S: Travel speed switch (18/64) in "Work" (tortoise) position.

16

• HML 42 AL: Travel speed switch (18/64) in "Work" position (tortoise standard steering or round steering, or crab steering). • HML 42 S: Select speed range I (18/65). Observe indicator lamp (17/67). • Travel direction switch (18/15) in “0” position.

HM42-018-N

Fig. 18 Operation

• Toggle switch (18/59) in "Travel with rocker pedal" position ("foot pedal" switch position). • Increase engine speed using the manual throttle (18/16) as required. • Travel by pressing the rocker pedal (18/9) off neutral position. • The rocker pedal automatically returns to neutral position. Before switching back to normal travel mode using the accelerator pedal (18/13), move the manual throttle (18/16) to neutral position.

HML 42

41

4 Operation 4.7.2 Steering Emergency steering system With the diesel engine switched off, power steering is deactivated. Very high steering-wheel forces! In case of malfunctions in the steering system, determine the cause immediately (see trouble chart, Chapter 8), and call for service personnel, if necessary.

• The green indicator lamp in the Travel speed / Steering mode switch (19/64) lights up. The lock ensures that there is no unintentional activation of all-wheel steering. All-wheel steering must always be intentionally activated by raising the lever. If all-wheel steering is chosen, only travel speed "Work" is possible.

HML 42, HML 42 S The mobile excavator features a fully hydraulically steerable front axle and an emergency steering system.

,

! 0

4/4

P

HML 42 AL The mobile excavator features two fully hydraulically steerable axles and an emergency steering system.

35 34

Standard steering • Travel speed / Steering mode switch (19/64) in "Road — Standard" (hare) or "Work — Standard" (tortoise) position. When changing from all-wheel steering to standard steering, the rear axle must be in "Straight ahead" position. Indicator lamp (19/34) lights up. All-wheel steering • All-wheel steering is operated using the Travel speed / Steering mode switch (19/64). • Raise lever from "Work travel speed" (tortoise) position to deactivate the lock and move forward to "All-wheel steering" "Round" or "Crab".

42

P

64

HM32-019-N

Fig. 19 Operation

HML 42

Operation 4

All-wheel steering "Round" When changing from standard steering to all-wheel steering "Round", the front axle must be in "Straight ahead" position. When changing from all-wheel steering "Crab" to all-wheel steering "Round", the front axle and the rear axle must be in "Straight ahead" position. • "Straight ahead" indicator lamp (19/35) for front axle lights up when the wheels are straight. ,

• "Straight ahead" indicator lamp (19/34) for rear axle lights up when the wheels are straight.

! 0

4/4

P

35 34

• Travel speed / Steering mode switch (19/64) in "Round" position. All-wheel steering "Crab" When changing from standard steering to all-wheel steering "Crab", the front axle must be in "Straight ahead" position. When changing from all-wheel steering "Round" to all-wheel steering "Crab", the front axle and the rear axle must be in "Straight ahead" position. • "Straight ahead" indicator lamp (19/35) for front axle lights up.

P

• "Straight ahead" indicator lamp (19/34) for rear axle lights up. • Travel speed / Steering mode switch (19/64) in "Crab" position.

HML 42

64

HM32-019-N

Fig. 19 Operation

43

4 Operation 4.7.3 Brakes Service brake • The service brake (20/12) is to be applied as required. 52

Parking brake • The parking brake (20/63) is to be applied when parking the machine. Only apply brake when machine is stationary. Excavator brake

P

• The excavator brake (service brake, 20/12) must be applied when performing excavator operations (fully depress pedal until the locking device (20/11) clicks in.)

62 63 10

11 12

With the excavator brake applied, the oscillating axle is locked at the same time.

4.7.4 Driving on roads

16

Buckets wider than 600 mm and ditch-cleaning buckets/swing buckets wider than 1,250 mm have to be dismounted. Ÿ Slew the superstructure to travel position and fix in place with the bolts of the superstructure slewing lock (20/21).

21

HM32-019

Fig. 20 Operation

Ÿ HML 42 AL — Choose "Standard steering" (see Chapter 4.7.2 "Steering"). Ÿ Fully raise boom. • Slew the work equipment to transport position using the sighting device (21/1). • Fully retract cylinder.

the

intermediate-boom

HM32-020

Fig. 21 Sighting device

44

HML 42

Operation 4 • Place dipperstick vertically until the color marks are in alignment. If a clamshell grab is mounted, attach the grab to the serrated pipe (23/1) and close it. Adjust the position of the dipperstick. If a front dozer blade is installed, the grab has to be dismounted before driving on roads. • Retract the bucket in compliance with the color mark (22 A) above the tilt control lever. • Retract the ditch-cleaning bucket in compliance with color mark (22 B) below the tilt control lever, position horizontally and fix in place so that it cannot oscillate. • Fully raise the stabilizers and secure the support pads mechanically with a chain. • Fully raise the support blade (option) and attach removable reflectors. • Fully raise the front dozer blade (option). • Switch off (20/52).

the

working

HM32-021

hydraulics Fig. 22 Lighting

• When driving on the road, the switch for the oscillating axle lock (20/62) must be in “OFF” position. • Manual throttle (20/16) in neutral position. • Affix the lighting unit to the bucket cylinder (22/1) and connect at the socket (front side of uppercarriage, next to cab) — only if necessary, e.g. poor visibility, darkness, etc. • Check the function of turning indicators, hazard warning system, horn, high beam and low beam. • Close the cab door. HM32-022

Exercise caution when driving downhill. Do not press the accelerator pedal to the floor.

Fig. 23 Serrated pipe

Before switching from fast gear to low gear, travel speed must be reduced.

HML 42

45

4 Operation 4.8 Parking the machine

48

• Park the machine on a preferable level and solid ground. • Travel direction pre-selector (25/15) in "0" position. • Lower the work equipment to the ground. 52

• Lower the stabilizers/ support blade. • Apply the parking brake (25/63). • Switch off the working hydraulics (25/52).

15

• Turn off the engine and remove the ignition key (25/48). • Raise the exit barrier (25/6).

P

• Windows and doors must be locked or closed.

63

• Battery main switch (25/18) in "0" position, if required. If necessary, secure the machine with chocks so that it cannot roll away. 6 15

18

HM32-025

Fig. 25 Operation

46

HML 42

Working Operation 5 5 Working Operation 5.1 General The excavator is equipped as standard with an "ISO-control" (function of control levers 30/5 and 30/14), on which the following description is based. If the customer so wishes, the mobile excavator can be equipped with a special control. Your mobile excavator must therefore be checked to see whether or not a special control is installed.

52

Incorrect handling may endanger persons or objects. When raising and lowering the exit barrier (30/6), ensure that no other control levers and/or pedals are operated.

15

Danger of accident due to uncontrolled machine movements!

P

With the exit barrier (30/6) raised or the service ladder (30/24) folded down, all work and travel functions are deactivated.

62 12

• Before working with the excavator, memorize the lever controls well. • Start at low rpm when familiarizing yourself with the controls.

6 5

14 15

• Always apply the excavator brake (30/12). • Travel direction pre-selector (30/15) in "Neutral" position. Working hydraulics (30/52) "ON". When performing excavating operations, the excavator brake (30/12) and the oscillating axle lock (30/62) must always be applied. In addition, the excavator must be supported by stabilizers and/or support blade, whereby sufficient wheel grip must continue to be ensured.

21

24 HM32-030

Fig. 30 Operation

This is the only way to ensure optimum stability. • Before operating the work function "Slew superstructure", the superstructure lock must be released (30/21).

HML 42

47

5 Working Operation 5.2 Moving the excavator at high engine speed To prevent the excavator from moving off abruptly during work at high engine speed, the following activities must be performed in the given sequence:

15

P

Risk of accident! 1. Foot on brake pedal (31/12).

62 11 12

2. Release excavator brake (31/11). 3. Switch off oscillating axle lock (31/62). 4. Select the travel direction (31/15). 5. Release the brake pedal slowly and carefully until the machine starts to roll.

15

HM32-031

Fig. 31 Operation

48

HML 42

Working Operation 5 5.3 Operation of work functions 5.3.1 Operation of work equipment Slewing slopes

the

superstructure

on

To prevent the superstructure from drifting off when it starts to swing off, the additional hydrostatic swing brake must be operated. To do so, press button (32/69) and keep pressed until the superstructure starts to slew.

69

5

14

HM32-032

Fig. 32 Operation

HML 42

49

5 Working Operation 5.3.2 Operation — intermediate boom/ articulation •

Press button (34/57) and keep pressed — the "articulation" function is activated. If wide work attachments, e.g. ditchcleaning buckets, swing buckets, extra-wide buckets, non-standard attachments, etc. are used, the driver must exercise special care when operating Knickmatik®.

57

10

Improper use may result in personal injury and/or damage.

HM42-034

Fig. 34 Operation

5.3.3 Operation — Stabilizers / Support blade With the support blade mounted, the control levers (35/2) and (35/3) must be operated at the same time.

rechts right droite

3

links 2 left gauche

HM32-035

Fig. 35 Operation

50

HML 42

Working Operation 5 5.3.4 Operation — Front dozer blade (option) •

P

Change-over switch (36/61) – front dozer blade - stabilizer left

61

links left

links 2 left gauche

HM32-036

Fig. 36 Operation

HML 42

51

5 Working Operation 5.3.5 Operation — Additional control circuit Additional control circuit I (37/55) Grab operations (swing bucket, etc.) • Change-over switch (37/53) in "Rock breaker operations OFF" position (indicator lamp in switch is off). If necessary, the work speed of the additional control circuit must be adjusted. To do so, adjust wheel (37/A).

53

55

68

Rock breaker operations • Change-over switch (37/53) in "Rock breaker operations ON" position (indicator lamp in switch is on). Additional control circuit II (37/68) • Diverse hydraulically operated special tools can be controlled by this control circuit.

5.3.6 Operation of oscillating axle lock • The oscillating axle lock is controlled by the excavator brake. With the excavator brake applied, the oscillating axle is locked automatically. • For special applications it is possible to activate the oscillating axle lock independently of the excavator brake. • To do so, set the switch for oscillating axle lock to "ON" (38/62). • The red indicator lamp in the switch lights up.

A HM32-037

Fig. 37 Operation

Upon completion of the special job, immediately re-set the switch for the oscillating axle lock to “OFF”.

P

62

HM32-038

Fig. 38 Operation

52

HML 42

Working Operation 5 5.4 Changing work attachments 5.4.1 General Various work attachments are available to achieve maximum utilization of the machine for a variety of applications. The machine is equipped with a quick-attach system hitch to shorten the time it would take to install attachments. When mounting a clamshell grab, slewable ditch-cleaning bucket or a hydraulic rock breaker, an additional control circuit is required. Additionally, an open return (return directly to tank) is required when operating the hydraulic rock breaker. Under certain circumstances there is the possibility to use the work attachments of predecessor models for our machines. When mounting the work attachments of predecessor models they may have to be adjusted and/ or subject to utilization restrictions. It is essential to consult your dealer before mounting such a work attachment. When the attachments have been removed, they must be secured against tilting and overturning to avoid possible injuries to persons.

HML 42

53

5 Working Operation 5.4.2 Assembly of work attachments The bearings of the quick-mount hitch and work attachment must be free of dirt. The system must be relieved of pressure before hydraulic connections are disconnected. Procedure for changing work attachments In the case of a hydraulically controlled attachment, first of all the hydraulic connection must be disconnected (no pressure in system). • For replacement, the work attachment must be lowered to the ground and positioned so that it cannot tilt. • Open the quick-mount hitch with the control rod (40/1) until the locking bolts are completely retracted. • Check the function of the quick-mount hitch lock and lubricate the bolts if required (see note on lubricating, Chapter 7.8.3). • Attach another work attachment and close the quick-mount hitch until the locking bolts are completely extended and the lock clicks in. • The control rod must be kept in the driver’s cab.

54

1 HR32-027

Fig. 40 Quick-mount hitch

HML 42

Working Operation 5 5.4.3 Clamshell grab During grab operations the changeover switch (41/53) must be in "Rock breaker OFF" position. The indicator lamp in the switch is off. Changing procedure • Attach the clamshell grab and close the quick-mount hitch.

53 links left gauche

4

• Fully retract the bucket cylinder piston rod and close the ball valves (51/3). Whilst assembling and using a clamshell grab with quick-attach system, the bucket cylinder piston rod must be fully retracted. • Connect the swivel motor to the couplings (51/1, additional control circuit) and the “Open/ Close” function to the couplings (51/2, Bucket cylinder). When the grab has been dismantled, re-open the ball valves (51/3).

3 2

1

rechts right droite

3

1

2

HM32-041

Fig. 41 Additional control circuit

HML 42

55

5 Working Operation 5.4.4 Hydraulic rock breaker Attachment Before mounting a rock breaker supplied by a company other than SCHAEFF-TEREX, it is absolutely necessary to consult your dealer.

Maintenance The maintenance of the hydraulic rock breaker must be performed in compliance with the instructions of the hydraulic rock breaker manufacturer.

• The mounting and operating instructions of the hydraulic rock breaker manufacturer must be observed! • The hydraulic circuit of the rock breaker must be secured in compliance with the instructions of the hydraulic rock breaker manufacturer.

53 links left gauche

• Standard protection: 300 bar

4

• When working in or under water, special rock breaker types must be used. • The hydraulic rock breaker is mechanically attached in the same manner as a bucket attachment.

2

• The hydraulic pressure supply for rock breaker SMS 140 is connected to the lines of the additional control circuit (42/1) by a hose coupling. • The hydraulic pressure supply for nonSCHAEFF-TEREX rock breakers is connected to a line of the additional control circuit (42/1) and the return line via the open return line connection (42/4).

rechts right droite

3

• Selector (42/53) in “Rock breaker operation” position. The indicator lamp in the switch lights up. Working with the hydraulic rock breaker

1

The mounting and operating instructions of the hydraulic rock breaker manufacturer must be observed! The pressure force must be applied axial to the rock breaker and perpendicular to the surface of the material.

1

2

HM32-042

Fig. 42 Additional control circuit

Improper use may lead to severe damage to the rock breaker, holder and the excavator itself.

56

HML 42

Working Operation 5 5.4.5 Using the machine for load hook applications Earth-moving machines are only to be used for load hook applications if they are equipped in the proper manner and if they have the license to this purpose. •

During load hook applications, the safety notes (Chapter 2.16) must be observed.

•

Only loads not exceeding the carrying capacity of the machine and the hoisting appliance are to be used (Chapter 3.14).

Using the applications

machine

for

load

hook

• During load hook applications, the overload warning device (43/54) must be switched on and attention be paid to the load display (43/40). As soon as the warning signal (buzzer sounding continuously) comes up •

immediately lower the load

•

reduce the reach and/or

•

reduce the load.

Overload warning device In case of overload, a visual and acoustic signal emit a warning.

40

There is still danger of tilting. The integrated overload warning device cannot completely exclude accidents as a result of incorrect operation.

,

! 0

4/4

P

In particular, this applies to: •

Hooking the load or the load holding equipment from underneath

•

Excessive deceleration or acceleration forces (hard braking or strong swinging off with the load to be moved)

•

Loads falling into the cable

•

Oblique lifting

•

The earth-moving machine is working on steep ground

•

Excessively high winds

54

HM32-043

Fig. 43 Operation

Avoid these dangers by operating the machine cautiously and with the proper care.

HML 42

57

5 Working Operation

Possible forms of attachment, attaching loads Loads must be attached in such a way that they cannot slip or fall out. • Lift hook attached instead of a bucket, etc. • Hook with safety net welded onto the bucket rod (in the case of quick-mounting buckets with ejectors, the hook must be dismounted). • A suitable, appropriately sized loading implement must be employed for picking up the material to be lifted. Always wear protective gloves when working with loading implements.

Checking the overload warning device The working order of the overload warning device is to be checked every time before using the machine for load hook applications. •

Switch on the overload warning device (43/54).

•

Move the boom completely (extend boom cylinder)

•

The overload warning indicator (43/40) enters the red area.

•

An acoustic warning signal (continuous signal) comes up.

•

The overload warning device is in working order.

upward

Attaching and guiding loads Personnel guiding the machine and attaching loads are not to leave the machine operator’s field of vision. The safety notes (Chapter 2.16) must be observed.

58

HML 42

Towing and Transport 6 6 Towing Machine

and

Transport

of

the

6.1 Towing the machine Absolute cleanliness is essential when working with the hydraulic system. Always secure the machine with chocks and relieve of hydraulic pressure before performing maintenance and repairs. To avoid damage to the hydrostatic travel drive, limit the towing of the machine to the shortest distance, only to clear obstructions such as road crossings or streets.

Opening the "Travel" oil circuit • At both high-pressure relief valves (45/1) with bypass (in the connecting plate of the hydraulic pump), slacken the nut (46/1), and screw in the bolt (46/2) until it is level with the nut. Re-tighten the nut. • After towing, slacken the nut (46/1) and screw back in the bolt (46/2) until the stop. Re-tighten the nut (46/1). Tightening torque: 30 Nm

If possible, let the diesel engine run idle during towing. Emergency steering system If the diesel engine is standing still, power steering is deactivated. Steering-wheel forces are very high!

Preparations for towing HML 42, HML 42 AL • Open the "Travel" oil circuit so that the hydrostatic transmission no longer acts as an auxiliary brake.

1 HM32-046

Fig. 45 Hydraulic pump

2 1

HML 42 S •

Manual transmission in neutral position.

HML 42, HML 42 AL, HML 42 S • Release the spring-loaded cylinder.

Tow fixing points: Front: on coupler head Rear: lugs on the right-hand and left-hand side of the undercarriage Max. load suspension of fixing points approx. 9,000 kg.

HML 42

HM32-047

Fig. 46 Valve

59

6 Towing and Transport Neutral position of manual transmission •

Draw or press the gearshift rod (47/1) to neutral position (center position) using appropriate tools. When the diesel engine and the hydraulic system are started the preselected gear is automatically engaged.

Vorderachse HML42S Front axle

1

Releasing the spring-loaded brake in an emergency •

Loosen the nuts (48/2) and screw back by approx. 8 mm on the screws (48/1).

•

Screw in the screws (48/1) until the stop on the pressure plate. Screw in by turns using a box wrench, each time ¼ turn. One full turn is the maximum for screwing in. After towing, re-adjust the springloaded brake.

HM42-047-N

Fig. 47 Neutral position of manual transmission

1

1

1

1

Adjusting the spring-loaded brake after emergency release •

Unscrew the screws (48/1) along with the nut (48/2) and the sealing washer (48/3). Replace the sealing washer (spare part no.: 5 370 651 868), grease or oil the screw and re-mount.

•

Screw in screws (48/1) until the adjusting dimension 31 ± 0,5 mm is reached.

•

Counter the screws with the nuts (48/2).

•

Check again the adjusting dimension.

31,5 0,5

2 1 Vorderachse Front axle

3

HM42-048

Fig. 48 Spring-loaded brake

60

HML 42

Towing and Transport 6 6.2 Loading the machine using a crane

1 Use a crane with sufficient lifting load capacity.

2 To load the excavator onto a flat bed trailer, etc., the following activities must be carried out: • Empty and fold in the bucket. • Position the work equipment straight ahead. • Slew the superstructure to travel position (work equipment is above steering axle).

HM32-049

Fig. 49 Loading the machine using a crane

• Secure the superstructure with the slewing lock (50/21). • Raise the boom. • Pull in the intermediate boom cylinder. • Retract the dipperstick. • Switch off the engine. • Dismount from the excavator and close the doors. • Attach the excavator to the 3-point hoisting appliance at the points illustrated below (Fig. 49) in the correct manner.

21 HM32-050

Fig. 50 Superstructure slewing lock

HML 42

61

6 Towing and Transport 6.3 Transporting the machine When transporting the machine on a flat bed trailer, by rail, etc., it has to be appropriately lashed at the marked points (Fig. 51), secured with chocks, and the stabilizers (and/or dozer blade) as well as the work equipment must be lowered to the ground. Be aware of the total transport height. Risk of accident when driving in tunnels, under bridges, etc.!

HM32-051

Fig. 51 Lashing for transport

62

HML 42

Maintenance and Service 7 7 Maintenance and Service 7.1 General The good operating condition and life expectancy of machines are largely influenced by care and maintenance. For this reason, it is in every machine owner’s interest to perform the specified maintenance work and comply with the service intervals. This section deals in detail with periodic maintenance, inspection and lubricating tasks. The type-specific maintenance and inspection plan lists all work to be performed on the machine at regular intervals. Maintenance and inspection plans for this purpose are contained in every instruction book. It is essential that the recommendations in Chapter 2, “Safety and Prevention of Accidents” are observed.

7.2 Intervals First inspection

once before first putting into operation 1)

Chapter 7.8.1

Daily jobs

every 10 op. h* or every work shift

Weekly jobs

weekly or after 50 op. h* 1)

Chapter 7.8.2

100 operating hours

once after first putting into operation 2)

Chapter 7.8.4

Every 500 operating hours

after every 500 operating hours

Chapter 7.8.4

Chapter 7.8.2

Every 1,000 operating hours after every 1,000 operating hours

Chapter 7.8.4

Every 2,000 operating hours after every 2,000 operating hours

Chapter 7.8.4

1)

whichever comes first

2)

also applicable when new or overhauled diesel engines are put into operation

* [op. h - operating hour]

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63

7 Maintenance and Service 7.3 Regular oil analyses Oil analyses are not intended as a substitute for the oil change intervals but – apart from a possible reduction of maintenance costs and as a form of preventive maintenance – they take into account the increasing environmental awareness. Advantages of an oil analysis • Extension of the oil change intervals under standard or light-duty operating conditions. • Minimum wear of high-quality components with optimum use of the lubricants. • Periodic laboratory analyses enable an early detection of imminent damage. • Repairs performed before they actually become absolutely necessary help prevent serious and unexpected damage. • Sequential damage can be avoided. Oil analysis intervals Periodic oil analyses reveal trends in the condition of the oil and the machine. When the scheduled oil change intervals have been reached, the oils should be analyzed in the following intervals to check their quality and thus extend the oil change intervals: • Hydraulic oil:

1,000 operating hours

• Transmission oil:

500 operating hours

• Engine oil:

100 operating hours

Based on the first results, the laboratory recommends the interval for the next sampling. Ask your SCHAEFF-TEREX dealer for an information booklet detailing the scope and procedures of the oil analysis.

7.4 Warranty During the warranty period thorough inspections are stipulated, which must be carried out by trained specialist dealer personnel. The inspections are obligatory and must be paid for. The performance of inspections as specified must be confirmed on the inspection cards in the warranty / handing over certificate. If they are omitted, the warranty may be subject to restrictions.

64

HML 42

Maintenance and Service 7 7.5 Inspection parts and aids Maintenance parts

Spare part no.

Hydraulic oil filter insert (return filter)............................

5 380 658 088

Hydraulic oil filter insert (suction filter)..........................

5 003 659 261

Breather ......................................................................

5 501 655 650

Engine oil filter .............................................................

5 411 656 298

Fuel filter......................................................................

5 411 656 493

Filter insert of fuel line pre-filter....................................

5 445 100 004

Air filter - main cartridge ..............................................

5 501 660 922

Air filter - safety cartridge ...........................................

5 501 660 924

Valve-cover gasket ....................................................

5 411 656 337

V-belt, breather 13x1,000 ............................................

5 411 656 409

V-belt, generator 10x950 .............................................

5 411 656 408

Cab ventilation dust filter .............................................

5 501 661 034

Service Packs Service Pack "Classic" — inspection after 100 h..........

MPS 420 001C

Service Pack "Classic" — inspection every 500 h ........

MPS 420 002 C

Service Pack "Classic" — inspection every 1,000 h .....

MPS 420 003 C

Extras SCHAEFF-TEREX – hydraulic oil, mineral...................

4 312 005 050

SCHAEFF-TEREX – hydraulic oil, biodegradable........

For further information, please contact your SCHAEFF-TEREX dealer!

Transmission oil (SAE 85 W 90 LS) ............................

4 314 005 775

Engine oil (SAE 15 W 40 ) ..........................................

4 312 905 759

Antifreeze and anti-corrosion agent for engine cooling ........................................................

4 440 305 025

Maintenance and wearing parts for inspections should be ordered well in advance! Observe our offer on service packs for inspections. Contact your dealer! Lubricants • Availability and life expectancy of the machine largely depend upon the use of the recommended lubricants and compliance with the specified maintenance intervals. • If lubricants are used which have not been recommended by us and subsequent damage is caused, we do not accept any liability under warranty, even within the warranty period. • For lubricant specifications, see Chapter 3.9.

HML 42

65

7 Maintenance and Service 7.6 Care and cleaning The machine must be cleaned on a suitable surface with an oil separator. • Neither a steam-jet appliance nor a highpressure cleaning apparatus are to be used for cleaning during the first two months after the machine is used for the first time or when newly painted to ensure that the paint can sufficiently harden. • Do not use aggressive detergents for cleaning the machine. We recommend using commercially available cleaning agents for passenger cars. • When cleaning with a steam-jet appliance, the hot water jet is not to exceed 80 °C and a spray pressure of approx. 70 bar. • Linings (insulating materials, etc.) are not to be exposed directly to water, steam or high pressure jets • When cleaning with water or steam jets, take care not to spray exhaust-gas and air filter openings. • If cleaning the engine with water or steam jets, do not expose sensitive engine parts, such as generator, cabling, oil pressure switch, etc. directly to the jet. • After each wet clean, the machine must be lubricated in accordance with the lubricating plan and a test of all work cycles, support and travel functions carried out.

7.7 Notes for use in winter During operation in winter, the points mentioned below and the notes in the engine operating instructions must be observed: Hydraulic oil • When the machine has been out of use for longer periods at temperatures around and below freezing, it must be warmed up at medium revs (approx. 3-5 min.). Engine oil • The ambient temperature at the site where the machine is to be used is the deciding criterion when selecting the viscosity class (SAE-standard). Coolant • The effectiveness of the antifreeze must be checked before the cold season starts and adjusted to the ambient temperature if necessary. • The antifreeze is factory-set to approx. – 25 °C. Battery • For good cold start performance, always keep the battery fully charged. By warming up the battery to approx. +20 °C (remove the battery after the engine has been turned off and store it in a warm room), the starting temperature range can be lowered by approx. 4 °C — 5 °C. • When installing the battery, ensure good contact of terminal connections. • Only tighten terminal screws so that they are “hand tight“ in order to avoid deformation of the terminal posts!

66

HML 42

Maintenance and Service 7 Fuel •

•

•

Only use brand-name diesel fuel with additives for cold temperatures to prevent clogging of the fuel system due to paraffin separation. Even if winter diesel fuel is used, disturbing paraffin separations (jelling) can occur at very low temperatures. If only summer diesel is available, or if winter diesel must be used at very low temperatures, we recommend the addition of petroleum (Fig. 52) or additives. These mixtures should only be used temporarily, not for longer periods. Only mix the components in the tank. First fill in the necessary quantity of petroleum, then add the diesel.

+32

0

+23

- 5

+14

-10

+ 5

-15

- 4

-20

-13

-25

-22

-30

°F

°C

A

B 0

D2011 D2012

D

10

20

30

40

50

60%

C HM23-052

Fig. 52 - Table for the addition of petroleum or additives

Additives should be chosen in compliance with the recommendations of your fuel supplier.

A = Summer diesel

Petrol is not to be added.

D = Outside temperature

B = Winter diesel C = Added proportion of petroleum

Danger of explosion!

HML 42

67

7 Maintenance and Service 7.8 Checking, maintenance and inspection plans 7.8.1 Initial inspection (delivery/ handing-over inspection)

HM42-053

7

6

3

5

2

6

1

9

7

4

8

Fig. 53 Initial inspection

68

HML 42

Maintenance and Service 7 Jobs to be carried out by trained dealer personnel. Chapter 1

Check whether machine-specific instruction book is in the machine

2

Check engine oil level

7.9.1

3

Check coolant level

7.9.3

4

Check hydraulic oil level

7.9.8

5

Check fuel level

7.9.4

6

Oil check: axles

7.9.14

7

Check air pressure and condition of tires. Check secure fastening of wheel nuts.

7.9.16

8

Battery fluid level and charge condition

7.9.21

9

Top up windshield washer system

7.9.20

10

Grease machine (all lubricating points)

7.8.3

11

Test run, hydraulic function check and test work

--

12

Visual inspection for tightness of all hoses, pipes, cylinders, etc.

--

13

Check function of electrical indicating and warning elements, and the lighting system

--

14

Initial delivery / handing-over certificate and return to manufacturer

HML 42

--

7.4

69

7 Maintenance and Service 7.8.2 Daily and weekly tasks Inspection and maintenance jobs to be performed by operating personnel: 20

16

HM32-054

21

17

15

3

5

2

6

19

24

17

1

4

Fig. 54 Inspection and maintenance plan

70

HML 42

Maintenance and Service 7 Daily Chapter 1

Check hydraulic oil level

7.9.8

2

Check engine oil level

7.9.1

3

Check coolant level

7.9.3

4

Check fuel pre-filter for water accumulation; drain if required

7.9.4

5

Check fuel level (fuel gauge on instrument panel)

7.9.4

6

Check water level for windshield wiper

7.9.20

7

General visual inspection for material cracks, external damage, completeness, etc.

8

Check for leaks in: pipes, hoses, control valve, hydraulic pumps, cylinders, etc.

--

-When tightening hose and line connections, the screw-in couplings must be locked to prevent rotation. 9

Check electrical indicating and warning elements, and the lighting system

10

Check smooth running of operator controls

11

Grease machine in compliance with overview of lubricating points

7.9.21 -7.8.3

Weekly Chapter 7.9.3

15

Clean cooling fins of the combined hydraulic oil-water cooler

16

The cleaning intervals should be shortened if there is high exposure to dust. Check that door catches function perfectly

17

Check tire pressure and wheel nuts

7.9.16

18

Check fastening of axles and propeller shaft

7.9.14

19

Check slewing drive fastening (hydraulic motor and transmission)

7.9.18

20

Check bearing bushings and bolts of the work equipment

21

Check hydraulic axle lock

22

Check that pneumatic springs of the service covers and the front windshield function perfectly

--

23

Check function, condition and completeness of safety devices

--

24

Check function "working hydraulics cut-off through service ladder"

--

25

Grease machine in compliance with overview of lubricating points

7.8.3

HML 42

--

-7.9.12

71

7 Maintenance and Service 7.8.3 Overview of lubricating points Replace damaged grease nipples immediately and check if grease passes through!

9

10

11 12 13

8 7 29

6

5 4 3

2 1

HM42-055 03-05-14

14

15

18

19

20 21

21

1x

30

2x

24

2x

28 27 30

34

2x

4x

25 26

31

Fig. 55 Lubrication plan

72

HML 42

Maintenance and Service 7 Grease all lubricating points with multi-purpose grease. The intervals stated are valid for one-shift operation Item

Lubricating point

Qty.

1 2

Bucket rod – Quick-mount hitch Quick-mount hitch For lubrication, place the bucket on the ground, open the quick-mount hitch — the bolts must be fully retracted — and start to lubricate. Close quick-mount hitch. Bucket cylinder – bucket rod – tilt control lever Dipperstick — Quick-mount hitch Dipperstick — Tilt control lever Bucket cylinder – Dipperstick Intermediate boom – Dipperstick Dipperstick cylinder — Dipperstick Intermediate boom cylinder – Intermediate boom Dipperstick cylinder — Intermediate boom Intermediate boom — Boom Boom cylinder – Boom Intermediate boom cylinder — Boom Slewing column — Boom Boom cylinder — Slewing column

Superstructure – Slewing column Stabilizer — Undercarriage Stabilizer cylinder — Undercarriage Stabilizer cylinder — Stabilizer Self-aligning bearing front/rear for front axle Ring gear — Bearing races Ring gear — Toothing Articulated cylinder — Superstructure (slewing column center pillar) Articulated cylinder — Slewing column Door hinges Steering gear case each Hinges for service ladder Non-standard equipment Clamshell grab type GS 3 Swing bucket Swing bucket hydraulic cylinder

3 4 5 6 7 8 9 10 11 12 13 14 15 --18 19 20 21 24 25 26 27 28 29 30 31 34 35 36

weekly

Chapter

1 2

X X

---

3 1 1 1 1 1 3 1 1 1 3 1 1

X X X X X X X X X X X X X

--------------

2 2 2 2 2 1 1 1

X X X X X X X X

-----7.9.18 7.9.18 --

1 2 2 2

X X X X

-----

11 2 2

daily

X X X

----

We recommend that for special operations, e.g. on sandy ground, the lubrication intervals are shortened. Increased frequency of lubrication helps self-cleaning of bearing points.

HML 42

73

7 Maintenance and Service 7.8.4 Inspection plan To be carried out by trained dealer personnel O = Checking, maintenance X = Replacement Perform work with machine at operating temperature 1 Check whether machine-specific instruction book is in the machine 2 Change engine oil 3 Change engine oil filter 4 Drain fuel tank 5 Replace fuel filter 6 Replace fuel pre-filter 7 Check air intake 8 Change air filter main cartridge 9 Change air filter safety cartridge 10 Clean cooling fins of combined hydraulic oilwater cooler

Operating hours

min 2x

min 1x

yearl y

yearl y

Chapte r --

X

X

7.9.1

X

X

7.9.2

after 100

every 500

O

O

O

O

every 1,000

every 2,000

O

O X

X

7.9.4

X

X

7.9.4

O

7.9.5

to service indicator as required

O

7.9.4

X

1)

O

7.9.5 7.9.5 7.9.3

O

In case of high exposure to dust, shorten the cleaning intervals. 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

74

Check antifreeze level in coolant Change coolant Check V-belt tension Check engine mounts and pump attachments Check engine speed adjustment, top-end and low idle speed Check valve lash of engine and adjust if necessary Check acid level and battery connections Replace cab ventilation dust filter Check condition of tires, tire pressure and tightness of wheel nuts Check secure fastening of axles and propeller shaft Check bearing bushings and bolts of work equipment and replace if necessary Check that door catches are in perfect condition and replace if necessary Check electrical indicating and warning elements, and lighting system Check smooth running of operator controls and adjust if necessary Check function of hydraulic axle lock and vent plunger cylinders Check function of steering

O 1)

7.9.3

O

O

7.9.3 7.9.6

O

O

--

O

O

--

as required

O

7.9.7

O

O

O

O

7.9.16

O

O

--

O

O

--

O

O

--

O

O

--

O

O

--

O

O

7.9.12

O

O

--

X

7.9.21 X

7.9.19

HML 42

Maintenance and Service 7

O = Checking, maintenance X = Replacement Perform work with machine at operating temperature 27 Check condition and function of support equipment 28 Check line rupture valves of support equipment 29 Check tightness of all pipes, hoses, control valve, hydraulic pumps, cylinders, etc.

30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

When tightening hose and line connections, the screw-in couplings must be locked to prevent rotation. Check or change hydraulic oil Replace insert of hydraulic oil return filter Replace insert of hydraulic oil suction filter Replace breather Check function of brakes and play of brake discs Differential of rear axle - oil check or oil change Differential of front axle - oil check or oil change Front axle transmission - oil check or oil change Wheel hubs of front and rear axles - oil check or oil change Check that ring gear attachment screws are securely fastened Check that swing-drive attachment (hydraulic motor and transmission) is securely fastened Grease machine in compliance with overview of lubricating points Check function, condition and completeness of safety equipment Hydraulic function check with pressure function test Test run and test work Initial inspection cards and return to manufacturer

Operating hours

min 2x

min 1x

yearl y

yearl y

after 100

every 500

O

O

Chapte r --

O

O

7.9.13

O

O

--

O

O

X

in compliance with service indicator

X

X

every 1,000

X

2)

7.9.8 X X

X O

every 2,000

7.9.9 7.9.10

X

O

7.9.11 7.9.15

X

X

X

7.9.14

X

X

X

7.9.14

X

X

X

7.9.14

X

X

X

7.9.14

O

O

7.9.18

O

O

7.9.18

O

O

7.8.3

O

O

--

O

O

--

O

O

--

O

O

3)

7.4

1. at least every 2 years 2. Extension of oil change intervals in compliance with oil sample analysis and lab report. For further information see Chapter 7.3 3. within warranty

HML 42

75

7 Maintenance and Service 7.9 Inspection and maintenance work 7.9.1 Engine oil Checking the engine oil level • The oil level must be checked daily before start-up, with the machine standing on level ground. • The notches on the oil dipstick (56/2) indicate the minimum and maximum oil levels.

1

• Top up engine oil if necessary. Open the cap (56/1) and add oil using a clean container. Engine oil change Collect the waste oil, do not allow it to seep into the ground. Dispose of regulations!

in

compliance

with

• Run the engine until it reaches operating temperature, engine oil temperature approx. 80 °C. • Park the machine on a level surface. • Slew the superstructure by 90° across the undercarriage.

2

3

HR42-041

Fig. 56 Engine oil

• Switch off the engine. • Place suitable oil drip pans below the opening. • Screw the oil drain hose onto the oilchange valve (56/3). Danger of scalding when hot oil is drained! • Remove the oil drain hose and screw the protective cap onto the valve (56/3). • Replace the engine oil filter (see 7.9.2). • Fill up with engine oil to the “MAX” mark on the dipstick. • Start the engine and run at low idle speed for approx. 2 min. • Switch off the engine. • Check the oil level, top up if necessary.

76

HML 42

Maintenance and Service 7 7.9.2 Engine oil filter The engine oil filter must be replaced with every oil change. • Place drip pan below the engine oil filter. • Clean the outside of the engine oil filter. • Loosen the filter cartridge (57/1) using a commercially available tool and unscrew it. Check if the fastening stud is firmly seated in the filter head. • Dispose of the filter cartridge in compliance with regulations. • Clean the filter head and check its condition. • Fill the new filter with oil, wet seal ring with oil and screw on firmly by hand until the seal is securely in place. • With one more half turn, tighten the filter cartridge.

1

HR42-042

Fig. 57 Engine oil filter

• After a test run, check the tightness of the engine oil filter cartridge.

HML 42

77

7 Maintenance and Service 7.9.3 Cooling system hydraulic oil-water cooler

—

Combined

Coolant level Only open the cooler cap with the engine cooled down. Hot coolant carries a risk of scalding! •

1

Remove the cap (59/1) and top up the water level. With the engine cooled down, the expansion tank should be half full. Refill with a 50%-50% mixture of water and antifreeze.

Checking the level of antifreeze • Before the beginning of the cold season, check the level of antifreeze. • At the factory, the antifreeze protection is set to approx. minus 25 °C. If temperatures are lower, the level of antifreeze must be increased accordingly.

HR32-044

Fig. 59 Coolant

Cleaning cooling fins Dirt accumulation in coolers causes the engine and/or the hydraulic oil to overheat. • The combined cooler is cleaned from the outlet side (60) with compressed air. • If necessary, e.g. in case of an oiled cooler, clean with cold cleaner or a steam jet device. • After cleaning, the engine must be brought to operating temperature in order to dry the cooler.

78

HR32-045

Fig. 60 Cooler

HML 42

Maintenance and Service 7 Changing coolant Only open the cooler cap when the engine is cold. Hot cooling water carries a risk of scalding! • Park the machine on level ground. • Switch off the engine and let cooling system cool down. • Remove the cooler cap (59/1).

1

• Unscrew the water drain plug (61/1) on the cylinder block and drain coolant. • Remove the drain plug from the water cooler and drain coolant. • Flush the cooling system with clean water if necessary. • Re-fit the drain plug to the engine and the water cooler. • Fill cooling system with coolant (see Technical Data, Chapter 3.9) and close the cap.

HR32-046

Fig. 61 Engine block

• Start the engine and bring to operating temperature, then turn off and allow to cool. • Check the coolant level and top up (several times, if necessary).

HML 42

79

7 Maintenance and Service 7.9.4 Fuel system Fuel level • Check the fuel level on the fuel gauge (62/43). • To prevent condensation from forming before the next time the machine is used, top up fuel after daily use.

,

! 0

4/4

43

P

When topping up fuel using the electrical refueling pump the fuel tank cap must be opened to avoid excessive pressure in the fuel tank! HM32-062

Fuel filter • Clean the outside of the fuel filter.

Fig. 62 Operation

• Unscrew the filter cartridge (63/1). Collect fuel! • Dispose of the filter cartridge in compliance with regulations. • Clean the filter head and check its condition. • Wet the seal or fuel filter cartridge with oil or diesel fuel respectively. • Screw on the cartridge by hand until the seal is securely in place. • With one more half turn, tighten the filter cartridge. The fuel system does not have to be vented.

1

HR42-048

Fig. 63 Fuel filter

• After a test run, check the tightness.

2

Fuel tank • Drain water from the fuel tank through the drain plug (64/1). • Clean the filling strainer (64/2) and check for damage.

1 HM42-064

Fig. 64 Fuel tank

80

HML 42

Maintenance and Service 7 Draining the fuel pre-filter •

Drain the fuel pre-filter through the drain valve (65/1).

Replacing the filter insert of the fuel prefilter •

Clean the outside of the fuel filter.

•

Drain fuel through the drain plug (65/1). Collect fuel!

•

Unscrew the center screw and remove the cover.

•

Pull out the filter insert by turning.

•

Flush the filter housing with clean fuel.

•

Install new or cleaned filter insert.

Cleaning the filter insert of the fuel prefilter When cleaning, ensure that no dust lands on the inside (clean side) of the insert.

1 HM42-065

Fig. 65 Fuel pre-filter

• Immerse the screen insert of the fuel prefilter in clean fuel. Meanwhile, blow out from the inside and brush off using a medium-hard cleaning brush. Only use brushes with synthetic or natural bristles. Do not use wire brushes! • After brushing, immerse the insert in clean fuel and blow out from the inside. • Remove the filter insert from the bath and blow out hard from the inside until there is no more fuel foam on the surface of the insert. • Check that the filter insert is undamaged and that there is no dirt on the inside. • The insert is ready to be re-installed.

HML 42

81

7 Maintenance and Service 7.9.5 Air filter, air intake All maintenance work on the air intake system must be carried out with the engine off. Do not start the engine while the filter cartridge is removed. Preparation of machine for maintenance

2

• Position the work equipment until it is straight as compared to the uppercarriage and place it on the ground.

3

1

75 °

• Slew the uppercarriage from the travel direction to the right by approx. 75° (Fig. 66).

• Switch off the engine. • Open the engine hood. • With your left hand, hold on to the frame (66/1) above the flush-fitted headlamp and step on the undercarriage access stairs. • With your right hand, hold on to the handle (66/2) and climb on the top step of the access stairs. • Standing on the service access, you can easily replace the air filter cartridge (66/3).

82

HM42-066

Fig. 66 Air filter maintenance

HML 42

Maintenance and Service 7 7.9.5.1 Air intake • Check the air filter attachment retaining straps for damage.

and

• Check the condition and function of the air intake manifold (67/1). • Check the tightness of the air duct between the air filter and the engine. • Examine rubber parts for damage. Replace damaged parts immediately.

1 HM32-066

7.9.5.2 Cartridge maintenance interval

Fig. 67 Air filter

Air filter — main cartridge • The air filter main cartridge must be replaced as soon as the indicator lamp for filter maintenance (68/29) on the instrument panel lights up during operation. • A brief delay in maintenance does not result in lower filter efficiency.

29

Air filter — safety cartridge

,

! 0

The air filter safety cartridge must be replaced in the following cases:

4/4

P

• after the fifth maintenance of the main cartridge • when it has reached the maximum service life of two years • if the service indicator switches on after maintenance of the main cartridge has just been performed

HM32-067

Fig. 68 Operation

• if the main cartridge is damaged • if the safety cartridge is damaged

HML 42

83

7 Maintenance and Service 7.9.5.3 Cartridge replacement Main cartridge • Release the wire fasteners (69/1) and remove the bottom of the housing (69/4). • Withdraw the main cartridge (69/2) by twisting slightly to and fro.

1.

1

2.

4

• Check whether the safety cartridge (69/3) must be replaced. Remove safety cartridge only in the case of necessary maintenance work. Only open the seal (69/5) of the safety cartridge for the purpose of replacement.

3.

• Note down the date of maintenance in the appropriate sections of the safety cartridge (69/3).

2

• Insert the new or cleaned main cartridge carefully into the filter housing and check that it is correctly positioned. • Fit on the lower part of the housing. (Pay attention to the position of the dust extraction valve). • Place the wire fasteners in the groove of the flange on the filter housing and tighten.

3

Safety cartridge • Remove the main cartridge.

5

Do not clean the safety cartridge and, once it has been removed, do not use it again.

6

• Using a suitable tool (e.g. screwdriver), pierce the seal (69/5) of the safety cartridge (69/3) from the inside, then lift up the two clips (69/6). • Grasp the safety cartridge (69/3) by the two clips (69/6), withdraw by twisting slightly to and fro, and dispose of it.

HM32-068

Fig. 69 Air filter

• Insert a new safety cartridge and check that it is correctly positioned. • Re-install the main cartridge.

84

HML 42

Maintenance and Service 7 7.9.5.4 Cleaning the main cartridge Never wash or brush out the main cartridge. When blowing out, ensure that dust does not land on the inside of the main cartridge. • The main cartridge can be cleaned up to 5x if necessary. It must be replaced once it reaches its maximum service life of two years, at the latest. A note must be made of the number of times it is cleaned.

max. 5 bar

• For cleaning, a pipe the end of which is bent at 90° should be attached to the compressed-air pistol. It must be sufficiently long to reach the floor of the cartridge. Blow out the filter cartridge from the inside to the outside with dry compressed air (max. 5 bar) by moving the pipe up and down in the cartridge. Continue until no more dust escapes. • Check the clean main cartridge for damage to the paper bellows and rubber seals. Tears and perforations in the paper bellows can be determined using a torch.

HR32-054

Fig. 70 Cleaning the main cartridge

Never continue to use damaged main cartridges. If in doubt, use a new one.

HML 42

85

7 Maintenance and Service 7.9.6 V-belts

Tensioning V-belts — generator

Check and replace V-belts only with the engine turned off.

• Slacken the fastening screws (71/3, x3) of the generator (71/5).

Risk of injury!

• Rotate the generator using the screw (71/4) until the V-belt tension is correct.

• Check the complete V-belts (visual inspection) and make sure that they are not damaged.

• Tighten the fastening screws (71/3).

Replace damaged or worn V-belts immediately. Checking the V-belt tension To check the V-belt tension, a tension measuring device is recommended. Check the tension in compliance with the manufacturer’s operating instructions.

1 2

5 4

1

When new V-belts are fitted, their tension must be checked and adjusted if necessary after the first 15 minutes.

3 HR42-056

Checking the V-belt tension without a measuring device

Fig. 71 V-belts

• To check the tension, press the V-belt with your thumb in the middle of the greatest free length, and measure the sag. • Using medium thumb pressure of approx. 45 N, the V-belt sag should equal 10 mm. Tensioning V-belts — coolant pump / fuel pump • Slacken the fastening screws (71/1, x2) on the adjuster. • Rotate the fuel pump (71/2) until the tension is correct. • Tighten the fastening screws (71/1) of the adjuster. • Check the tension again.

86

HML 42

Maintenance and Service 7 7.9.7 Checking the valve lash • The valve lash (72/1) is tested by placing a reed gauge between the valve (72/3) and the rocker arm (72/2) on the cold engine. • The correct valve lash is 0.30 mm for the intake valve and 0.50 mm for the outlet valve. Checking and adjusting

2

5 4

1

Before adjusting the valve lash, let the engine cool down for at least 30 min.

3

Oil temperature below 80 °C. • Detach the vent valve and swivel to the side. • Remove the cylinder head cover. Crankshaft position "1" • Turn the crankshaft until both valves intersect at the 1st cylinder (outlet valve not yet closed, intake valve begins to open).

1

1

2

3

4

1

2

3

4

• The valves marked black can be adjusted. To check the completed adjustment, mark the respective valve with chalk. Adjust valve lash if necessary. To do so:

2

Þ Slacken the lock nut (72/4). Þ Using a screwdriver (72/5), adjust the setting screw so that the correct valve lash (72/1) is obtained when the lock nut is tightened.

HM32-072-N

Fig. 72 Valve lash

Crankshaft adjustment "2" • Turn the crankshaft by one more revolution (360°). • The valves marked black can now be adjusted. • Re-install the cylinder head cover along with a new gasket. • Turn the vent valve back to its correct position.

HML 42

87

7 Maintenance and Service 7.9.8 Hydraulic oil tank Checking the hydraulic oil level • Check the oil level using the sight glass (74/1). Top up hydraulic oil if required.

1

The hydraulic cylinders of the work equipment should be retracted as far as possible.

3

2

4

Hydraulic oil change Danger of scalding when hot oil is drained. • Bring the hydraulic temperature.

oil

to

5

operating

• Retract all hydraulic cylinders. • Stop the engine. • Unscrew the breather (74/2). • Place suitable oil drip pans below the oil outlet. • Screw the oil drain hose onto the oilchange valve (74/5). Collect waste oil, do not allow it to seep into the ground.

HM42-074

Fig. 74 Hydraulic oil tank

1 = Sight glass 2 = Breather 3 = Return filter 4 = Suction filter 5 = Drain

Dispose of in compliance with regulations! • Flush and clean the hydraulic oil tank as required (remove return filter 74/3). • Remove the oil drain hose and screw the cap onto the valve (74/5). • Remove the cover of the return filter. • Fill with clean hydraulic oil up to the correct level on the sight glass (74/1). • Re-fit the filter cover. • Screw back in the filter. • Check the tightness of the filter and the drain plug.

88

HML 42

Maintenance and Service 7 7.9.9 Hydraulic oil return filter Cartridge maintenance interval • The filter cartridge must be serviced as soon as the indicator lamp for filter maintenance (75/30) in the instrument panel lights up during operation.

30 ,

!

After a larger repair job, following the test run the filter cartridge of the return filter (74/3) must be replaced as well.

0

4/4

P

Damaged hydraulic work attachments may shorten the life of the return filter.

HM32-075

Fig. 75 Operation

Replacing the filter insert: • Switch off the engine.

1

3

2

4

• Detach the filter (74/2). • Remove the cover (76/1) of the return filter. • Pull out the filter bowl (76/2) together with the filter insert (76/3).

5

Always place a receptacle for the collection of waste oil under the working area when removing the filter insert. • Remove the filter element from the filter bowl by turning and pulling at the same time. • Clean the filter bowl with petroleum ether or similar.

HM42-074

Fig. 74 Hydraulic oil tank

1

• Check O-rings (76/4; 76/5; 76/6) and replace any damaged parts.

4

• Insert a new filter element in the filter bowl.

5

• Install the filter bowl in the tank, together with the new insert.

2

• Apply a light coat of grease to the cover seal and tighten the cover by hand.

3

• Screw back in the filter. • Check the tightness of the filter.

6 HR32-062

Fig. 76 Return filter

HML 42

89

7 Maintenance and Service 7.9.10 Hydraulic oil suction filter After a larger repair job on the hydraulic system, following the test run the filter cartridge of the suction filter (74/4) must be renewed as well.

• Tighten the filter cover further with the aid of a tool. • Screw back in the breather. • Check the tightness of the filter by means of a test run.

Replacing the filter insert • Release the breather (74/2). • With the aid of a tool, remove the filter cover (77/1). The valve (77/2) in the end plate of the paper insert (77/9) closes.

1

3

2

4

• Remove the assembly (77/10) by turning and completely removing the filter cover. While doing so, pay attention to the O-ring (77/3). Always place a receptacle for the collection of waste oil under the working area when removing the filter insert. • Grasp the assembly by the filter cover (77/1) and unscrew the valve (77/2). • Pull out the filter insert and dispose of in compliance with regulations. • Clean the filter cover with center rod (77/8) and valve with diesel oil or petroleum ether. While doing so, pay attention to the retaining plate (77/6), seals (77/5, 77/7) and compression spring (77/4).

HM42-074

Fig. 74 Hydraulic oil tank

A

• Check the O-ring (77/3) and seals (77/5, 77/7, 77/11), and replace any damaged parts. • Place surface “A” of the filter cover on a solid base, push a new filter insert onto the center rod and fit the seal (77/5). • Push the filter insert downward against the springs and tighten the valve (77/2) by hand. • Push the assembly (77/10) into the housing (77/12), screw on the filter cover tightly by hand and check that the O-ring (77/3) is in exactly the right position.

90

12

1 3 4 5 6 8 7 9

10

11 2 HM32-077

Fig. 77 Suction filter

HML 42

Maintenance and Service 7 7.9.11 Hydraulic oil tank breather • Remove the breather (74/2), replace it by a new one and tighten so that it is hand-tight.

1

3

2

4

Replace the filter if the cap is dirty, e.g. due to oil vapor.

HM42-074

Fig. 74 Hydraulic oil tank

HML 42

91

7 Maintenance and Service 7.9.12 Venting the plunger cylinders • The pressure is supplied by the circulation of flushing oil in the hydrostatic drive. • The oscillating axle is locked by means of a locking valve which blocks the connecting line between the plunger cylinders and is activated by pressing the excavator brake (78/12) or pressing the “oscillating axle lock” toggle switch (78/62).

P

62 63

• With the excavator brake applied or the oscillating axle lock toggle switch pressed, the axle is not to swing.

11 12

Venting • Secure the machine so that it cannot roll away. • Release the excavator brake (78/11). • Release the parking brake (78/63). • Oscillating axle lock toggle switch (78/62) in “OFF” position. • Let the engine run at medium revs. • Open the right and left-hand vent screws (79/1) on the plunger cylinder one after the other, until hydraulic oil escapes without bubbles.

HM32-078

Fig. 78 Operation

• Close the vent screws.

1

7.9.13 Line-rupture valves for stabilizers During this test, the machine must be secured in such a way as to ensure that there can never be a danger to persons or objects in the event of a fault in the line-rupture valves! • Subject the stabilizer to a load applied in the non-operating direction. • Switch off the engine; switch on the ignition.

HM32-079

Fig. 79 Plunger cylinder

• Operate the stabilizer control lever. The stabilizer is not to respond!

92

HML 42

Maintenance and Service 7 7.9.14 Axles General The axle oil must be checked at operating temperature. Collect the waste oil, do not allow it to seep into the ground. Dispose of in compliance with regulations! After topping up the axles with oil, drive the machine for approx. 5 min. to make sure that the oil is evenly distributed. Check the oil level again, top up if required.

HML42, HML42AL

3

7.9.14.1 Differential of front axle Checking the axle oil level • Remove the inspection plug (81/1), check oil level and top up oil if required (filler hole 81/3).

1 2

Changing axle oil • Park the machine on level ground.

HML42S

3

• Open the inspection plug (81/1) and filler plug (81/3). • Open the drain plugs on the differential (81/2) and the brake housing, and drain the oil. • Flush out the axle if necessary. • Carefully close the drain plug. • Pour in oil via the filler hole (81/3) until oil escapes from the inspection hole (81/1). • Carefully close both the filler and the inspection holes.

HML 42

1 2

HM42-081-N

Fig. 81 Front axle differential

93

7 Maintenance and Service 7.9.14.2 Differential of rear axle

HML42, HML42S

3

Checking the axle oil level • Remove the inspection plug (82/1), check oil level and top up oil using the filler hole (82/3) if required Changing axle oil • Park the machine on level ground.

1

• Open the inspection plug (82/1) and the filler plug (82/3). • Open the drain plugs on the differential (82/2) and the bottom housing and drain oil.

2 HML42AL

3

• Flush out the axle if necessary. • Carefully close the drain plugs. • Pour in oil via the filler hole (82/3) until oil escapes from the inspection hole (82/1). • Carefully close both the filler and inspection holes.

1 2 HM42-082-N

Fig. 82 Rear axle differential

94

HML 42

Maintenance and Service 7 7.9.14.3 Front axle transmission

HML42, HML42AL

Checking the oil level • Remove the filler and inspection plug (83/1), check oil level and top up oil if required. Changing oil

1

1

• Park the machine on level ground. • Open the inspection plug (83/1) on the transmission. • Open the drain plug (83/2) transmission and drain oil.

on

2

the

• Flush out the transmission if necessary.

HML42S

• Carefully close the drain plug. • Pour in oil via the inspection and filler hole (83/1) until oil escapes. • Carefully close the filler and inspection plug.

1 2 HM42-083-N

Fig. 83 Reduction gear

HML 42

95

7 Maintenance and Service 7.9.14.4 Wheel hub HML 42, HML 42 S, HML 42 AL: Front axle HML 42 AL: Rear axle Checking the oil level The wheel hub has a combined hole for inspection, filling and draining. • Turn the wheel hub to the inspection position. • Remove the screw plug, check the oil level and top up oil if required. Changing oil

Vorderachse HML42, HML42S, HML42AL Front axle Hinterachse HML42AL Rear axle

1

• Turn the wheel until the screw plug (84/1) is at the bottom of the hub. • Open the screw plug and catch the escaping oil. • Flush out if necessary. • Turn the wheel to the filling and inspection position. The inspection mark must be horizontal.

Hinterachse Rear axle

HML42, HML42S

2

• Fill in oil up to the lower edge of the hole. • Carefully close the filler hole. HML 42, HML 42 S: Rear axle Checking the oil level • Turn the wheel hub to the inspection position. • Remove the screw plug (84/2), check the oil level and top up oil if required. Changing oil • Turn the wheel until the screw plug (84/2) is at the bottom of the hub. • Open the plug (84/2) and the drain plug (84/3) and catch the escaping oil. • Flush out if necessary.

3 HM42-084-N

Fig. 84 Wheel hub

• Carefully close the drain plug (84/3). • Turn the wheel to the filling and inspection position. The inspection mark must be horizontal. • Fill in oil up to the bottom edge of the hole. • Carefully close the filler hole (84/2).

96

HML 42

Maintenance and Service 7 7.9.15 Brakes

Vorderachse/Front axle - HML42, HML42AL, HLM42S Hinterachse/Rear axle - HML42AL

HML 42, HML 42 S, HML 42 AL: Front axle HML 42 AL: Rear axle

1

Checking the brake disc play • Apply the parking brake (86/63). • Open the inspection hole (85/1). • Check the wear of the brake discs using a test gauge. • Minimum thickness S = 4.5 mm HML 42, HML 42 S: Rear axle The brake plates of the disc brakes in the wheel hubs cannot be examined.

1 HM42-085-N

Fig. 85 Brake discs

P

12

63

Fig. 86 Operation

HML 42

97

7 Maintenance and Service Bleeding the service brake

Vorderachse HML42, HML42S, HML42AL Front axle

1

This task is to be performed by two persons. • Let the engine run at medium revs.

1

• Press down brake pedal (86/12) by 50%. • Open the vent screws (87/2) on both front axle brake cases one after the other, until brake fluid (hydraulic oil) runs out without bubbles.

2

2 2

2

1

1

2

1

2

1 2

2

1

1

2

2 1

Collect the waste oil, do not allow it to seep into the ground. Dispose of it in compliance with regulations! • Close the vent screws. • Open the vent screws (HML 42, HML 42 S, - 87/3; HML 42 AL – 87/4) on both rear axle wheel hubs one after the other, until brake fluid (hydraulic oil) runs out without bubbles.

Hinterachse HML42, HML42S Rear axle

3

• Close the vent screws. • Open the vent screw on the brake inching device (hydraulic pump for travel) until brake fluid (hydraulic oil) runs out without bubbles. • Close the vent screw. Bleeding the spring-loaded brake

Hinterachse HML42AL Rear axle

This task must be done by two persons! • Secure the machine so that it cannot roll away, e.g. by supporting it. • Let the engine run at medium revs. • Release the excavator brake and the parking brake. • Open the vent screw (87/1) on the front axle brake case until brake fluid (hydraulic oil) runs out without bubbles.

4 HM42-087-N

• Close the vent screw. Fig. 87 Bleeding the brake

98

HML 42

Maintenance and Service 7 7.9.16 Wheels Checking the tire pressure • Check the tire pressure in accordance with the pressure chart, Chapter 3.8, at regular intervals. Checking the tire condition • The tires must be inspected for cracks, cuts, foreign bodies, etc. • Tightness of wheel nuts. • During the first 50 operating hours, check the tightness of the wheel nuts (type A 22) daily, and subsequently at regular intervals, and tighten to the required torque if necessary. • Tightening torque: 610 Nm When changing a wheel, always tighten the nuts to the specified torque crosswise in several steps.

HML 42

99

7 Maintenance and Service 7.9.17 Swing gear The swing gear is maintenance-free. Circulation lubrication provided by hydraulic system.

1 3

7.9.18 Swing bearing Lubrication of toothing • The lubricating nipple (90/1) mounted in the driver’s cab lubricates the toothing of the ring gear via a nozzle (90/2). • To this purpose, slowly turn the superstructure and lubricate it thoroughly at the same time using a grease gun.

1

3 4

5

Lubrication of bearing races • The bearing races are lubricated via the lubricating nipple (90/3) mounted in the driver’s cab and through a lubricating pipe (90/4). • Slowly turn the superstructure clockwise and anti-clockwise, and lubricate it thoroughly until both gaskets have a collar (90/5) of fresh grease.

100

2

5

HM42-090

Fig. 90 Swing bearing

HML 42

Maintenance and Service 7 Checking the secure fastening If the screws are mounted for the first time, they must also be checked after 100 operating hours. The following mounting instructions are the prerequisite for a perfect screw connection on the undercarriage and the superstructure:

MA = 72 Nm

MA = 195 Nm

• The contact faces of screw heads must be of bright metal, i.e. absolutely free of grease and paint. • The thread and the screw head, in particular the toothing of the head, are not to be damaged. Damaged screws must be replaced by new ones! All accessible screws must be examined to ensure that they are tightened to the torques specified in Figure 91.

MA = 325 Nm MA = 325 Nm HM42-091

Fig. 91 Tightening torques

HML 42

101

7 Maintenance and Service 7.9.19 Cab ventilation dust filter

2

Removal • Slew the superstructure undercarriage).

90°

1

(across

• Remove the cover (92/3) on the bottom of the superstructure below the cab. • Remove the filter bracket along with the filter (92/1). • Replace filter (92/2). Installation • Position new filter in bracket.

3 HM32-092 010905

Observe the mounting position! The air flow arrows must point towards the heater.

Fig. 92 Cab ventilation dust filter

• Attach the filter bracket along with the filter. • Re-mount the cover on the bottom of the superstructure.

7.9.20 Windshield washer system • Top up the washer tank (93/1) as required. • Add antifreeze when temperatures are around or below freezing.

1 HM32-093

Fig. 93 Windshield washer tank

102

HML 42

Maintenance and Service 7 7.9.21 Electrical equipment

Lighting and warning equipment

Battery

• Check function of lighting equipment.

The battery is located under the cover (94/2) of the service ladder.

• Check function of indicator lamps. • Check function of warning equipment.

The instructions of the battery manufacturer must be observed when using the battery for the first time. • The acid level should be approx. 10 mm above the plates. If necessary, top up with pure distilled water.

1

• Only check the battery when the engine is turned off. Maintenance-free batteries do not have to be checked. Disconnecting the battery • Fold down the service ladder and remove the cover (94/1). • Disconnect first the battery ground cable (-), then the positive cable (+). • Lift out the battery. Installing the battery

1

• Place the battery into the machine. • Connect the positive cable (+), then the battery ground cable (-). Ensure that the negative terminal is attached to the negative pole (-) and the positive terminal to the positive pole (+).

HM42-094

Fig. 94 Battery

• Re-fit the cover (94/1). In winter, in particular, ensure that the battery is well charged.

HML 42

103

7 Maintenance and Service 7.10 Shutdown

7.10.2 During shutdown

7.10.1 Preservation (temporary shutdown)

• When the machine is out of use for 6 months, after this time all assemblies must be brought to operating temperature and maneuvered for approx. 15 minutes.

To prevent damage (corrosion, etc.) from storage during shutdown periods over three months, certain preservation measures must be taken: • We recommend keeping the machine in a dry, dust-free room during the storage period.

• Beforehand, the anti-corrosion coat must be removed from the piston rods, and the openings of the air filter system and the exhaust pipe freed.

• Clean the inside and outside of the machine, including the engine.

• After the maneuvering cycle, preserve the machine once more as previously described.

• Lubricate the machine in compliance with the lubrication plan. • Check the oil levels of all assemblies, such as transmission(s), etc. and top up if necessary. • Check the hydraulic oil level and top up if necessary.

7.10.3 After shutdown Before putting the machine into operation once more, the following measures must be carried out:

• Repair paint damage.

• Anti-corrosion coat must be cleaned from the piston rods.

• Fill the diesel tank completely, in order to prevent corrosion of the tank walls.

• The openings of the air filter and exhaust pipe must be freed.

• Check the antifreeze level in the coolant and adjust if necessary.

• Check the condition of the air filter main cartridge / safety cartridge and replace if required.

• Perform all the preservation measures contained in the diesel engine operating instructions. • Check the tire pressure in compliance with the prescribed values and protect the tires (rubber crawler chains) from direct sunlight.

• Clean the detergent.

machine

with

a

neutral

• Check and - if required - re-charge and install the battery.

• Treat bare piston rods with a commercially available anti-corrosion agent.

• Carry out all measures for putting the diesel engine back into operation stated in the engine operating instructions.

• Remove and clean the battery and keep it in compliance with regulations in a dry - in winter, frost-proof - room. Coat connections with a little pole grease.

• If the machine has been out of use for more than 6 months, the oil in the assemblies such as transmission(s), etc. must be changed.

• Seal off the air intake opening of the air filter system and the exhaust pipe opening.

• If hydraulic oil filters (return and suction filters, breathers — if installed) have been out of use for 6 months, they must be replaced. • Lubricate the machine in compliance with the lubrication plan.

104

HML 42

Trouble-Shooting 8 8 Trouble-Shooting 8.1 Generalities Operating problems are often the result of incorrect handling of the machine, the use of unsuitable materials or irregular maintenance. The following table presents a summary of a range of problems and their probable causes. If a problem can only be eliminated through repair, then the responsible Service Agent must be called in.

8.2 Engine All faults in the diesel engine must be examined as described in their specific operating instructions. During the warranty period, malfunctions must be dealt with by the responsible Service Agent or a specialist workshop.

Fault

Possible cause

Remedy

8.3 No steering movement 1

Oil supply to pump interrupted

Check and repair suction line

2

Hydraulic pump damaged

Check, repair or replace

3

Priority valve damaged

Remedy fault (call Service Agent)

4

Steering control unit damaged

Remedy fault (call Service Agent)

5

Steering cylinders damaged

Repair

6

Mechanical fault

Repair

8.4 Insufficient performance of service brake 1

Brake discs worn

Repair

2

Braking system damaged

Repair or replace

3

Mechanical fault

Repair

8.5 Parking brake without function 1

Spring-loaded released

brake

mechanically

2

Hydraulic fault in actuation of springRepair loaded brake

Activate spring-loaded brake

8.6 Insufficient braking power of swing brake 1

Brake linings worn

Replace brake linings

2

Fault in brake actuation

Repair

HML 42

105

8 Trouble-Shooting

Fault

Possible cause

Remedy

8.7 No zero position of travel direction 1

Switch for travel direction damaged Repair or replace (short circuit)

2

Solenoid sticks or is damaged

Repair or replace

3

Hydr. cylinder without zero position

Check, re-calibrate (call Service Agent)

4

Internal damage displacement pump

to

variable Replace complete pump unit

8.8 Hydraulic oil exceeds max. admissible temperature 1

Thermostat damaged

Replace

2

Oil level too low

Top up oil to mark on sight glass

3

Oil cooler clogged or faulty

Clean, check, replace if necessary

4

Suction filter clogged

Replace

5

High pressure valves do not respond Check high pressure valves, re-adjust if all the time necessary

6

Flushing circulation does not function

7

Variable displ. pump and/or variable- Replace capacity motor damaged (worn)

Check pressure of flushing and charge pump, possible back pressure in circuit, check housing pressure

8.9 Sluggish acceleration and deceleration, too little propulsive power

106

1

Insufficient engine power

Check diesel engine

2

A brake is sticking

Check, remedy damage

3

No tank pressurization

Check tank cap, replace

4

Suction filter clogged

Replace filter

5

Oil loss in rotary joint

Re-seal rotary joint

6

Charge pump (travel) sucks up air

Check, re-seal

7

Charge pressure too low

Check pressure, re-adjust

8

Pressure limiting valve of filling circuit Check, re-adjust or replace clogged or faulty

9

High pressure too low

10

Variable displacement pump does not Insufficient pilot pressure. Mechanical open fully damage to pump displacement control. Check, adjust or repair

11

No flow adjustment of variable-capacity Start of control set too high. Mech. damage motor to regulator or displacement control. Adjust, or call Service Agent

12

Internal damage to variable displacem. Replace unit pump or variable-capacity motor

Check high pressure (pressure cut-off), and re-adjust if necessary

HML 42

Trouble-Shooting 8

Fault

Possible cause

Remedy

8.10 Transmission works in one direction only 1

Switch for travel direction damaged

Repair or replace

2

Solenoid valve sticks or is damaged

Check and replace if necessary

3

Power supply to travel direction switch Check and repair (incl. ground connection) or solenoid valve interrupted

4

Non-return valve of filling circuit faulty

5

High pressure limiting valve is faulty or Swap valves around. If machine now incorrectly set travels in the other direction, examine valve, clean and replace if necessary

6

Leakage at actuating piston

7

Mechanical damage to variable Check, call Service Agent if necessary displacement pump and/or variablecapacity motor

Check and replace if necessary

Check actuating pressure at piston (behind actuating time nozzle)

8.11 Transmission works in neither direction 1

Too little hydraulic oil in tank

2

Mechanical connection to diesel engine Check, repair faulty

3

Charge pump damaged, no charge Replace variable displacement pump pressure

4

Switch for direction of travel damaged

Check and replace if necessary

5

Valve for direction of travel damaged

Check, repair and replace if necessary

6

Power supply to direction switch and/or Check and repair solenoid valve interrupted

7

Pressure limiting pressure) damaged

8

Suction filter clogged

Replace filter

9

Suction line from tank to pump kinked

Check

10

No or insufficient charge pressure

Check pressure and search for fault

11

Trigger of variable displacement pump Check pressure and search for fault interrupted

12

Mechanical damage to variable Check, call Service Agent if necessary displacement pump and/or variablecapacity motor

13

Internal damage to variable Replace complete unit displacement pump and/or variablecapacity motor

14

Mech. connection between variable- Check, repair capacity motor and axle interrupted

HML 42

valve

Top up to mark on sight glass

(charge Check and replace if necessary

107

8 Trouble-Shooting

Fault

Possible cause

Remedy

8.12 Excavator installation is not working 1

Working hydraulics toggle switch in Change to "ON" “OFF" position

2

Travel speed position

3

Left work panel raised, or switch Check, repair or replace if necessary damaged

4

Oil supply interrupted

5

Hydraulic pump has stopped working

6

Main pressure relief valves have Check main pressure relief valves and stopped working replace if necessary

7

Service ladder is folded down

Fold up service ladder

8

Switch on service ladder damaged

Repair or replace

switch

to

in

“FAST" Change to "slow"

hydraulic

pump Check lines Get hydraulic pump checked by a specialist, replace if necessary

8.13 Decrease in machine’s performance 1

Insufficient engine power

Check diesel engine

2

Hydraulic oil level too low

Top up hydraulic oil to the mark

3

Pump is sucking up air

Tighten hose connections. Replace O-ring or seals

4

Insufficient operating pressure

Re-adjust main pressure relief valves (pressure cut-off), replace valves if necessary

8.14 Machine is working too slowly and hydraulic oil is becoming hot

108

1

Main pressure relief valves (pressure Re-adjust main pressure relief valves cut-off) set too low or faulty (pressure cut-off), replace if necessary

2

Hydraulic pump degree of wear

3

Insufficient hydraulic oil level

Top up hydraulic oil to mark

4

Incorrect hydraulic oil

Quality of hydraulic oil must conform to our recommendation

5

Air in hydraulic system

Tighten connections with engine off and system relieved of pressure

6

Oil cooler dirty or damaged

Clean, check and replace if necessary

has

impermissible Replace hydraulic pump

HML 42

Trouble-Shooting 8

Fault

Possible cause

Remedy

8.15 Superstructure slews too far 1

Swing brake damaged

Check condition of brake, repair or replace if necessary

2

Impermissible degree of wear in swing Check or replace drive

8.16 Working cylinders are not working satisfactorily 1

Seals in cylinders worn

Re-seal cylinders

2

Secondary valves faulty

Check secondary valves and complete valves if necessary

replace

8.17 Plunger cylinders fail to lock or lock insufficiently 1

Mechanical fault

Check switch valves, replace if necessary

2

Electrical fault

Check switches, cables, connections and fuses

3

No pressure build-up

Check hydraulic supply

4

Inexact lock

Vent plunger cylinders

8.18 Overload warning device malfunctions 1

No visual indicator

Overload warning device sensor or indicator module damaged. Have checked by service specialist

2

No acoustic warning

Overload warning device not switched on. Overload warning device sensor or indicator module damaged. Have checked by service specialist

HML 42

109

8 Trouble-Shooting

Fault

Possible cause

Remedy

8.19 Trouble in the electrical system 1

Outside and/or internal lighting does Check cables, connections, bulbs and fuses not come on

2

Windshield wiper does not work

Check cables, connections and fuses. Examine windshield wiper for mechanical damage. Replace complete wiper motor if necessary

3

Horn does not work

Check cables, connections Replace complete horn

4

Control organs are imprecise

Determine the fault or source of the problem, call Service Agent if necessary

5

Starting system satisfactorily

does

not

and

fuses.

work Check charge capacity of battery. Test starter function. Check connection and condition of power and battery ground cables. Check function of ignition lock, replace complete unit if necessary.

110

HML 42

Appendix 9 9 Appendix 9.1 Electrical system Fuse and relay box — Assignment diagram

A 13

14

11

12

9

10

8

6

7

4

5

3

2

B 1

A

20

FA1

21

19

18

17

15

16

FB1

K3

K2

K1

C K11

K01

D B

K02

C HM42-E01

A = Instrument panel

B = Service ladder

C = Starter box

Fuses Position

Amps

F1

10

F2

20

F3

10

F4 F5 F6

15 15 15

F7

10

F8

15

F9 F 10

10 5

F11

5

F12 F13 F14 F 15 F 16

5 10 10 15 15

HML 42

assigned to

Interior light, radio, immobilizer Socket, additional heating (option) Hazard lamp, headlamp flasher, rotating beacon Working floodlight, front Working floodlight, rear Fuel-filling pump, electrical seat heating (option) Horn, switch lighting, immobilizer Heater fan, air conditioning Wish-wash system, radio Hydr. oil level, overload warning, rock breaker, additional control circuit Travel, parking brake, brake light switch Working hydraulics Brake light Hazard lamp High beam Low beam

D = Relay K03 Fuses

Position

Amps

assigned to

F17 F18 F19 F20

10 10 10 10

F21

10

Side marker lamp, left Side marker lamp, right Additional module All-wheel steering (option) Option

FA1 FB1 FC1

50 40 175

Main fuse Pre-heating Heating flange (K03)

Colors of fuses 5A 15 A

brown blue

10 A 20 A

red yellow

Relays Position K 01 K 02 K 03 K1 K2 K3 K11

Function Pre-heating relay Start-up relay Power relay Working floodlight, front Working floodlight, rear not assigned (air condit. — option) Directional indicator

111

9 Appendix

1.4

1.3

1.6

1.7

1

rt/ge

BE1 X3:1

XM1

11

E21 15

sw/bl 2,5ø

rt 2,5ø

85 87

2

XB1

1 rt

2

X1

1 3 16 XMOT XMOT XMOT 16 3 1

XMOT sw 4,0ø

G+

+

B+

30 M

rt 2,5ø

17

G1

1

1

Y2

50a 50b

+ Y1

2

M7

M

2

-

31 M1 XMOT

2

4

2 br 2,5ø

4 2

XMOT

1

2

br

1

S0

br br

FC1

br 2,5ø

-

br

G2

2 br 2,5ø

11 XM2

1

1

86 30

B-

1

5

K02

D+

rt 2,5ø

rt/ge

rt

5

rt

100 /3.5

17

XK1 13 13

4

XM1

2

12 XM2

8

X2

1

F6 2

/1.15 133

1

sw/bl 2,5ø

BE1 X2:17

sw 4,0ø

X5

5

rt 0,5ø

FB1 1 sw 6,0ø

1

F2

F1 2

X2 3

2

sw 10ø

2

7 X2

rt

sw 2,5ø

1

rt

sw/bl 2,5ø

sw 4,0ø

sw 10ø

120 /3.4

2 FA1 1

15 54 19 17 50A

rt 2,5ø

30

sw 4,0ø

1.8

sw 2,5ø

sw 2,5ø rt 2,5ø

20 /3.1

S1

1.5

light, Fuel-filling pump

ge 2,5ø

1.2

Interior socket

br 2,5ø

1.1

Shut-off

ge 2,5ø

Start-up system

ge 2,5ø

Power supply

/3.4 30 31

Path

Code

1.1 1.2 1.2 1.2 1.2 1.2

X5 G1 FA 1 FB 1 G2 SO

1.3 1.3 1.3 1.3

FC1 S1 M1 K02

112

HM42-E02

br 10ø

Device Power supply Service ladder socket Generator Fuse Fuse Battery Battery disconnect switch Start-up system Fuse (heating flange) Pre-heat starter switch Starter Start-up relay

Path

Code

1.4 1.5

Y2 Y1

1.6 1.6 1.7 1.7

F1 E21 F2 X1

Device Shut-off Extra-large quantity for start-up Shut-off Interior light, socket Fuse Interior light Fuse Instrument panel socket

1.8 1.8

F6 M7

Fuel-filling pump Fuse Fuel-filling pump

HML 42

Appendix 9

Heater fan, conditioning 1.11

1.12

ge

2 gn

ge

gn/vi

ge

B1

87 87a 243 M

M6

+ M

M5

1

XK1

-

1

1

S35

+SP-

1

2

XK1

11

XK1

11

12 12

1 br 2,5ø

1

X0 br

M4

br

br

br

M

gn

br

2

A +SP-

br 2,5ø

ge/gn

17

31 XRADIO

br/ws

XM2

8

bl/sw

gn/sw gn/gr gn/bl

gn

2 2

ge/gn

br/gn

B3 4

LL+ R+ R15 30

XRADIO

1

br

B2

XRADIO 7

3

17 /2.5 150

31

3

XK1 30

85

2

XK1

13

K3

1

9

4 XK1 4

8 XB1 8

13 XB2

10

5 XK1 5

br 2,5ø

9

6 7

br 2,5ø

9

86

S90

ge

3

S34 XM2

br/gn

14

10

/1.10 104

5

gn/vi

14

10

bl

ge/sw

br/gn

bl/rt

1

3

12 12

6 XK1 6

2

bl

XB2

2

S11

S3

bl/sw

ge/sw

31 1

7

A4

C1 A2 A3 A1

1

9

B10

XM1

B1

ge

2

gn/sw

S18

ge

X2

ge

ge

ge

XM2 13 6 13

F9 2

2

ge 104 /1.13 /2.7 /2.1 10 5

1.16

133 /1.6 F1

1

F8

2

1.15

1.14

1

1

F7

1.13

sw

1.10

Radio

sw

1.9

air Wish-wash system

br

Horn

YMK HM42-E03 03-06-27

Path

Code

1.9 1.9 1.9

F7 B10 S90

1.10 1.10

S18 S34

1.10 1.10

K3 S35

1.10

YMK

1.11 1.12 1.12

F8 S3 M6

HML 42

Device Horn Fuse Horn Coordinate lever horn button Heater fan, air conditioning Air conditioning switch Air conditioning temperature switch Relay Air conditioning pressure switch Compressor magnetic coupling Fuse Heater fan switch Heater fan

Path

Code

1.13 1.13 1.13 1.13

M5 S11 F9 M4

1.15

B1

Device Wish-wash system Washer pump Wish-wash switch Fuse Wiper motor Radio Radio

1.16 1.16

B2 B3

Loudspeaker Loudspeaker

1.16

A

Central mass, cab

113

9 Appendix

Lighting system

sw

ge rt

56b

E1

1 2

43

sw/rt

XBL

13 XBL

4

E2

1

31

14

E4

43

52

1

1 X10 2

1

1

2

2

br

br

br

br

br

br

br

E13 br

gr/rt 0,75ø

10 XBL 10

4

14

XBL 13

6

ws ws/ge sw/gn0,75ø

XBL

8

gr/rt 0,75ø

6

gr/rt 0,75ø

8 XBL

5 2 56a 56b 1 2

E3

31

2

/2.3 R1

2 XBL 2

gr/rt 0,75ø

XBL 11 11

gr /2.11 S10

E14 br

56a

E5

sw/rt

1

XBL 9 9

sw 0,75øsw/ws 0,75ø

BE1 X3:34

1 XBL 1 3 XBL 3

ws ws/ge sw/ws 0,75ø

vi/ws

14

BE1 X3:28

X1:2

sw/rt

7 XBL 7

5 XBL 5

gr/sw 0,75ø

sw/ws

/2.3 L1

gr/sw0,75ø

sw/ws/gn 0,5ø

14

2

/3.7 XB2 P1 4 :58 /2.4 /2.3 L R

K11 C L R 31

XK1

F18

gr/rt

4

1

F17 2

gr/rt 0,75ø

3 XB2 3

1

BE2 110 /4.13 sw 0,75ø

5 XB2 ws/ge XB2 1 1 6 6 2 F15 F16 2

gr/rt

5

X1:3

sw 0,75ø sw/gn0,75ø

49a

2

XB2 7 7

rt

gr/sw

49

2 XB2 2 sw/ws/gn

6 30

ws/ge

sw/ws/gn

/2.7 R1

F13

S30

1

gr/sw

ws

br

/2.7 R

3

S8

4 br 2 3 5 7

sw/gn

vi/ws

31

8 1

ws 0,5ø ws ws ws/ge ws/ge

1

1 5 10

1

6

9 2

8 XB2 8 br/gn

sw sw/gn sw/gn sw/ws/gn

9

6

10 8

L0 R

S4

1

2.10

2.9

1

XB2 150 /1.10

sw/rt

ge rt

2 8 3

S16 10 5

104 /1.10

gr/rt 0,75ø

L1 2 /2.6 L /2.6

2.8

sw

F14

sw/ws sw/ws

104 /1.10

2.7

sw

1

2

2.6

2.5

gr/rt

2.4

1

rt

F3

2.3

sw/ws

2.2

2.1

II I 0

Rotating beacon

HM42-E04 03-06-27

Path

Code

2.1 2.2 2.2

S4 E5 F3

2.3 2.3 2.3 2.6 2.5 2.6 2.5

F14 S16 K11 S8 F15 F16 E1

114

Device Rotating beacon Rotating beacon switch Rotating beacon Fuse Lighting system Fuse Hazard warning switch Directional indicator Steering column switch Fuse Fuse Headlamp, left

Path

Code

2.6 2.8 2.7 2.7 2.8 2.8 2.9 2.9 2.9 2.10 2.10

E3 S30 E2 F17 F18 E4 F13 BE2 X10 E13 E14

Device Rear light, left Light switch Headlamp, right Fuse Fuse Rear light, right Fuse Additional module Side marker lamp socket License-plate illumination License-plate illumination

HML 42

Appendix 9

Working floodlights

Rear fog lamp

2.13

2.12

2

gr 10

5

10

5

9

1

S20 9

31 rt 2,5ø

gr/rt 0,5ø

gr

16 16 XB1

gr/sw 0,5ø

1

2

9

gr 3 S10

104 /1.10

104 /1.10

1

S51

31

31

rt 2,5ø

6

2

gr/rt

gr 10 8

F5

II I 0

/2.10 F17

2.16

1

1

F4 104 /1.10

2.15

2.14

gr/ws

2.11

2.10

17

18 XB1

18 XB1 gr/ws

17

30

86

86

K1

1

gr/rt

E7

2

2

gr/rt

gr/ws

gr/sw

XM2 10 10

1

E8

1

E12

1

2

2

2 br

E6

XK1 9 9

br

1

br

E10

XBL 12 12

gr/sw

gr/sw

7

br

br

2

7

XK1

gr/rt

1

br

gr/rt

E9

gr/sw

gr/rt

gr/rt

8 XK1 10 8 10

XK1

87a

85 87

br

87a

85 87

br

30

K2

HM42-E05

Path

Code

2.7 2.10

F17 S10

2.11

K1

Device Working floodlights Fuse Switch for working floodlights, front & rear Floodlight relay, front

2.11 2.11 2.11 2.12 2.12

E9 E10 F4 F5 K2

Working floodlight, front Working floodlight, front Fuse Fuse Floodlight relay, rear

HML 42

Path

Code

2.12

E6

2.13

E7

2.14

S20

2.14

E8

2.16 2.16

S51 E12

Device Working floodlight, rear Working floodlight, rear Switch for boom-mounted working floodlight Boom-mounted working floodlight Rear fog lamp Rear fog lamp switch Rear fog lamp

115

9 Appendix

Control module

3.1

Pre-heat system

3.2

3.3

Instruments, warning devices

3.5

3.4

3.7

3.6

100 /1.1

3.8

3.9

3.11

3.10

/2.7

1

/3.11 br

G

ws X7 1

X7 2

X7 3

X7 4

X7 5

BE1 X3:18

BE1 X3:3

BE1 X3:4

BE1 X3:5

BE1 X3:19

BE1 X3:17

3.4 3.4 3.4

K01 K03 R1

XM2

4

XM2 5 5

4

4

1

Device Control module Control module Fuse Additional module Pre-heating Pre-heat relay Power relay Glow plugs

gn/ws/vi

ge

sw/vi

rt/ws rt/ws

1

S4

2

1

S7 2

2

1

B2

1

Q

B1

2

1

1

B20 2

3

br

S5

br

31

XM2

6

6 XMOT

br 4,0ø

br

BE1 F19 BE2

4

6 XMOT

br

31

br 0,5ø

50a

br 4,0ø

br

br

br

11 11

K03

X 2 K03 1 R1 2 30 2 /1.3

3.1 3.3 3.3

XM1

2

gn/ge

gn 1 XK03 1

M

Code

2

6 XVor2

30

Path

XM2

6

gn

sw4,0ø

1

6

XM1

bl/ws

sw 6,0ø

X2:12 X2:15 X2:9 X2:8 X2:7 X2:10 X2:11

ws 0,5ø ws 0,5ø ws 0,5ø

3

XM1

3

sw 4,0ø

X4:2 X4:3 X4:5 X4:7 X4:8 X4:9

BE1 X3:6 ge gn/ws/vi 0,5ø

87

sw/vi 0,5ø

85

K01 BE2

rt/ws 0,5ø

30

gn/ge 0,5ø

86

bl/ws 0,5ø

XVor1 gn 0,5ø

sw 6,0ø

1

BE1 X3:20

br

vi/ws

120 /1.2

ws

sw

bl 0,5ø BE1 X2:9

BE1

116

Q

X1:5

X1:4

X1:3

BE1 X1:1 X1:2

P1

15 58 15 58 p 31 31 t° 31 P3 31 br 31 br P2 G G 31

15

58

XM1

sw

br

2

ge ge

rt

sw sw sw

2

br gr/bl

sw

br

gr/bl

ws

F19

gr/bl

2

bl

20/1.4

HM42-E06 03-06-27

Path

Code

3.5 3.6 3.7 3.7 3.8 3.8 3.9 3.9 3.10 2.12

S5 S4 P1 S7 P2 B2 P3 B1 B20 F10

Device Instruments, warning devices Oil pressure switch Air filter maintenance Fuel gauge Hydraulic oil filter Temperature indicator Coolant temperature Overload warning device Tank sensor Hydraulic oil level Fuse

HML 42

Appendix 9

Overload warning device

Hydraulic functions

3.11

3.12

3.14

3.13

3.15

3.16

1

F10

XB1 1 1

S40

2

ge

gn/rt 0,5ø

BE1 X3:9

1

S44

2

3 XB1

rt/sw 0,5ø

gn/rt 0,5ø

2 2

1

S41

sw/rt

7 1

31 BE1 X3:36

ge

1

S9 9

ge

200 /4.1

/4.2

1

BE1 X3:21

3

2 bl/br

5

1

8 XB1

BE1 X3:22

8

XM1

bl/br 0,5ø

10

XM2

rt/sw

ge

104 /1.10

ge 0,75ø 136

ge 0,75ø

ge

2

rt/sw 0,5ø

/3.10 B20

BE1 X3:23

XM2 7 7

gn/rt

ge

8 XM2 8

2

3

B7

br

1

HM42-E07

Path

Code

Device

Path

Code

Overload warning device

Device Hydraulic functions

3.11

B7

Overload warning signal sensor

3.14

S40

Brake light pressure switch

3.12

F10

Fuse

3.14

S41

Axle lock pressure switch

3.12

S9

Overload warning switch

3.15

S44

Accumulator pressure

HML 42

117

9 Appendix

Hydraulic functions

4.1

4.2

1 2 104 /1.10

104 /1.10

ge

ge

140 /5.2

ge

ge 5 S15

S42

31

BE1 X3:12

10

31

BE1 X3:27

ge 10

5 S37

9

sw/bl/gn 0,5ø

31

6 5

9 8 27 1

1 br/ge 0,5ø

9

10

/4.6 S6

5 S8

9

1 rt/sw 0,5ø

10

4.5

F11

136 /3.16

104 /1.10 ge

4.4

1 rt/sw 0,5ø

200 /3.13

4.3

31

BE1 X3:26

BE1 X3:31

BE1 X2:7

sw/bl/gn

rt/sw rt/sw

7

1

1

Y17

Y11 2

2

1

br

7 XB1

3

bl/rt

2 br

3

br

br

2 1 XDDF2 2 PE 7 DDF PE 7 7 XDDF8 8 7 8 1

Y10 2

XU1 1 1

br

1

Y4

XM2 sw/bl/gn

br/ge

XB1 14 14

bl/rt

BE1 X2:8

bl/rt

BE1 X2:2 br/ge

BE1 X2:10

HM42-E08

Path

Code

4.1

S15

4.1

Y4

4.2

F11

4.2

S42

4.2

Y10

118

Device Hydraulic functions Rock breaker switch Rock breaker valve Fuse Parking brake switch Parking brake valve

Path

Code

4.4

S37

4.4

Y11

4.5

S8

4.5

Y17

Device Axle lock switch Axle lock valve Front dozer blade switch Front dozer blade valve

DDF

Rotary joint

HML 42

Appendix 9

Working hydraulics cut-off

4.9

4.10

4.11

4.12

4.13

4.15

4.14

1

F12 104 /1.10

104 /1.10

gn/ws

2

BE1 X3:30

BE1 X3:14

BE1 X3:13

BE1 X3:15

BE1 X3:32

ge

BE1 X3:24

BE1 X3:10

9

1

S36

12 12 XB1

BE1 X3:29

BE1 X3:11

9

BE1 X2:1

B

1

Y15

B9

13

1 C A

2

Y3 2

br

2

2

13

bl/ge

XB1

sw

Y14

2

9

ge

sw 1,0ø

gr gr

sw/ws

1

1

Y16

110 /2.8

20 XM2 20

br

br

XM2 19 19

1

Y5 2

br

2

XM2 21 21 rt 1,0ø

1

Y6

br

Y13

2 br

5

10 XM1 10

BE1 X2:12

br

1

H10

15

rt 1,0ø

bl/rt

gn

15 XM2

BE1 X2:11

sw/ws

XM2 18 18

BE1 X2:6

br

bl/rt

XM2 9 9

BE1 X2:4 rt

gn

BE1 X2:14

1

10

31

XM1

BE1 X2:5

2

bl/ge

S45 1

2

1

S29

bl/ge/gn 0,5ø

6

BE1 X3:16

31

3

A1 C1

S5a

rt/ge 0,5ø III II I 0 A3 A2 B1 A5

bl/ge/gn

6

1

1

sw 0,5ø

XM3

9

5

3

gr 0,5ø

5 31

5 S5

gn/ws0,5ø

XM3

10

ge

gn/rt 0,5ø

1

gn/ge 0,5ø

gn/ws 0,5ø

31

9

rt/bl 0,5ø

1

gn/ge

9

5 S39

rt/ge 0,5ø

10

5 S6

ge

ge

ge

ge

11 11 ge XB1

104 /1.10

S43 /4.5 S8 10

2

bl/ge 0,5ø

104 /1.10

4.16

ge

4.8

bl/ge

4.7

br

4.6

bl/ge 0,5ø

Travel drive

HM42-E09

Path

Code

4.6 4.6 4.7

S6 H10 S45

4.8 4.8 4.9 4.9 4.10 4.11

S39 Y13 S5 Y6 Y5 S5a

HML 42

Device Travel drive Travel motion alarm switch Travel motion alarm horn Travel motion alarm pressure switch Accelerator pedal switch Accelerator pedal valve "FAST/SLOW" switch "FAST" valve "FAST" valve All-wheel steering switch

Path

Code

4.12 4.12 4.13 4.11

Y14 S43 Y15 Y16

Device Valve for travel, forward "Forward/Reverse" switch Valve for travel, reverse Valve for flushing (travel motor)

4.13 4.15 4.15 4.16 4.16

B9 F12 S36 S29 Y3

Working hydraulics cut-off Service ladder proximity switch Fuse Working hydraulics cut-off Armrest switch Working hydraulics valve

119

9 Appendix

Coordinate lever, right

5.1

5.2

Coordinate lever, left

5.3

5.4

5.5

Armrest, left

5.7

5.6

5.8

5.9

5.10

5.11

ge

140 /4.2

5

5

ge

1

ge

3

XB1

2 bl/sw

ge

ge 5 S50

10

S38

1 9 rt/bl

9 1 rt/bl

2

1

10 5

rt/sw

bl/rt

2

1

S22

S21

4

6

9

10

11

4 XB1

6 XB1

9 XB2

10 XB2

11 XB2

rt/bl 0,5ø

rt/bl 0,5ø

BE1 X1:11

BE1 X1:9

BE1 X1:10

BE1 X1:12

BE1 X1:13

BE1 X3:33

BE1 X2:13

BE1 X2:14

BE1 X2:16

BE1 X2:18

BE1 X2:19

BE1 X2:20

BE1 X2:21

BE1 X2:13

1

4

1

1

Y12

Y25 2

br

2

4

XM3

1

2

br

Y22 2

1

rt/bl

XM3

rt/bl

bl/rt

rt/sw 1

Y24 2

2

XM1 16 16

br

Y23

rt/bl

rt/sw

bl/sw

br

br

bl/sw

2

2

3

1

1

Y21

3

XM3

br

2

br

1

Y20

br

1

Y19

XM3 2 2

XM1

br

13

or 1,0ø

13

12

or 1,0ø

12 XM1

1

Y18

or

rt/sw

bl/sw

11

rt/sw

bl/sw 11

XM1

rt/bl

bl/rt 0,5ø

BE1 X1:8

bl/rt

rt/sw 0,5ø

BE1 X1:7

or 0,5ø

bl/sw 0,5ø

31

rt/sw 0,5ø

31

rt/bl

ge

bl/sw 0,5ø

2

1

S24

rt/bl

ge

3

S25

HM42-E10

Path

Code

5.2

S25

5.1

Y18

5.2

Y19

5.4 5.4 5.5

S24 Y20 Y21

120

Device Coordinate lever, right Push-button for additional control circuit 1 Valve for additional control circuit 1 Valve for additional control circuit 1 Articulation changeover switch Valve for articulation Valve for articulation

Path

Code

5.6

S21

5.6

Y23

5.7

Y24

5.8 5.8

S22 Y22

5.10 5.10 5.11 5.11

S50 Y25 S38 Y12

Device Coordinate lever, left Push-button for additional control circuit 2 Valve for additional control circuit 2 Valve for additional control circuit 2 Swing pressure boost Swing pressure valve Armrest, left Switch for option Valve for option Steering changeover switch Steering changeover valve

HML 42

Appendix 9

Steering

Option

6.1

6.2

6.3

6.4

6.5

6.6

6.7

6.8

1

F20

6.9

1

F21

2

6.10

2

X1:6

BE2

6 XDDF6

ge 0,5ø

gn/ws

gn/rt 1

1

B

Y8

B11 br

br

XDDF8 2

C A

2 br

2

2

XDDF8

1

B

B12

3

ge

XDDF8

3

BE2 X2:17

C A

4 XDDF8 4

BE1 X2:15 gn

1

XDDF8

6

Y7

rt/gn/vi

2 3 1 XDDF62 XDDF6 3 XDDF6 1 3 2 DDF DDF 1DDF 2 3

vi

6

XDDF8

15

4

rt/gn/vi

6 6

DDF

5

XB2

4

XU1

ge 0,5ø

5

14

1

bl/ge/gn

5 5

DDF

XB2

rt/gn/vi

6

5 XDDF6

ge

5

XU1 2 XU1 3 2 3 bl/ge/gn

gn/ws XU1 6 6 gn/ws

XU1 5 5 gn/rt

gn/rt

X1:5

BE1 X3:35

br

X1:4

bl/ge/gn 0,5ø

BE1 X3:25

Option XM1

14

XM1

BE1 X2:3

rt

X1:1

ge

ge

ge

ge

15

XM2

16

4 4

DDF

4 4

br

XDDF6

HM42-E11 03-06-27

Path

Code

Path

Code

Device

F20

Device Steering Fuse

6.2

6.4

B11

6.2

BE2

Additional module

6.5

B12

6.2 6.3

Y7 Y8

Valve round/crab (steering) Valve round/crab (steering)

6.9

F21 DDF

Front axle proximity switch, steering angle Rear axle proximity switch, steering angle Fuse (option) Rotary joint

HML 42

121

9 Appendix Control module BE1

Control module

HM32-E15

122

X1

Power supply

1

Power supply Terminal 30

2

Power supply Terminal 30

3

Power supply Terminal 30

4

Central mass

5

Power supply Terminal 15

6

--

7

--

8

--

9

--

X2

Signal outputs

1

Working hydraulics

2

Rock breaker

3

FAST – SLOW

4

FAST – SLOW

5

Travel motion alarm

6

Flushing

7

Axle lock

8

Parking brake

9

Pre-heating

10

Front dozer blade

11

Travel, forward

12

Travel, reverse

13

Steering changeover

14

Accelerator pedal

15

Option

16

--

17

Start-up magnetic switch terminal 50A

18

--

X3

Signal inputs

1

Start-up ignition lock terminal 50A

2

--

3

Oil pressure switch

4

Air filter clogging

5

Hydraulic oil filter clogging

6

Hydraulic oil float switch

7

--

8

--

9

Overload warning switch

10

Service ladder proximity switch

11

Armrest switch

HML 42

Appendix 9 Additional module BE2 12

Rock breaker switch

X1

Plug

13

--

1

--

14

FAST – SLOW switch

2

Brake lights

15

--

3

Power supply Terminal 15

16

Travel motion alarm switch

4

--

17

Tank sensor

5

--

18

Central mass

19

Coolant temperature

20

Charge control

21

Brake light signal

22

Axle lock signal

23

Accumulator pressure signal

24

Switch for travel, reverse

25

6

--

7

Additional control circuit 1 push-button

8

Additional control circuit 1 push-button

9

Additional control circuit 2 push-button

10

Additional control circuit 2 push-button

11

Articulation changeover push-button

12

Swing pressure boost push-button

13

Bucket changeover switch (option)

Front axle steering angle signal

14

--

26

Axle lock switch

15

--

27

Parking brake switch

16

--

28

Direction indicator lamp signal

17

--

29

Working hydraulics switch

18

--

30

Accelerator pedal switch

X2

Plug

31

Front dozer blade switch

1

--

32

Switch for travel, forward

2

--

33

Steering changeover switch

3

--

34

High beam signal

4

--

35

Rear axle steering angle signal

5

--

6

--

36

Overload warning signal

7

Connection control module X4:9

37

--

8

Connection control module X4:8

X4

Interface

9

Connection control module X4:7

1

--

10

Central mass

2

--

11

Central mass

3

--

12

Power supply Terminal 15

4

--

13

Valve additional control circuit 1

5

--

14

Valve additional control circuit 1

6

--

15

Power supply Terminal 15

7

Connection additional module X2:9

16

Valve for articulation

8

Connection additional module X2:8

17

Valve for articulation

9

Connection additional module X2:7

18

Valve for additional control circuit 2

19

Valve for additional control circuit 2

20

Swing pressure boost

21

Bucket changeover (option)

HML 42

123

9 Appendix 9.2 Hydraulic system S T P

A

P 0,6

R 0,8

140 bar L T

T S2 S

P

100/250

100/250

5

2

S1

LS

4 CF

A

6

R

B

P

EF

7

P HÜV 230 bar

31

A

22

A

33 32

10

B

A

DDF

B

BB

A

24

S 110 bar P T

HM42-H01 02-02-06

1

30

150 bar

T

T

9 1bar

11

X

13 14 20

23

3/2 MV

12

27 26 25

-1

4/3 MV

16

21

HÜV LS 300 280 bar bar P T

P=67 kW n=2000 min

28

Deutz BF4M2012

29

B B B B B 300 300 300 150 300

300 300 300 300 300 A A A A A

T

15

17 18 K T

19 34

5bar

Fig. H01 "TPA" hydraulic installation

124

HML 42

Appendix 9

HML 42

1

Swing drive

2

Valve for swing brake release

3

--

4

Priority valve

5

Steering unit

6

Steering cylinder

7

Cut-off valve

8

--

9

Accumulator valve (braking system)

10

Travel motor

11

Variable-capacity pump — excavation

12

Travel pump

13

Suction filter

14

Gear pump — steering, excavating, braking

15

Hydraulic oil tank

16

Diesel engine

17

Hydraulic oil cooler

18

Hydraulic oil temperature control

19

Return filter

20

Operation — Rock breaker (3/2 directional control valve)

21

Operation — Additional control circuit (4/3 directional control valve)

22

Emergency steering

23

Control valve 1

24

Control valve 2

25

Dipperstick

26

Additional control circuit / Rock breaker

27

Bucket

28

Intermediate boom

29

Boom

30

Stabilizer

31

Stabilizer

32

Articulation

33

Slewing

34

Return collector

125

9 Appendix

9.3 Immobilizer The AUTO-SCAN Immobilizer, type Mini AR2000, is a self-activating immobilizer. The Immobilizer provides effective protection against theft of the machine. The AUTO-SCAN Immobilizer Mini AR2000 is recognized as antitheft protection by almost all insurance companies. The Immobilizer may only be installed by the manufacturer of the machine or a qualified specialist workshop. The manufacturer or the specialist workshop has to fill out the certificate confirming the correct installation for presentation to the insurance company.

9.3.2 Deactivating the system Your machine cannot be started as long as the immobilizer is activated. If somebody tries to start the machine with the immobilizer activated, an alarm sounds. For deactivation, proceed as follows: • With the electronic code key, touch the operating unit (Position 1). • LED is OFF. • Switch on the ignition on the machine within 30 seconds and start. If the machine is not started within 30 seconds, the immobilizer again activates itself automatically.

2

9.3.1 Activating the system

1

The immobilizer is self-activating. The immobilizer activates itself 30 minutes after the ignition is switched off. Within this period, the engine can be started again “normally”, thus taking consideration of engine stops owing to traffic, etc. The LED (Position 2) lights up as soon as the system is activated. HM32-0101-W

Fig. 101 Immobilizer

1 = operating unit 2 = LED (luminous diode)

126

HML 42

Appendix 9 9.3.3 Operating malfunctions In the event of malfunctions or damage to the immobilizer, the system is never to be removed without the instructions provided by the specialist workshop (otherwise, system becomes useless).

9.3.4 Damaged or lost code keys With the delivery and handing over of the machine you receive 2 code keys and one key code card. If a code key is lost, a new key can be ordered from your specialist workshop by presenting the key code card.

If voltage is lost (for example, if the battery is disconnected), the immobilizer returns to the status activated before the voltage loss once the supply voltage is reapplied. Possible sources of malfunction • No deactivation of immobilizer Þ use second key • LED OFF and machine cannot be started Þ replace fuse If these measure do not help, contact your specialist workshop.

HML 42

127

9 Appendix

128

HML 42

DELIVERY AND HANDING-OVER INST RUCT IONS The following checklist is to be adhered to when handing over the machine to the customer: 1. Operating instructions The operating instructions should be read side by side, and be explained in detail through practical training on the machine. The following items are of special importance: • Regulations for the prevention of accidents published by the employer’s liability insurance associations in the user’s country • Technical data • Operator controls, indicating and warning elements • Checks before putting the machine into operation • Specifications for diesel engine start-up • Turning on and off the diesel engine • Explanation of hydrostatic travel drive • Travel, speed ranges and notes for driving on roads • Towing and transport of the machine • Operation of all functions • Oscillating axle lock • Explanation of maintenance and inspection intervals in compliance with Maintenance and Inspection Plan by demonstrating maintenance points on machine • Lubrication intervals and points of lubrication in compliance with overview of lubricating points and demonstration of these points on the machine • Handing over of the diesel engine operating instructions 2. Spare parts list • Structure of spare parts list, of figures and the respective descriptions • Instructions for ordering spare parts: always state the type of machine, the vehicle identification number (Fz-Id.Nr.), parts designation, complete spare part number, piece number, delivery address, etc. 3. Warranty • Explanation of warranty covered by manufacturer • Explanation of inspection cards and note on maintenance and inspection plan • Explanation of how to fill out and return the warranty-handing-over card correctly

Mobile Excavator

HML 42 Maintenance and Inspection Plan The careful performance of all prescribed inspections is the best prerequisite for the machine’s continuous readiness for operation. All maintenance work mentioned should therefore be performed in the prescribed sequence with the machine at operating temperature. The inspections are obligatory. If omitted, this may affect the warranty covered by us. The machine must be thoroughly cleaned before inspection takes place.

Inspection plan To be carried out by trained specialist dealer personnel

O = Checking, maintenance X = Replacement Perform work with machine at operating temperature 1 Check whether machine-specific instruction book is in the machine 2 Change engine oil 3 Change engine oil filter 4 Drain fuel tank 5 Replace fuel filter 6 Replace fuel pre-filter 7 Check air intake 8 Change air filter main cartridge 9 Change air filter safety cartridge 10 Clean cooling fins of combined hydraulic oil/ water cooler.

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

In case of high exposure to dust, shorten the cleaning intervals. Check antifreeze level in coolant Change coolant Check V-belt tension Check engine mounts and pump attachments Check engine speed adjustment, top-end and low idle speed Check valve lash of engine and adjust if necessary Check acid level and battery connections Replace cab ventilation dust filter Check condition of tires, tire pressure and tightness of wheel nuts Check secure fast.of axles and propeller shaft Check bearing bushings and bolts of work equipment and replace if necessary Check that door catches are in perfect condition and replace if necessary Check electrical indicating and warning elements, and lighting system Check smooth running of operator controls and adjust if necessary Check function of hydraulic axle lock and vent plunger cylinders Check function of steering Check condition and function of support equipment

Operating hours after 100

every 500

O

O

O

X X O

every 1000

every 2000

min. 2x yearly

min. 1x yearly

X X

O O to service indicator as required 1) O O

X X X O

O

O

O O O

O O

O

O

O

O

O

O

O

O

O O

O O

30 31

When tightening hose and line connections, the screw-in couplings must be locked to prevent rotation Check or change hydraulic oil Replace insert of hydraulic oil return filter

X

Operating hours after 100

every 500

O

O

O

O

3.

within warranty

every 1000

every 2000

O X

O X 2) in compliance with service indicator X X O

min. 2x yearly

min. 1x yearly

.

X Replace insert of hydraulic oil suction filter Replace breather Check function of brakes and play of brake O discs X 35 Differential of rear axle - oil check or oil change X 36 Differential of front axle - oil check or oil change X 37 Transfer gear - oil check or oil change X 38 Wheel hubs of front and rear axles - oil check or oil change O 39 Check that ring gear attachment screws are O securely fastened O 40 Check that swing-drive attachment (hydraulic O motor and transmission) is securely fastened O 41 Grease machine in compliance with overview O of lubricating points O 42 Check function, condition and completeness O of safety equipment O 43 Hydraulic function check with pressure O function test O O 44 Test run and test work O 3) 45 Initial inspection cards and return to O manufacturer 1. at least every 2 years 2. Extension of oil change interval in compliance with oil sample further information see Chapter 7.3 32 33 34

as required 1) O O O O O O

O X O

Perform work with machine at operating temperature 28 Check line rupture valves of support equipment 29 Check tightness of all pipes, hoses, control valve, hydraulic pumps, cylinders, etc.

O X X

O

O = Checking, maintenance X = Replacement

X

X X

X

X

X

X

X X

X X

analysis and lab report. For