Service Manual-DHJ40169-6040(RH170169) EM028957-0_en-us

EM028957-0 (en-us)
Service Manual
6040
Hydraulic Shovel No. DHJ40169
Caterpillar: Confidential Green

Published by: Caterpillar Global Mining HMS GmbH
Dept. Technical Publications
D-44149 Dortmund, Karl-Funke-Straße 36
Email documentation.HEX@cat.com
Tel. 49 (0) 231 922-4340
Fax 49 (0) 231 922-5005
https://mining.cat.com www.bucyrus-hex.com
© Copyright Caterpillar Global Mining HMS GmbH 2018. The reproduction, distribution and utilization of this
manual / file as well as the communication of its content to others without express authorization is prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.
Printed in Germany

CONTENTS
Volume 1
1. General
2. Technical data
3. Tools, Assembly
4. Undercarriage
5. Superstructure
6. Drive unit
7. Gearboxes
8. Hydraulic system
9. Electric system
10. Attachment
11. Central lubrication system
12. Options
13. free
14. free
Volume 2
3720200en – (01) Page 1

CONTENTS
Volume 2
15. Service Manual for fundamental principles of electricity
16. Service Manual for handling circuit diagrams
17. Service Manual for general information, conversion cal-

culations and tightening torques
18. Service Manual for sealing, protective, testing and clean-

ing agents
19. Service Manual for fittings, tube assemblies and hose

assemblies
20. Repair welding manual
21. Service Manual for oil samples and oil analysis
Page 2 3720200en – (01)

08.2018
1. General
6040

CONTENTS
1. GENERAL
1.1 Introduction ...................................................................................... 1.1 - 1
1.1.1 Service Manual ................................................................. 1.1 - 1
1.1.2 How to use the Service Manual ......................................... 1.1 - 1
1.1.3 Servicing and repair ........................................................... 1.1 - 2
1.1.4 Important hints ................................................................... 1.1 - 2
1.2 Safety instructions ........................................................................... 1.2 - 1
1.2.1 Risks of disregarding safety instructions ........................... 1.2 - 1
1.2.2 Safety regulations .............................................................. 1.2 - 1
1.2.3 Modification of the machine ............................................... 1.2 - 4
1.2.4 Re-commissioning ............................................................. 1.2 - 4
1.3 General .............................................................................................. 1.3 - 1
3720201en – (02) Page 1 - 1

CONTENTS
Page 1 - 2 3720201en – (02)

1 GENERAL
1.1 Introduction Most tables referring to the drawings contain the

following information:
This Caterpillar hydraulic excavator is a part of
the extensive range of Caterpillar mining 1. Item number
equipment.
2. Quantity
Decades of experience in the manufacture of
3. Designation
earthmoving machines, modern design and pro-
duction techniques, stringent testing procedures 4. Weight
and the highest demands on quality guarantee the
reliability and functionality of your
Caterpillar hydraulic excavator. The information on the bolts contains:
 Thread size M 20
1.1.1 Service Manual  Steel grade 10.9
 Size of wrench SW 30
This Service Manual is written with the servicing  Tightening torque MA = 630 Nm
mechanic in mind and contains important informa-  Liquid adhesive, if required Loctite
tion required to carry out repair and servicing pro-
cedures. Some drawings contain symbols and reference
numbers under them.
Read the Service Manual, but also the Operation
and Maintenance Manual for the Caterpillar hy- The symbols mean:
draulic excavator before commencing any servi-
cing or repair work. The Service Manual, as well Bolt joint with a certain
as the Operation and Maintenance Manual and tightening torque
Spare Parts Catalog should be used as a source
of reference and assistance - even when the user
is well acquainted with the range of Caterpillar ex- Component with a certain
cavators. play setting
Using the Service Manual allows the experienced

mechanic to carry out repair work correctly.
Bolt joint secured with ad-
hesive (P/No. 8432623)
Splines coated with mineral

1.1.2 How to Use the Service Manual
lubricating paste
(P/No.0244905)
The Service Manual contains information on the
main and subordinate construction elements of the
originally delivered excavator. It does not describe
The part "Sealing, Protective, Testing and Cleaning
any elements or special features introduced later.
Agents" contains comprehensive information on
adhesives and lubricating pastes.
The main table of contents allows you to find the
required information quickly.
To make it easier to understand the content, some

illustrations are simplified and therefore can slightly 1.1.3 Servicing and repair
differ from the actual appearance of the machine.
If you need some servicing and repair work, carry it
The item references in sectional and 3-D drawings out as soon as possible. It minimizes overall servic-
are mostly the same as those in the corresponding ing and repair costs and increases the functionality
drawings of the Spare Parts Catalog. It makes of the Caterpillar excavator.
cross referencing easier.
3849221en - (00) Page 1.1 - 1

1 GENERAL
During all servicing and repair work always follow  When components are removed, close up
the instructions contained in the Service Manual all open hoses, pipes, ports and housings
and Operation and Maintenance Manual. to keep dirt out.
Caterpillar Service always performs major work  Always use suitable tools, e.g. snub-nosed
that is not described in the Service Manual. screwdriver, when removing seals and
worn parts. Seal surfaces must not be
Caterpillar has a widespread net of customer damaged.
service and spare parts depots with fully
equipped workshops and qualified personnel.  Always change all seals and O-rings to
prevent leaks at a later stage.
Use only original Caterpillar spare parts.
Caterpillar Global Mining HMS GmbH cannot be  Fix any leakages as soon as possible.
held liable for any damage or injury caused by im-
proper operation of the Caterpillar hydraulic exca-  Tighten up leaking fittings only after de-
vator or by non-observance of instructions written pressurization. Do not repair damaged
in this Service Manual. pipes. Change them. Change hoses im-
mediately if you see damages or "sweat-
This Service Manual does not supplement, in ing".
any way whatever, the general terms of sale
and delivery of the Caterpillar Global Mining  Ensure that all changed consumables and
HMS GmbH. worn components, such as oil filters, hy-
draulic hoses and drained fluids are dis-
Please contact the Caterpillar Service for assis- posed of safely and with minimal environ-
tance and advice. mental impact.
When making any inquiries, please always use the  Ensure that all national and local regula-
machine model and serial number. tions regarding environment protection are
carefully followed.
 Check all mechanical connections and

1.1.4 Important hints locks, e.g. screws, nuts, bolts, lock wash-
ers, before inserting them again. Change
them if necessary.
 Before carrying out any work on
the electrical system or before  All seating surfaces must be even and free
welding set the red battery isola- of paint, grease, acid, dirt and rust.
tor switch on the power module to
OFF and lock it.  Prepare suitable containers to catch all es-
 After finishing the work set the caping fluids, e.g. cleaning fluid, hydraulic
oil, brake fluid, fuel, water, battery electro-
battery isolator switch to ON and
lyte. Dispose of the fluids in accordance
unlock it (see Operation and
with the requirements on environmental
Maintenance Manual).
protection.
 Always provide the servicing and repair  Dispose of used filter cartridges, old batter-
personnel with a suitable working place. ies and irreparable parts, such as hydraulic
hoses, in accordance with environmental
 Before disassembling a component for protection requirements as well.
servicing or repair clean it thoroughly.
 Connect the weld earth clamp as near to
 To keep the working place clean is espe- the weld area as possible. Do not allow the
cially important. Never use cotton waste or welding current to run through swing bear-
other fibrous material for cleaning pur- ings, hydraulic cylinders, pins or bearing
poses. Use only fibreless cloths. points.
Page 1.1 - 2 3849221en - (00)

1. GENERAL
1.2 Safety instructions

1.2.1 Risks of disregarding safety 1.2.2 Safety regulations
instructions
Personnel
This Caterpillar hydraulic excava- The machine must not be started
tor has been built in accordance by unauthorized people.
with state-of-the-art standards and
the recognized safety rules. Therefore secure and lock it.
However, operating the machine if Follow the accident prevention

a fault is suspected or has oc- regulations.
curred, or carrying out repair work Only specially trained and qualified
inexpertly personnel with the appropriate
technical knowledge can operate,
 endangers the lives of people in service or repair the hydraulic ex-
contact with it cavator.
 damages the machine and other If you lack such knowledge, ex-
property. perienced personnel, e.g. from
Caterpillar, are to give you detailed
Stop the hydraulic excavator im-
instructions.
mediately if you suspect or notice
any damage to ensure the safety of The personnel must have read and
the operator, other people or mate- understood the Operation and
rial property at the application area Maintenance Manual and in par-
of the excavator. ticular the chapter
All components of Caterpillar ma- ‘Fundamental Safety Instructions.’
chines are perfectly tuned to each
Only such people can start up the
other. Trouble-free operation and a
machine after assembly work to
long service life can only be
adjust the attachment.
achieved with original Caterpillar
spare parts. Incorrect operation of the machine
or the equipment can result in life-
threatening situations.
During all works, always observe
the start and shut down proce-
dures described in the Operation
and Maintenance Manual.
2440539en – (01) Page 1.2 - 1

1. GENERAL
Personnel Tools and devices

Personal protective equipment and Tools, hoists, slings, trestles and
safety working clothing: other devices must be in a reliable,
safe state.
Wear a safety helmet, safety foot-
wear and safety gloves. Metal splinters may cause injury
when you take in or out attachment
Wear closely fitting working cloth-
bolts. Therefore during this proce-
ing when working on the machine.
dure use a brass or copper man-
Loose, wide garments can catch on
drel and wear safety glasses.
machine parts and result in injury.
When climbing onto or off the ma-
Personnel carrying out work at
chine use only ladders, steps, plat-
greater heights must wear safety
forms and handrails provided for
harnesses. Always put on a tested
this purpose.
harness which is equipped with fall
arrestors and safety lines. Always keep ladders, steps and
platforms in a non-slip state. Re-
If you need assistance to carry out
move any oil, grease, earth, clay,
the work, e.g. marshallers, clearly
snow, ice and other foreign matter
define the responsibilities of each
immediately.
assistant beforehand. The individ-
ual responsibilities are to be care-
fully observed to ensure safety.
Securing the working equip-
ment
Secure the machine and the work-
ing equipment against inadvertent
and unauthorized start. Position
working equipment on the ground
in such a way that it cannot move
when mechanical or hydraulic
connections become detached.
Use hoists or other appropriate
support devices when you install,
remove or displace any equipment
or component. Thus you prevent
them from inadvertent movements,
slip or fall.
Page 1.2 - 2 2440539en – (01)

1. GENERAL
Before opening systems and units Before carrying out works, espe-
(e.g. pipes, coolers, hydraulic res- cially on the electrical system, dur-
ervoirs and accumulators) depres- ing which tools, spare parts, etc.
surize them properly. can contact electric cables, always
disconnect the battery: first the
Open or remove protective devices
negative pole and then the positive
on moving machine parts only
pole. When reconnecting the bat-
when the drive unit is shut down
tery, connect first the positive and
and secured against inadvertent
then the negative pole.
start.
Always replace defective, me-
Before re-commissioning install all
chanically prestressed compo-
protective devices.
nents. Never open them! The Ser-
Before carrying out assembly work, vice Manual contains no informa-
the machine and the equipment tion on such work.
must be secured against inadver-
The operating temperature of the
tent movement, e.g. by placing the
machine is high and the consum-
working equipment on the ground.
ables have at least the same tem-
perature. Therefore take care to
avoid burns or scalds.
Hydraulic and lubricating sys-
tem: Be careful when handling acids,
e.g. battery acid. Acid splashes
Always observe the safety regula- may injure the eyes and the skin.
tions applicable to the product
when handling oils, greases and If the acid is splashed onto your
other chemical substances. skin, rinse it with plenty of clean
running water and seek medical
Close open unused bores, pipe and care immediately.
hose connections so that they are
impermeable to pressure. If the acid is splashed in your eyes,
rinse thoroughly with running wa-
Refill the hydraulic system with ter and seek medical care immedi-
collected drain hydraulic oil only ately.
through the return flow filters. Dis-
pose of waste oil without polluting Never smoke when handling flam-
the environment. mable liquids.
Observe the correct working se- Be careful with open flames and
quence when fitting or replacing unprotected light. Not only fuel but
components or equipment. also other consumables often have
a low flash point and catch fire
easily.
2440539en – (01) Page 1.2 - 3

1. GENERAL
1.2.3 Modifications of the machine 1.2.4 Re-commissioning
Unauthorized conversions or modi- Before re-commissioning:

fications of the hydraulic excavator
are forbidden for reasons of safety.  Grease all lubricating points.
Never modify the nominal pressure  Check all oil levels and correct
value of pressure relief valves them if necessary.
without explicit approval from Cat-
erpillar. Do not remove the lead  Carry out function checks of all
seals from pressure relief valves repaired components.
and hydraulic accumulators.
 Check all functions of the exca-
vator including brakes during a
test run. Release the hydraulic
excavator for re-commissioning
only if all its functions operate
properly.
Page 1.2 - 4 2440539en – (01)

1. GENERAL
1.3 General
This Service Manual contains information in addi- The Service Manual covers the information you
tion to the Operation and Maintenance Manual need when handling your excavator. However,
and the Spare Parts Catalog, to familiarise the Caterpillar Global Mining HMS GmbH will be
personnel with the designated use, maintenance pleased to answer any questions you have on its
and repair of the CAT hydraulic excavator. products. Please contact your local CAT dealer or
your Caterpillar subsidiary.
The information in the Service Manual corre-
sponds to the standard technical specification of
the machine when it was delivered.
All sketches and drawings show general principles.

They do not represent the actual design of the
machine and are not to be used for manufacturing.
Special equipment is normally not considered.
Technical modifications, which are introduced after

delivery of the machine, may also be incorporated
in machines which are already in operation.
In this case, you can find the updated version of
the Service Manual on the Caterpillar website.
2440540en – (02) Page 1.3 - 1

1. GENERAL
Page 1.3 - 2 2440540en – (02)

08.2018
2. Technical Data
6040

CONTENTS
2. TECHNICAL DATA
2.1 Introduction ......................................................................................... 2 - 1
2.1.1 Foreword .............................................................................. 2 - 1
2.1.2 Safety ................................................................................... 2 - 1
2.1.3 General ................................................................................. 2 - 1
2.2 Engine / Motor ..................................................................................... 2 - 3
2.3 Hydraulic system ................................................................................. 2 - 4
2.3.1 Main pump ............................................................................ 2 - 4
2.3.2 Swing system ....................................................................... 2 - 5
2.3.3 Auxiliary pressure pump / Gear oil pump .............................. 2 - 6
2.3.4 Servo- and swing charge pump ............................................ 2 - 6
2.3.5 Cooling system hydraulic oil / water ..................................... 2 - 7
2.3.6 Travel motor ......................................................................... 2 - 9
2.3.7 Control block......................................................................... 2 - 9
2.3.8 Filter elements for hydraulic system ..................................... 2 - 9
2.4 Pressure setting ................................................................................ 2 - 10
2.5 Governing current for proportional valves...................................... 2 - 11
2.6 Hydraulic cylinder ............................................................................. 2 - 12
2.6.1 Face shovel ........................................................................ 2 - 12
2.6.2 Backhoe ............................................................................. 2 - 12
2.7 Transmission ratio ........................................................................... 2 – 13
3720202en – (00) Page 2 - 1

CONTENTS
2.8 Weights of modules and components ............................................. 2 - 14
2.8.1 Modules .............................................................................. 2 - 14
2.8.2 Components ....................................................................... 2 - 15
2.9 Tightening procedures for bolts ...................................................... 2 - 16
2.9.1 Tightening procedures for module bolts ............................. 2 - 16
2.9.2 Tightening procedures for component bolts ....................... 2 - 18
Page 2 - 2 3720202en – (00)

2.1 TECHNICAL DATA
2.1 Introduction
2.1.1 Foreword 2.1.2 Safety Instructions
The Service Manual contains important informa- Any person entrusted with com-
tion for personnel servicing the machine. Machine missioning, operation, inspection
specifications listed in other machine documents and servicing of the Caterpillar
are not always repeated in this section. hydraulic excavator are to have
read and understood the Operation
The documentation of a Caterpillar mining machine and Maintenance Manual and, in
includes: particular, the chapter FUNDA-
MENTAL SAFETY INSTRUCTIONS
 Operation and Maintenance Manual before starting any work.
 Spare Parts Catalog


 Service Manual.
2.1.3 General
The present brochure does not contain the specifi- Technical modifications, which are introduced after
cations of auxiliary units for the operation of addi- delivery of the machine, may also be incorporated
tional or optional equipment or the specifications of in machines which are already in operation.
individual machines. In this case, you can find the updated version of
the Service Manual on the Caterpillar website
The refilling quantities specified for consumables
are approximate quantities which are intended as a
help for planning consumable requirements.
Each unit is equipped with suitable checking de-

vices, e.g. dipstick or checking plugs, permitting
the operator to check proper filling of the units.
2440542en - (01) Page 2 - 3

2.1 TECHNICAL DATA
Page 2 - 4 2440542en - (01)

2. TECHNICAL DATA
2.2 Engine
Designation Unit Quantity
Manufacturer and Type Caterpillar C 32 2
Rated output SAE J 1995 kW (HP) 758 / (1016)

Idling speed rpm 800
Rated speed (on full load) rpm 1 750
Weight kg 2 946
Max. altitude without output reduction m 3 000
Alternator V/A
Battery V / Ah
Fuel filter
Oil filter
Oil filter (Bypass)
Water filter (Service.)
Water filter (pre-charge)
Air intake filter (main filter element)
Air intake filter (safety filter element)
3720621en – (06) Page 2 – 3

2. TECHNICAL DATA
2.3 Hydraulic system

2.3.1 Main pump
Designation Unit
Quantity 4
Type Variable-displacement, axial-piston
Model A4V SO 500 HD

Displacement cm3 / rev. 500
Operating speed rpm 1486
Governing pressure bar 7.5 – 42.5
Max. oil flow l / min 720
Max. working pressure bar 300 / 360
2.3.2 Swing system

2.3.2.1 Swing pump
Designation Unit
Quantity 2x2
axial-piston - double pump
Type
variable-displacement
Model A4VG 125 MS
Displacement cm3 / rev. 2 x 2 x 125
Governing pressure bar 7.5 - 34
Max. oil flow l / min 2 x 2 x 316
Max. working pressure bar 370
Setting of relief valve bar 420
Thermo switch in pump housing 1 x per pump
setting (high) °C 92
setting (low) °C 87
Page 2 – 4 3720621en – (06)

2. TECHNICAL DATA
2.3.2.2 Hydraulic swing pump - (charge pump)
Designation Unit
Quantity 2x1
Type gear pump
Model KP 3/100
Displacement cm3 / rev. 2 x 99.5
Max. oil flow l / min 2 x 140
2.3.2.3 Swing motor
Designation Unit
Quantity 3
Type Fixed-displacement, axial-piston motor
Model A2F 180
3720621en – (06) Page 2 – 5

2. TECHNICAL DATA
2.3.3 Servo pump / Gear oil pump
Designation Unit
Quantity 2x1
Type Double gear-pump
Servo pump Model KP 2/28
Displacement cm3 / rev. 27.7
Max. oil flow l / min 37
Gear oil-pump Model KP 1/8
Displacement cm3 / rev. 7.9
Max. oil flow l / min 10.5
2.3.4 Cooling system Hydraulic oil / Water

2.3.4.1 Hydraulic pump - fan drive oil-cooling / water-cooling
Designation Unit
Quantity 2x2
Type Variable-displacement, axial piston
Model LA 10 VO 71
Displacement cm3 / rev. 2 x 2 x 71
Max. oil flow l / min 2 x 2 x 123 ( = 0.96)
Page 2 – 6 3720621en – (06)

2. TECHNICAL DATA
2.3.4.2 Circulating pump oil cooling
Designation Unit
2x1
Quantity
Type gear pump
Model KF 6/400
Displacement cm3 / rev. 2 x 405
Max. oil flow l / min 2 x 776 ( = 0.96)
2.3.4.3 Fan-motor oil cooling / water-cooling
Designation Unit
Quantity 2x2
Type gear motor
Model KM 3/100
Max. operating speed rpm 1 180 ( = 0.96)
3720621en – (06) Page 2 – 7

2. TECHNICAL DATA
2.3.5 Travel motor
Designation Unit
Quantity 4
Type Variable-displacement, axial-piston
Model AA4SVE
Max. displacement cm3 / rev. 250
Operating speed at max. displacement rpm 1400
Min. displacement cm3 / rev. 150
Operating speed at min. displacement rpm 2300
2.3.6 Control block
Designation Unit
(piston stroke measured from neutral position)
Boom, stick, crowd, clam mm 28

Travel mm 17
Float valve mm 17
2.3.7 Filter elements for hydraulic system
Quantity
Designation rating [m
High pressure filter element for working pumps 100 4

Return flow filter element for Hydraulic tank 10 7
Return flow filter element for oil cooling system 10 2
Filter element - feed line swing circuit 40 4
Filter element - servo circuit 40 2
Air breather filter - hydraulic tank 2
Bypass valve-screen - hydraulic tank screen size 1.5 mm 4
Bypass valve-screen - return comp. oil cooling screen size 1.5 mm 2
Page 2 – 8 3720621en – (06)

2. TECHNICAL DATA
2.4 Pressure Setting
Description Unit
Pressure cut-off – main pumps Cylinders bar 300
Travel bar 350
Primary relief for main pumps bar 380
Secondary relief for Boom cylinders bar 350
Stick cylinders bar 350
Bucket cylinders bar 350
Clam cylinders (Attachment control manifold) bar 350
Clam cylinders (back wall) bar 330
Travel motors bar 360
Main pump (governing pressure) control pressure bar 4 - 43
Pilot pressure bar 35
Auxiliary pressure 1 bar 50
Swing system – working pressure max. bar 350
Swing system – charge pressure (approx.) bar 25
Swing system – safety valve (approx.) bar 22
Swing system – supply pressure to pressure balance valve bar 35
Fan drive - pressure Hydraulic oil cooling bar 280
Engine cooling bar 280

Cooling circuit pres- Hydraulic oil cooling bar ≤5
Track tensioning sys- Change over valve bar 70
t
Pilot pressure system - emergency lowering bar 22 (N2)
Pre-charge pressure of until DHX40156
hydraulic accumulator Emergency lowering valid for machines from
bar 35 (N2)
DHX40159 and up
Auxiliary pressure 1 bar 40 (N2)
Pre-charge pressure of
Track tensioning system bar 50 (N2)
hydraulic accumulator
Ladder bar 65 (N2)
Travel motor valid for machines from
In-line accumulator bar 2.1 (N2)
DHX40159 and up
3720621en – (06) Page 2 – 9

2. TECHNICAL DATA
2.5 Governing current for proportional valves
Governing pressure
Working pump Governing current Engine speed
working pumps
pressure (approx..) (approx.)
(approx.)
[ bar ] [ mA ] [ bar ] [ rpm ]
0 - 300 (360) 225 - 850 4 - 43 900 - 1920
Page 2 – 10 3720621en – (06)

2. TECHNICAL DATA
2.6 Hydraulic cylinder

2.6.1 Face shovel equipment
Designation Unit
Rod - [mm] Piston - [mm]
Boom cylinder mm 200 300

Stick cylinder mm 180 250
Bucket crowd cylinder mm 180 250
Clamshell cylinder mm 100 190
2.6.2 Backhoe equipment
Designation Unit
Rod - [mm] Piston - [mm]
Boom cylinder mm 250 350

Stick cylinder mm 200 300
Backhoe cylinder mm 200 280
3720621en – (06) Page 2 – 11

2. TECHNICAL DATA
2.7 Transmission ratio
Designation Unit
Pump gear - working pumps i = 0.826

Pump gear - swing pumps i = 1.449
Swing gear i = 48.461
Final drive i = 283.14
Page 2 – 12 3720621en – (06)

2. TECHNICAL DATA
2.8 Weights of modules and components

2.8.1 Modules
Designation Unit
RH crawler module with track (1 200 mm) kg 55 000

LH crawler module with track (1 200 mm) kg 55 000
Undercarriage module with swing ring kg 36 000
Superstructure module kg 51 000
Engine module with oil and diesel kg 32 000
Counterweight kg 39 000
Oil cooler module kg 7 500
Cab module kg 6 000
Cab kg 4 500
FS boom (without cylinders) kg 36 000

FS arm kg 13 000
3
FS backwall 22 m (without hard facing) kg 23 500
FS front lip 22 m3 (without hard facing) kg 23 500
Backhoe mono boom 9.5 m (without cylinders) kg 36 000

Backhoe stick 4.5 m (without cylinders) kg 13 000
3
Backhoe bucket 22 m (without hard facing) kg 38 000
3720621en – (06) Page 2 – 13

2. TECHNICAL DATA
2.8.2 Components
Designation Unit
Diesel engine kg 3 000
Final drive (with hydraulic motors) kg 4 500
Swing gearbox (with hydraulic motor) kg 1 500
Pump gearbox (without pumps) kg 1 500
Valve block „Travel“ compl. (with rotor) kg 900
Valve block „Equipment“ kg 600
Working pumps kg 400
Swing pumps (double pump) kg 200
Swing motor kg 50
Travel motor kg 150
Swing bearing kg 7 100
Bottom roller kg 750
Support roller kg 500
Idler kg 3 000
Sprocket kg 2 200
Boom cylinder (face shovel) kg 3 000
Arm cylinder (face shovel) kg 2 000
Bucket crowd cylinder (face shovel) kg 2 000
Clamshell cylinder (face shovel) kg 600
Boom cylinder (backhoe) kg 5 000
Stick cylinder (backhoe) kg 3 500
Bucket cylinder (backhoe) kg 2 500
Page 2 – 14 3720621en – (06)

2. TECHNICAL DATA
2.9 Tightening procedures for bolts

2.9.1 Tightening procedures for module bolts
Designation Chapter
Crawler frame - carbody Bolt size / wrench size M 30 x 190 / 46

(vertical connection) Quantity 84
Grade 12.9
Bolt treatment oiled
1) Pre-torque Md = 600 Nm
2) Angle 60°
Crawler frame - carbody Bolt size / wrench size M 36 x 350 / 55
(horizontal connection) Quantity 32
Grade 12.9
1) Pre-torque Md = 1 100 Nm
2) Angle 90°
Engine module Bolt size / wrench size M 30 x 210 / 46
Quantity 24
Grade 10.9
Tightening procedure Md = 1 700 Nm
3720621en – (06) Page 2 – 15

2. TECHNICAL DATA
Designation Chapter
Operators module Bolt size / wrench size M 24 x 220 / 36

Quantity 21
Grade 10.9
Tightening procedure Md = 850 Nm
Oil cooler module Bolt size / wrench size M 24 x 200 / 36

Quantity 14
Grade 10.9
Tightening procedure Md = 850 Nm
Counterweight Bolt size / wrench size M 48 x 580 / 75

Quantity 5
Grade 12.9
Bolt treatment molycoted
Tightening procedure Md = 5 000 Nm
Page 2 – 16 3720621en – (06)

2. TECHNICAL DATA
2.9.2 Tightening procedures for component bolts
Designation Chapter
Undercarriage – swing ring see chapter 5.2
Superstructure – swing ring see chapter 5.2
Bottom roller see chapter 4.5
Top roller see chapter 4.6
Sprocket see chapter 4.7
Engine mounting see chapter 5.3
Engine coupling see chapter 5.4
Travel gearbox see chapter 7.2
Swing gearbox see chapter 7.3
Pump gearbox - engine see chapter 7.4
3720621en – (06) Page 2 – 17

2. TECHNICAL DATA
Page 2 – 18 3720621en – (06)

08.2018
3. Tools, Assembly
6040

CONTENTS
3. TOOLS, ASSEMBLY
3.1 Introduction....................................................................................... 3.1 - 1
3.1.1 Foreword ........................................................................... 3.1 - 1
3.1.2 Safety ................................................................................ 3.1 - 2
3.1.3 General .............................................................................. 3.1 - 8
3.1.4 Corrosion protection for pins and bearings ........................ 3.1 - 9
3.2 Tools ................................................................................................. 3.2 – 3
3.3 Assembling the excavator ............................................................... 3.3 - 1
3720203en - (00) Page 3 - 1

CONTENTS
Page 3 - 2 3720203en – (00)

3.1 TOOLS, ASSEMBLY
3.1 Introduction
3.1.1 Foreword 3.1.2 Safety
Danger in case of non-observance of safety
The Service Manual contains important instructions
information for personnel servicing the machine.
Machine technical data listed in other machine This Caterpillar hydraulic
documents are not always repeated in this book. excavator has been built in
accordance with state-of-the-art
The documentation of a Caterpillar mining machine standards and the recognized
includes: safety rules.
 Operation and Maintenance Manual However, operating the machine if
a fault is suspected or has
 Spare Parts Catalog occurred, or carrying out repair
 work inexpertly
 Service Manual
 endangers the lives of people in
contact with it
The service manual does not contain technical
data on auxiliary units for the operation of specific  damages the machine and other
or optional equipment or data of individual devices. property.
Stop the hydraulic excavator
The refilling quantities specified for consumables
immediately if you suspect or
are approximate quantities which are intended as a
help for planning consumable requirements. notice any damage to ensure the
safety of the operator, other people
Each component is equipped with suitable or material property at the
checking devices, e.g. a dipstick or checking plugs, application area of the excavator.
permitting the operator to check exactly the filling of All components of Caterpillar
the components. machines are perfectly tuned to
each other. Trouble-free operation
and a long service life can only be
spare parts.
3849044en - (00) Page 3.1 - 1

3.1 TOOLS, ASSEMBLY
Rules for safety at work
Personnel Personnel
The machine must not be started Personal protective equipment and
by unauthorized people. safety working clothing:
Therefore secure and lock it. Wear a safety helmet, safety
footwear and safety gloves.
Follow the accident prevention
regulations. Wear closely fitting working cloth-
Only specially trained and qualified Loose, wide garments can catch on
personnel with the appropriate machine parts and result in injury.
service or repair the hydraulic Personnel carrying out work at
excavator. greater heights must wear safety
If you lack such knowledge, harness which is equipped with fall
experienced personnel, e.g. from arrestors and safety lines.
Caterpillar, are to give you detailed
instructions. If you need assistance to carry out
The personnel must have read and define the responsibilities of each
understood the Operation and assistant beforehand. The
Maintenance Manual and in individual responsibilities are to be
particular the chapter carefully observed to ensure
‘Fundamental Safety Instructions.’ safety.
Incorrect operation of the machine
the start and shut down
procedures described in the
Operation and Maintenance
Manual.
Page 3.1 - 2 3849044en - (00)

3.1 TOOLS, ASSEMBLY
Tools and devices Before carrying out works,

especially on the electric system,
Tools, hoists, slings, trestles and during which tools, spare parts,
other devices must be in a reliable, etc. can contact electric cables,
safe state. always disconnect the battery: first
Metal splinters may cause injury the negative pole and then the
when you take in or out attachment positive pole. When reconnecting
bolts. Therefore during this the battery, connect first the
procedure use a brass or copper positive and then the negative
mandrel and wear safety glasses. pole.
When climbing onto or off the Always replace defective,

machine use only ladders, steps, mechanically prestressed
platforms and handrails provided components. Never open them!
for this purpose. The Service Manual contains no
information on such work.
Always keep ladders, steps and
platforms in a non-slip state. The operating temperature of the
Remove any oil, grease, earth, clay, machine is high and the
snow, ice and other foreign matter consumables have at least the
immediately. same temperature. Therefore take
care to avoid burns or scalds.
Be careful when handling acids,
Securing the working e.g. battery acid. Acid splashes
equipment may injure the eyes and the skin.
Secure the machine and the If the acid is splashed onto your
working equipment against skin, rinse it with plenty of clean
inadvertent and unauthorized start. running water and seek medical
Position working equipment on the care immediately.
ground in such a way that it cannot If the acid is splashed in your eyes,
move when mechanical or rinse thoroughly with running
hydraulic connections become water and seek medical care
detached. immediately.
Use hoists or other appropriate Never smoke when handling
support devices when you install, flammable liquids.
remove or displace any equipment
or component. Thus you prevent Be careful with open flames and
them from inadvertent movements, unprotected light. Not only fuel but
slip or fall. also other consumables often have
easily.
3849044en - (00) Page 3.1 - 3

3.1 TOOLS, ASSEMBLY
Before opening systems and units Hydraulic equipment

(e.g. pipes, coolers, hydraulic
reservoirs and accumulators) Check all lines, hoses and screwed
depressurize them properly. connections regularly for leaks and
obvious damage. Repair damage
Open or remove protective devices immediately. Splashed oil may
on moving machine parts only cause injury and fire.
when the drive unit is shut down
and secured against inadvertent Before carrying out any repair work
start. depressurize all system sections
and pressure pipes. Remove them
Before re-commissioning install all in accordance with the specific
protective devices. instructions.
Before carrying out assembly work, Install hydraulic lines properly.
the machine and the equipment Ensure that no connections are
must be secured against interchanged. The fittings, length
inadvertent movement, e.g. by and quality of the hoses must
placing the working equipment on comply with the technical
the ground. requirements.
Hydraulic and lubricating

system:
Always observe the safety
regulations applicable to the
product when handling oils,
greases and other chemical
substances.
Close open unused bores, pipe and
hose connections so that they are
impermeable to pressure.
Refill the hydraulic system with
collected drain hydraulic oil only
through the return flow filters.
Dispose of waste oil without
polluting the environment.
Observe the correct working
sequence when fitting or replacing
components or equipment.
Page 3.1 - 4 3849044en - (00)

3.1 TOOLS, ASSEMBLY
Modifications of the machine

Warning of special dangers
Unauthorized conversions or
modifications of the hydraulic Electric energy
excavator are forbidden for
Use only original fuses with the
reasons of safety.
specified current rating. Switch off
Never modify the nominal pressure the machine immediately, if trouble
value of pressure relief valves occurs in the electrical system.
without explicit approval from
When working with the machine,
Caterpillar. Do not remove the lead
maintain a safe distance from
seals from pressure relief valves
overhead electric lines.
and hydraulic accumulators.
If the work is to be carried out
close to overhead lines, keep the
working equipment far away from
Transport and re-commissioning them.
Caution: danger!
Before re-commissioning: Check out the prescribed safety
distances.
 Grease all lubricating points.
If your machine comes into contact
 Check all oil levels and correct with a live wire, do not leave the
them if necessary. machine, but drive the machine out
of the hazard zone;
 Carry out function checks of all warn others against approaching
repaired components. and touching the machine;
 Check all functions of the de-energize the live wire;
excavator including brakes
do not leave the machine until the
during a test run. Release the
damaged or contacted line has
hydraulic excavator for re-
been safely de-energised.
commissioning only if all its
functions operate properly. Check the electrical equipment of
the machine at regular intervals.
Rectify immediately such defects
as loose connections or scorched
cables.
Transport and re-
commissioning
Load and transport the machine
only in accordance with the
Manual.
Use only appropriate means of
transport and lifting gear of
adequate capacity.
Carry out the re-commissioning
procedure only in accordance with
the Operation and Maintenance
Manual.
3849044en - (00) Page 3.1 - 5

3.1 TOOLS, ASSEMBLY
Gas, dust, steam and smoke 3.1.3 General

Operate engines and fuel operated
heating systems only on This Service Manual contains information in
adequately ventilated premises addition to the Operation and Maintenance
(risk of explosion). Manual and the Spare Parts Catalog, to
familiarise the personnel with the designated use,
Before starting the machine on
maintenance and repair of the Caterpillar
enclosed premises, ensure that
excavator.
there is sufficient ventilation.
Observe the legal regulations at The information in the Service Manual
the respective site. corresponds to the standard technical specification
of the machine when it was delivered.
Before carrying out welding, flame
cutting and grinding operations, All sketches and drawings show general principles.
clean the machine and its They do not represent the actual design of the
surroundings from dust and other machine and are not to be used for manufacturing.
inflammable substances and make
sure that the premises are Special equipment is normally not considered.
adequately ventilated.
Carry out welding, flame cutting
and grinding work on the machine
only if it is authorised. Otherwise
you face a risk of explosion and
fire.
The Service Manual covers the information you

need when handling your excavator. However,
Caterpillar Global Mining HMS GmbH will be
pleased to answer any questions you have on its
Noise products. Please contact your local Caterpillar
dealer or your Caterpillar subsidiary.
During the operation close all
sounds baffles.
Always wear the prescribed ear
protectors.
Oil, grease and other

chemical substances
When handling oil, grease or other
chemical substances, observe the
product related safety regulations.
Be careful when handling hot
consumables (risk of burning or
scalding).
Page 3.1 - 6 3849044en - (00)

3.1 TOOLS, ASSEMBLY
3.1.4 Corrosion protection for pins

and bearings
Application of anticorrosive agent

Use only "GLEITMO 815"
anticorrosive agent. 1) Clean off grease, oil, dirt and corrosion
protection agents from pins and bearings
Other agents are not approved by
using white spirit or diesel fuel. Remove
Caterpillar Global Mining HMS
thoroughly any rust patches. All parts
GmbH. should have a dry shiny metal surface.
2) Apply a thin layer of the anticorrosive agent

Before fitting treat all pins and bearings (bushings on pins and all bearings using a brush or a
and hubs) of the working equipment or in spray can. Pin shafts and bearings should
equipment components with "GLEITMO 815" be completely covered by the protective
anticorrosive agent. layer. If the protective layer of a pin treated
with the anticorrosive agent is damaged,
Anticorrosive agent rework these areas before fitting the part.
 ensures easy fitting and dismantling

Fitting and securing of pins
1) If the pin is too heavy to be fitted manually,

 protects against rust, oxidation and wear apply the anticorrosive agent at first only at
a quarter of the pin length.
 prevents non-moving parts of bearings from
seizing and fretting corrosion. 2) Position the pin for fitting with a lifting gear.
It is achieved because aluminium and copper 3) Apply the anticorrosive agent on the
particles form a protective layer on the metal. This remaining length of the pin shaft, fit the pin
layer removes surface irregularities and does not and fix it.
“sweat”, seize or harden.
Part no. for "GLEITMO 815" is 2764305. It is

available at CGM HMS GmbH Spare-Parts
Service.
3849044en - (00) Page 3.1 - 7

3.1 TOOLS, ASSEMBLY
Page 3.1 - 8 3849044en - (00)

CONTENTS
3.2 TOOLS
3.2.0 Tools reference list........................................................................ 3.2.0 - 1
3.2.1 Torque tools ................................................................................... 3.2.1 - 1
3.2.2 Cutting and tapping tools ............................................................. 3.2.2 - 1
3.2.3 Electric tools .................................................................................. 3.2.3 - 1
3.2.4 Hand tools ...................................................................................... 3.2.4 - 1
3.2.5 Miscellaneous ................................................................................ 3.2.5 - 1
3.2.6 Measuring tools ............................................................................. 3.2.6 - 1
3.2.7 Support ........................................................................................... 3.2.7 - 1
3.2.8 Consumables ................................................................................. 3.2.8 - 1
3.2.9 Service adaptors............................................................................ 3.2.9 - 1
3720620en - (02) Page 3.2 - 1

CONTENTS
Page 3.2 - 2 3720620en - (02)

3.2.0 TOOLS REFERENCE LIST
3.2 Tools
This section lists recommended tools essential for

carrying out servicing and assembly procedures.
These are not included in the machine’s own tool

set.
Items in the tools list that have part numbers can

be ordered from the
Caterpillar Global Mining HMS Spare Parts Divi-

sion
They are to be ordered in the same manner as

other spare parts.
3720691en – (07) Page 3.2.0 - 1

3.2.1 Torque Tools
6030/FS
6015/FS
6018/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
RECOMMENDED TOOLS AND AC-
Pos CESSORIES FOR MAINTENANCE, Part No.
INSPECTION AND ASSEMBLY
Hydraulic drive unit/Power Pack 240V
1 3.2.1.01 1* 1* 1* 1* 1* 1* 1* 6002267
(torque only)
Hydraulic drive unit/Power Pack 240V
2 3.2.1.02 1* 1* 1* 1 1 1 1 1478386
(torque and angle)
3 3.2.1.03 HP Hose Set (6x5m) 1* 1* 1* 1 1 1 1 2470564
Hydraulic Torque Wrench 1 MXT
4 3.2.1.04 1* 1* 1* 1* 1* 1 2482923
(max. 1850 Nm)
5 3.2.1.04 1* 1* 1* 1* 1 2470558
(max. 4.450 Nm)
6 3.2.1.04 1* 1* 1* 1* 1 6003121
(max. 7.700 Nm)
7 3.2.1.04 1 1 1 6003104
(max. 27.000 Nm)
8 3.2.1.05 Impact Socket ¾” drive 30mm 1 1* 1* 1* 1* 1* 1 2482959
9 3.2.1.05 Impact Socket ¾” drive 32mm 1* 1* 1* 1* 1* 1 6004549
11 3.2.1.05 Impact Socket ¾” drive 41mm 1* 6003599
13 3.2.1.06 Impact Socket 1” drive 32mm 1 1 1 1 1 1 1 6004537
14 3.2.1.06 Impact Socket 1” drive 36mm 1* 1 1 1 1 1 1 1434705
15 3.2.1.06 Impact Socket 1” drive 41mm 1 1 1434706
Impact Socket 1” drive 46mm (Ø 69
16 3.2.1.06 1 1 1 1 1 1 1434707
mm)
Impact Socket 1” drive 46mm (Ø 65
17 3.2.1.06 1 6100296
mm)
18 3.2.1.06 Impact Socket 1” drive 55mm 1 1* 1434709
19 3.2.1.06 Impact Socket 1” drive 60mm 1* 1434710
20 3.2.1.06 Impact Socket 1” drive 95mm 1 1 1 6003610
21 3.2.1.07 Impact Socket 1½” drive 36mm 1 1 1461521
22 3.2.1.07 Impact Socket 1½” drive 46mm 1 1 1 1 1461523
23 3.2.1.07 Impact Socket 1½” drive 50mm 1461524
24 3.2.1.07 Impact Socket 1½” drive 55mm 1 1461525
28 3.2.1.07 Impact Socket 1½” drive 75mm 1 1 1 1 1461528
29 3.2.1.08 Impact Socket 2½” drive 95mm 1 1 1 2482837
Hydraulic Torque Wrench “Stealth 2”
30 3.2.1.09 1* 1* 6003868
41mm (170 – 2.400 Nm)
31 3.2.1.09 1* 6003869
55mm (400 – 5.500 Nm)
Page 3.2.0 - 2 3720691en – (07)

6030/FS
6015/FS
6018/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
32 3.2.1.09 1 6003870
65mm (800 – 11.000 Nm)
Drive Cylinder for Hydraulic Torque
33 3.2.1.10 1 1 1 1477300
Wrench XLCT
Ratchet Insert 55mm for Hydraulic
34 3.2.1.10 1 1 1 1477299
Torque Wrench XLCT
Torque Multiplier XVR40
35 3.2.1.11 1 1 1 1 1 1 1437544
(max. 4.000 Nm) 1½” drive
Torque Multiplier XVR65
36 3.2.1.11 1 1 1 1 1 1448441
(max. 6.000 Nm) 1½” drive
37 3.2.1.12 ½” Torque Wrench (60-300 Nm) 1 1 1 1 1 1 1 1446762
38 3.2.1.13 Torque Wrench DSG 6 (500-1.300 Nm) 1 1 1 1 1 1 1331433
39 3.2.1.14 Torque Wrench DSG 7 (800-2.000 Nm) 1 1 1 1 1 1 0900890
Spanner Insert for DSG 6 + DSG 7
40 3.2.1.15 1 1 1 1 1 1 1 1590922
(36mm)
41 3.2.1.15 1 1 0900891
(41mm)
42 3.2.1.15 1 1 1 1 1 1740801
(46mm)
43 3.2.1.15 1 1 1 1 1740115
(55mm)
Ratchet Insert for DSG 6 + DSG 7
44 3.2.1.16 1 1 1 1 1 1 1472005
(1”drive)
45 3.2.1.16 Repair Kit for Ratchet Insert 1 1 1 1 1 1 1472006
46 3.2.1.17 Air Impact Gun ½” drive 1 1 1 1 1 1 1 2482463
47 3.2.1.18 Ratchet and Socket Set ½” drive 1 1 1 1 1 1 1 0559027
48 3.2.1.19 Allen Key Socket Set ½” drive (4-19mm) 1 1 1 1 1 1 1 2482522
49 3.2.1.20 Air Impact Gun ¾” drive 1 1 1 1 1 1 1 2482462
50 3.2.1.21 Ratchet and Socket Set ¾” drive 1 1 1 1 1 1 1 2482464
51 3.2.1.22 Air Impact Gun 1” drive 1 1 1 1 2482461
52 3.2.1.23 Ratchet and Socket Set 1” drive 1 1 1 1 1 1 1 2482523
Adaptor for Socket Wrenches
53 3.2.1.24 1 1 1 1 1 1 1 2482471
(1” to ¾”)
Adaptor for Socket Wrenches
54 3.2.1.24 1 1 1 1 1 1 1 1431749
(1½” to 1”)
55 3.2.1.25 Impact Extension 1” drive, 6” length 1 1 1 1 1 1 1 2482956
56 3.2.1.25 Impact Extension 1” drive, 12” length 1 1 1 1 1 1 1 2482957
57 3.2.1.26 Universal Joint ½” drive 1 1 1 1 1 1 1 2482955
*Recommended/Optional
To ease assembly
3720691en – (07) Page 3.2.0 - 3

3.2.2 Cutting and Tapping Tools
6015/FR
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 90
H 40
1 3.2.2.01 Hacksaw 1 1 1 1 1 1 1 0059324

2 3.2.2.01 Spare hacksaw blades 6 6 6 6 6 6 6 0060784
3 3.2.2.02 M6 x 1 tap 1 1 1 1 1 1 1 0059912
4 3.2.2.02 M8 x 1,25 tap 1 1 1 1 1 1 1 0059915
5 3.2.2.02 M10 x 1,5 tap 1 1 1 1 1 1 1 0059918
6 3.2.2.02 M12 x 1,75 tap 1 1 1 1 1 1 1 0059925
7 3.2.2.02 M14 x 2 tap 1 1 1 1 1 1 1 6003618
8 3.2.2.02 M16 x 2 tap 1 1 1 1 1 1 1 0059929
9 3.2.2.02 M20 x 2,5 tap 1 1 1 1 1 1 1 0157223
10 3.2.2.02 M24 x 3 tap 1 1 1 1 1 1 1 0157226
11 3.2.2.02 M27 x 3 tap 1 1 6003619
12 3.2.2.02 M30 x 3,5 tap 1 1 1 1 1 1 6003620
13 3.2.2.02 M36 x 4 tap 1 1 1 1 6003621
14 3.2.2.02 M39 x 4 tap 1 6003622
15 3.2.2.02 M42 x 3 tap 1 2739509
16 3.2.2.02 M48 x 5 tap 1 1 1 1 1 6003623
17 3.2.2.02 M64 x 4 tap 1 1 1 6004426
3.2.3 Electric Tools

6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90

1 3.2.3.01 Electric Connector Assortment 1 1 1 1 1 1 1 2482882
2 3.2.3.02 Bootlace ferrule Assortment 1 1 1 1 1 1 1 2482529
3 3.2.3.03 Tool Set 1 1 1 1 1 1 1 1190887
4 3.2.3.04 Digital Multimeter 1 1 1 1 1 1 1 1088932
5 3.2.3.04 Pincers red 1 1 1 1 1 1 1 0764860
6 3.2.3.04 Pincers black 1 1 1 1 1 1 1 0764861
Installation Bar for grounding Cable
7 3.2.3.05 1* 1* 1* 1* 1* 1* 1* 1791163
Harness
8 3.2.3.06 Grounding Cable Harness 1* 1* 1* 1* 1* 1* 1* 0925649
9 3.2.3.07 Cable-hook 1* 1* 1* 1* 1* 1* 1* 2270413
10 3.2.3.08 Fuse Tool 1* 1* 1* 1* 1* 1* 1* 1725313
11 3.2.3.09 High Voltage Tester 1* 1* 1* 1* 1* 1* 1* 0255962
*for electric power train only
Page 3.2.0 - 4 3720691en – (07)

3.2.4 Hand Tools
6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
1 3.2.4.01 ROE Spanner Set metric 6-32mm 1 1 1 1 1 1 1 2482524

2 3.2.4.01 ROE Spanner Set imperial ¼” - 1¼” 1 1 1 1 1 1 1 2482944
3 3.2.4.02 ROE Spanner 15mm 1 1 1 1 1 1 1 0717906
4 3.2.4.02 ROE Spanner 17mm 1 1 1 1 1 1 1 6003612
5 3.2.4.02 ROE Spanner 19mm 1 1 1 1 1 1 1 0717908
6 3.2.4.02 ROE Spanner 22mm 1 1 1 1 1 1 1 0717911
7 3.2.4.02 ROE Spanner 24mm 1 1 1 1 1 1 1 0717913
8 3.2.4.02 ROE Spanner 36mm 1 1 1 1 1 1 1 0215313
9 3.2.4.02 ROE Spanner 41mm 1 1 1 1 1 1 1 0717921
10 3.2.4.02 ROE Spanner 46mm 1 1 1 1 1 1 1 6003613
11 3.2.4.02 ROE Spanner 55mm 1 1 1 1 1 1 1 6003614
12 3.2.4.03 Open End Spanner 17mm 1 1 1 1 1 1 1 6003615
23 3.2.4.04 Shifter 10” 1 1 1 1 1 1 1 2482947
24 3.2.4.04 Shifter 12” 1 1 1 1 1 1 1 2482948
25 3.2.4.05 14” Pipe Wrench 1 1 1 1 1 1 1 2482951
26 3.2.4.06 Multigrip 1 1 1 1 1 1 1 0059336
27 3.2.4.07 Vice Grip 1 1 1 1 1 1 1 2482949
28 3.2.4.08 Allen Key 12mm 1 1 1 1 1 1 1 0014128
29 3.2.4.08 Allen Key 14mm 1 1 1 1 1 1 1 0014129
30 3.2.4.08 Allen Key 17mm 1 1 1 1 1 1 1 0014130
31 3.2.4.09 INHEX Socket ½” drive, 10mm 1 1 1 1 1 1 1 0059530
35 3.2.4.10 Pointed Pry Bar 1 1 1 1 1 1 1 2482521
36 3.2.4.11 Flat File 10” 1 1 1 1 1 1 1 0307679
37 3.2.4.12 Half round File 10” 1 1 1 1 1 1 1 0307697
3720691en – (07) Page 3.2.0 - 5

6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
38 3.2.4.13 Paint Scraper 2” 3 3 3 3 3 3 3 0153425

39 3.2.4.14 Drift Punch Set (6Pcs.) 1 1 1 1 1 1 1 2482941
40 3.2.4.15 Chisel 1 1 1 1 1 1 1 2482952
41 3.2.4.16 Centre Punch 1 1 1 1 1 1 1 0309200
42 3.2.4.17 Wire Brush 3 3 3 3 3 3 3 0059644
43 3.2.4.18 Measuring Tape 5m 1 1 1 1 1 1 1 0661813
44 3.2.4.19 Ball Peen Hammer 1kg 1 1 1 1 1 1 1 0059687
Page 3.2.0 - 6 3720691en – (07)

3.2.5 Miscellaneous
6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
1 3.2.5.01 Sledge Hammer 7kg 1 1 1 1 1 1 1 0059690

2 3.2.5.02 Crow Bar 1500mm 1 1 1 1 1 1 1 1477241
3 3.2.5.02 Crow Bar 1250mm 1 1 1 1 1 1 1 2482520
4 3.2.5.03 2” Paint Brush 3 3 3 3 3 3 3 0014234
5 3.2.5.04 Air Gun 1 1 1 1 1 1 1 Local
6 3.2.5.05 1/4” Air Die Grinder 1 1 1 1 1 1 1 Local
7 3.2.5.05 Cleaning pads for Grinder 10 10 10 10 10 10 10 Local
8 3.2.5.05 Grinding Bit 2 2 2 2 2 2 2 Local
9 3.2.5.06 Air Hose 13x4m 1 1 1 1 1 1 1 0530240
10 3.2.5.07 Electric Angle Grinder 1 1 1 1 1 1 1 Local
11 3.2.5.07 Various disks for angle grinder 10 10 10 10 10 10 10 Local
12 3.2.5.08 Extension Lead (10m) 1 1 1 1 1 1 1 Local
13 3.2.5.09 Control Body – Dye Penetrant Testing 1 1 1 1 1 1 1 6004972
Comparison Body – Magnetic Powder
14 3.2.5.10 1 1 1 1 1 1 1 6004973
Testing
UVA/LUX-Meter – Dye Penetrant &
15 3.2.5.11 1 1 1 1 1 1 1 6004974
Magnetic Powder Testing
16 3.2.5.12 Cleaner – Dye Penetrant Testing 1 1 1 1 1 1 1 6004975
17 3.2.5.13 Developer – Dye Penetrant Testing 1 1 1 1 1 1 1 6004976
18 3.2.5.14 Cleaner – Dye Penetrant Testing 1 1 1 1 1 1 1 6004977
19 3.2.5.15 Dye Penetrant – Dye Penetrant Testing 1 1 1 1 1 1 1 6004978
20 3.2.5.16 Cleaner – Magnetic Powder Testing 1 1 1 1 1 1 1 6004979
Underground – Magnetic Powder Test-
21 3.2.5.17 1 1 1 1 1 1 1 6004980
ing
Magnetic Powder Fluid – Magnetic
22 3.2.5.18 1 1 1 1 1 1 1 6004981
Powder Testing
Hook wrench (1.3 ltr. diaphragm accu-
23 3.2.5.19 1 1 6100264
mulator)
Hook wrench (2,8 ltr. diaphragm accu-
24 3.2.5.20 1 1 1 1 1 6004214
mulator)
3720691en – (07) Page 3.2.0 - 7

3.2.6 Measuring Tools
6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
1 3.2.6.01 PMS Diagnostic: PC-CAN Dongle USB 1 1 1 1 1 1 1 2482239

2 3.2.6.02 PMS Diagnostic: PC-CAN Cable 1 1 1 1 1 1 1 3685323
3 3.2.6.03 PMS Diagnostic: PC-Software 1 1 1 1 1 1 1 2768865
4 3.2.6.04 PMS Diagnostic: PC Notebook WinXP 1 1 1 1 1 1 1 Local
5 3.2.6.05 3-way heavy Duty Coolant Test Kit 1 1 1 1 1 1 1 1469685
Charging and Testing Unit for Nitrogen
6 3.2.6.06 1 1 1 1 1 1 1 6003705
Accumulators (incl. adaptor 6003918)
Adaptor for Nitrogen Bottles G2: GB /
7 3.2.6.06 1441286
Austr.
8 3.2.6.06 Adaptor for Nitrogen Bottles G3: France 1441287
Adaptor for Nitrogen Bottles G4:
9 3.2.6.06 1441288
USA/Mex
Adaptor M28x1,5 – 7/8-14UNF for
10 3.2.6.06 6003918
charging and testing unit
11 3.2.6.07 Pressure Gauge Box 1 1 1 1 1 1 1 1476323
12 3.2.6.08 Oil Analysis Set (Box of 1) 6003611
13 3.2.6.08 Oil Analysis Set (Box of 6) 1 1 1 1 1 1465077
14 3.2.6.08 Oil Analysis Set (Box of 12) 1 1 6003624
15 3.2.6.08 Hand Pump 1465079
16 3.2.6.08 Hose for Hand Pump 1465080
17 3.2.6.09 Dial Gauge 1 1 1 1 1 1 1 2482692
18 3.2.6.09 100mm Extension for Dial Gauge 1 1 1 1 1 1 1 2482693
19 3.2.6.09 60 mm Extension for Dial Gauge 1 1 1 1 1 1 1 2482694
20 3.2.6.09 Magnetic Base for Dial Gauge 1 1 1 1 1 1 1 2482695
21 3.2.6.10 Digital Pressure Check Equipment 1 1 1 1 1 1 1 6003400
22 3.2.6.11 Pressure sensor 60 bar 1 1 1 1 1 1 1 6003401
23 3.2.6.11 Pressure sensor 600bar 6003399
24 3.2.6.11 Straight Fitting 6003798
25 3.2.6.11 90° Fitting 6003799
26 3.2.6.12 Extension Cable 2,5m 6003363
27 3.2.6.12 Extension Cable 5m 6003364
30 3.2.6.13 Power Supply 6003410
31 3.2.6.14 Stroke Gauge for Main Control Valves 1 1 1 1 3715535
32 3.2.6.14 Stroke Gauge for Main Control Valves 1 1 1 1 3715545
33 3.2.6.15 CAMP Test Equipment 1 1 1 1 1 1 1 6003905
34 3.2.6.16 Hydraulic Test Equipment 1 1 1 1 1 1 1 6003979
- spare parts and additional pieces (extensions, adaptors etc.) optional or where necessary
Page 3.2.0 - 8 3720691en – (07)

3.2.7 Support
6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
1 3.2.7.01 Leaver Chain Hoist 1,5 t 2 2 2 2 2 2 2 2482933

2 3.2.7.01 Leaver Chain Hoist 3 t 2 4 4 4 4 4 0219531
3 3.2.7.01 Leaver Chain Hoist 6 t 1 1 1 1 1 1 6004529
4 3.2.7.02 Shackle 3ton 4 4 4 4 4 4 4 2482519
5 3.2.7.02 Shackle 4,75ton 4 4 4 4 4 4 4 2482928
6 3.2.7.02 Shackle 9,5ton 4 4 4 4 6004532
7 3.2.7.02 Shackle 17ton 4 4 4 4 6004531
8 3.2.7.02 Shackle 25ton 4 4 4 6004530
9 3.2.7.03 Lifting Eye Bolt M10 4 4 4 4 4 4 4 2482683
15 3.2.7.03 Lifting Eye Bolt M30 2 2 2 2 2482698
16 3.2.7.03 Lifting Eye Bolt M36 2 2 2482699
17 3.2.7.03 Lifting Eye Bolt M48 2 2 2 2 2 2 2482697
18 3.2.7.03 Lifting Eye Bolt M64 2 2 2 2 2 2 2482696
19 3.2.7.04 4 Leg Chain 5t/10mm 1 1 1 2 2 2 2 6004533
20 3.2.7.05 2 Leg Chain 25t/22mm 1 2 2 4 4 4 4 6004536
21 3.2.7.06 Roll of 3/8” Nylon Rope 1 1 1 1 1 1 1 Local
24 3.2.7.07 Lifting Gear/Slings 1ton, 2m 2168811
25 3.2.7.07 Lifting Gear/Slings 1ton, 3m 2 2 2 2 2 2 2 2168812
- additional lifting gear optional
3720691en – (07) Page 3.2.0 - 9

6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
37 3.2.7.08 30-ton Hydraulic Jack 1 1 1 1 1 1 1 Local
38 3.2.7.09 Hydraulic Hand Pump 800bar 1 1 1 1 1 1 1 6001915
39 3.2.7.10 Hydraulic Cylinder (250kN) 1 1 1 1 1 1 1 6001918
40 3.2.7.10 Hydraulic Cylinder (130kN) 1 1 1 1 1 1 1 6003597
41 3.2.7.11 HP Hose for Hand Pump 1 1 1 1 1 1 1 6001916
42 3.2.7.12 Spirit Level 1m 1 1 1 1 1 1 1 2358109
Wooden Blocks
43 3.2.7.13 10 10 30 30 30 30 30 Local
1 500 mm x 250 mm x 150 mm
Wooden Blocks
44 3.2.7.13 10 10 20 20 20 20 20 Local
750 mm x 250 mm x 150 mm
45 3.2.7.14 Wooden Pallets 2 2 4 4 6 6 6 Local
46 3.2.7.15 Ladder 3m long 1 1 1 1 1 1 1 Local
47 3.2.7.16 Safety Harnesses 2 2 4 4 4 4 4 2482969
48 3.2.7.17 Box of Hand Gloves 1 1 1 1 1 1 1 Local
49 3.2.7.18 Loctite O-ring Set for gluing 1 1 1 1 1 1 1 0925395
50 3.2.7.19 O-Ring Set metric 1 1 1 1 1 1 1 1423537
51 3.2.7.20 O-Ring Set imperial 1 1 1 1 1 1 1 1424013
52 3.2.7.21 Loctite o-ring set Viton 1 1 1 1 1 1 1 2482525
53 3.2.7.22 Seal kit (green) 3/4 to 2" 1 1 1 1 1 1 1 6002000
54 3.2.7.23 Plastic Tarp 5m x 6m 1 1 1 1 1 1 1 2482970
55 3.2.7.24 Torches 2 2 2 2 2 2 2 Local
56 3.2.7.25 Empty 44 Gallon Drums for Waste 2 2 4 4 6 6 6 Local
57 3.2.7.26 Heavy duty plastic Buckets 5 5 10 10 10 10 10 Local
58 3.2.7.27 Hand Grease Pump 1 0 0 0 0 0 0 6004583
Page 3.2.0 - 10 3720691en – (07)

3.2.8 Consumables
6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90
1 3.2.8.01 Tubes of Omnifit 5 5 5 5 5 5 5 1991467

2 3.2.8.02 Assembly Spray for Pins 4 4 8 8 8 8 8 2764305
4 3.2.8.03 Loctite Master Gasket 1 1 6 6 6 6 6 Local
5 3.2.8.04 Loctite Thread Lock 1 1 2 2 2 2 2 Local
6 3.2.8.05 Paint stripper 5L 10L 10L 10L 10L 10L 10L Local
7 3.2.8.06 Solvent to remove rust inhibitor 20L 20L 40L 40L 60L 60L 60L Local
8 3.2.8.07 Sandpaper (fine) 2 2 2 2 2 2 2 Local
9 3.2.8.08 Sandpaper (coarse) 2 2 2 2 2 2 2 Local
10 3.2.8.09 Bag of Rags 2 4 4 6 6 6 6 Local
3.2.9 Service Adapters

6015/FS
6018/FS
6030/FS
6040/FS
6050/FS
6060/FS
6090/FS
RH 120
RH 170
RH 200
RH 340
RH 400
RH 40
RH 90

1 3.2.9.01 Gear Oil refilling Adapter 1960234

2 3.2.9.02 Engine Oil refilling Adapter 1960235
3 3.2.9.03 Hydraulic Oil refilling Adapter 1960236
4 3.2.9.04 Coolant Water refilling Adapter 2764855
5 3.2.9.05 Grease refilling Adapter 1960731
6 3.2.9.06 Diesel refilling Adapter 1438372
- used for service lift connection to refill fuel, grease etc.

necessary should service vehicle not have been equipped already
3720691en – (07) Page 3.2.0 - 11

Page 3.2.0 - 12 3720691en – (07)

3.2.1 TORQUE TOOLS
Pos. 3.2.1.01
Hydraulic Drive Unit (240V)
Part No.:
6002267
Only torque adjustable
Fig.641567
Pos. 3.2.1.02
Hydraulic Drive Unit (240V)
Part No.:
1478386
Torque and angle adjustable
Fig.641505
Pos. 3.2.1.03
HP Hose Set (6x5m)
Part No.:
2470564
Coupling type 716
Fig.641699
3720692en – (02) Page 3.2.1 - 1

3.2.1 TORQUE TOOLS
Pos. 3.2.1.04
Hydraulic Torque Wrench MXT
Part No.:
1 MXT:
200 – 1.850 NM 2482923
¾” drive
3 MXT:
450 – 4.450 Nm 2470558
1” drive
5 MXT
800 – 7.700Nm 6003121
1½” drive
20 MXT
2.800 – 27.000Nm 6003104
2½” drive
Fig.641510
Pos. 3.2.1.05
Impact Socket ¾” drive (double hex)
Part No.:
30mm 2482959
32mm 6004549
36mm 6003598
41mm 6003599
46mm 6003601
Fig.641512
Pos. 3.2.1.06
Impact Socket 1” drive (double hex)
Part No.:
32mm 6004537
36mm 1434705
41mm 1434706
46mm (Ø 69 mm) 1434707
46mm (Ø 65 mm) 6100296
55mm 1434709
60mm 1434710
95mm 6003610
Fig.641512
Page 3.2.1 - 2 3720692en – (02)

3.2.1 TORQUE TOOLS
Pos. 3.2.1.07
Impact Socket 1 ½” drive (double hex)
Part No.:
36mm 1461521
46mm 1461523
50mm 1461524
55mm 1461525
60mm 6003602
65mm 6003603
70mm 6003604
75mm 1461528
Fig.641512
Pos. 3.2.1.08
Impact Socket 2 ½” drive (double hex)
Part No.:
95mm 2482837
Fig.641512
Pos. 3.2.1.09
Hydraulic Torque Wrench “Stealth”
Part No.:
Stealth 2, 41mm
6003868
(170 – 2.400Nm)
Stealth 4, 55mm
(400 – 5.500Nm) 6003869
Only for RH120
Stealth 8, 65mm
6003870
(800 – 11.000Nm)
Fig.641511
3720692en – (02) Page 3.2.1 - 3

3.2.1 TORQUE TOOLS
Pos. 3.2.1.10
Hydraulic Torque Wrench XLCT
Part No.:
Drive 1477300
Ratchet Insert
1477299
(55mm)
550 – 5450 Nm
Extra flat ratchet insert for tightening

swing bearing on RH170, RH200 and
RH340.
Fig.641830
Pos. 3.2.1.11
Torque multiplier 1½” drive
Part No.:
XVR 40
1437544
Max. torque 4000 Nm
XVR 65
1448441
Max. torque 6200 Nm
Input drive: ¾”
Output drive: 1½”
Fig.641694
Pos. 3.2.1.12
½” Torque Wrench
Part No.:
Torque range:
1446762
60 – 300 Nm
Includes ½” on ¾” adapter for use

with XVR 40 and XVR 65 (Part No.
1437544 + 1448441)
Fig.641574
Page 3.2.1 - 4 3720692en – (02)

3.2.1 TORQUE TOOLS
Set-up when working with XVR 40 and XVR 65
Fig. 640099
Pos 3.2.1.13
Torque wrench DSG 6
Part No.:
Torque range:
1331433
500 – 1300 Nm
Fig.641529
Pos 3.2.1.14
Torque wrench DSG 7
Part No.:
Torque range:
0900890
800 – 2000 Nm
Fig.641529
3720692en – (02) Page 3.2.1 - 5

3.2.1 TORQUE TOOLS
Pos 3.2.1.15
Flat ring spanner insert for DSG 6 + DSG 7
Part No.:
36mm 1590922
41mm 0900891
46mm 1740801
55mm 1740115
Fig.641531
Pos. 3.2.1.16
Ratchet Insert for DSG 6 + DSG 7
1” drive Part No.:
Ratchet Insert 1472005
Repair Kit 1472006
Fig.641530
Pos. 3.2.1.17
Air Impact Gun ½” drive
Part No.:
max 490Nm 2482463
Fig.641509
Page 3.2.1 - 6 3720692en – (02)

3.2.1 TORQUE TOOLS
Pos. 3.2.1.18
Metric Ratchet and Socket Set ½” drive
Part No.:
10 - 32mm double hex 0559027
Fig.641696
Pos. 3.2.1.19
½” drive metric Socket Set
Part No.:
4-19mm 2482522
Fig.641698
Pos. 3.2.1.20
Air Impact Gun ¾” drive
Part No.:
~900Nm 2482462
Fig.641568
3720692en – (02) Page 3.2.1 - 7

3.2.1 TORQUE TOOLS
Pos. 3.2.1.21
Metric Ratchet and Socket Set ¾” drive
Part No.:
22 – 50mm double hex 2482464
Fig.641697
Pos. 3.2.1.22
Air Impact Gun 1” drive
Part No.:
Max 2750Nm 2482461
Fig.640098
Pos. 3.2.1.23
Metric Ratchet and Socket Set 1” drive
Part No.:
36 – 80mm double hex 2482523
Fig.641695
Page 3.2.1 - 8 3720692en – (02)

3.2.1 TORQUE TOOLS
Pos. 3.2.1.24
Adaptor for socket wrenches
Part No.:
1” to ¾” 2482471
1 ½” to 1” 1431749
Fig.641542
Pos. 3.2.1.25
Impact Extension 1”drive
Part No.:
6” extension 2482956
12” extension 2482957
Fig.641503
Pos. 3.2.1.26
Universal Joint
Part No.:
For ½” drive 2482955
Fig.641534
3720692en – (02) Page 3.2.1 - 9

3.2.1 TORQUE TOOLS
Page 3.2.1 - 10 3720692en – (02)

3.2.2 CUTTING AND TAPPING TOOLS
Pos. 3.2.2.01
Hacksaw
Part No.:
Hacksaw 0059324
Spare hacksaw
0060784
blades
Fig. 641513
Pos. 3.2.2.02
Taps
Part No.:
M6 x 1 0059912
M8 x 1,25 0059915
M10 x 1,5 0059918
M12 x 1,75 0059925
M14 x 2 6003618
M16 x 2 0059929
M20 x 2,5 0157223
M24 x 3 0157226
M27 x 3 6003619
M30 x 3,5 6003620
M36 x 4 6003621
M39 x 4 6003622
M42 x 3 2739509
M48 x 5 6003623
M64 x 4 6004426
No sets, only one plug type tap to retap

thread holes prior to assembly.
Fig.641518
3720694en - (01) Page 3.2.2 - 1

3.2.2 CUTTING AND TAPPING TOOLS
Page 3.2.2 - 2 3720694en - (01)

3.2.3 ELECTRIC TOOLS
Pos. 3.2.3.01
Electric Connector Assortment
Part No.:
2482882
Fig. 641526
Pos. 3.2.3.02
Bootlace ferrule Assortment
Part No.:
2482529
Fig. 641527
Pos. 3.2.3.03
Tool Set
Part No.:
1190887
Fig. 641582
3720698en - (00) Page 3.2.3 - 1

Pos. 3.2.3.04
Digital Multimeter
Part No.:
1088932
Includes test leads
Optional croc clips:

Pincers red 0764860
Pincers black 0764861
Fig. 641520
Pos. 3.2.3.05
Installation Bar for Grounding Cable Harness
Part No.:
1791163
for electric power train only
Fig. 640095
Pos. 3.2.3.06
Grounding Cable Harness
Part No.:
0925649
Fig. 640094
Page 3.2.3 - 2 3720698en - (00)

Pos. 3.2.3.07
Cable Hook
Part No.:
2270413
Fig. 640092
Pos. 3.2.3.08
Fuse Tool
Part No.:
1725313
Fig. 640093
Pos. 3.2.3.09
High Voltage Tester
Part No.:
0255962
Fig. 640097
3720698en - (00) Page 3.2.3 - 3

Page 3.2.3 - 4 3720698en - (00)

3.2.4 HAND TOOLS
Pos. 3.2.4.01
Ring Open End Spanner Set DIN 3113
Part No.:
Metric:
2482524
6mm – 32mm
Imperial:
2482944
¼”-1¼”
Fig. 641506
Pos. 3.2.4.02
Ring Open End Spanner DIN 3113
Part No.:
15mm 0717906
17mm 6003612
19mm 0717908
22mm 0717911
24mm 0717913
36mm 0215313
41mm 0717921
46mm 6003613
55mm 6003614
Fig. 641502
Pos. 3.2.4.03
Open End Spanner DIN 894
Part No.:
17mm 6003615
19mm 0014079
22mm 0014080
24mm 0014082
27mm 0014083
30mm 0014084
32mm 0014085
36mm 0014086
41mm 0014087
46mm 6003616
55mm 0014088
Fig. 641533
3720693en - (00) Page 3.2.4 - 1

3.2.4 HAND TOOLS
Pos. 3.2.4.04
Shifter
Part No.:
10“ 2482947
12“ 2482948
Fig. 641508
Pos. 3.2.4.05
Pipe Wrench 14”
Part No.:
2482951
Fig. 641507
Pos. 3.2.4.06
Multigrip
Part No.:
0059336
Fig. 641519
Page 3.2.4 - 2 3720693en - (00)

3.2.4 HAND TOOLS
Pos. 3.2.4.07
Vice Grip
Part No.:
2482949
Fig. 641566
Pos. 3.2.4.09
Allen Key Large
Part No.:
12mm 0014128
14mm 0014129
17mm 0014130
Fig. 641501
Pos. 3.2.4.10
INHEX Socket ½” drive
Part No.:
10mm 0059530
12mm 6003617
14mm 0717951
17mm 0511683
Fig. 641543
3720693en - (00) Page 3.2.4 - 3

3.2.4 HAND TOOLS
Pos. 3.2.4.11
Pointed pry bar
Part No.:
2482521
Fig. 641823
Pos. 3.2.4.12
Flat File
Part No.:
10” 0307679
Fig. 641517
Pos. 3.2.4.13
Half round File
Part No.:
10” 0307697
Fig. 641517
Page 3.2.4 - 4 3720693en - (00)

3.2.4 HAND TOOLS
Pos. 3.2.4.14
Paint Scraper
Part No.:
2” 0153425
Fig. 641571
Pos. 3.2.4.15
Drift Punch Set
Part No.:
6 Pcs. 2482941
Fig. 641565
Pos. 3.2.4.16
Chisel
Part No.:
300x23x13 2482952
Fig. 641546
Pos. 3.2.4.17
Centre Punch
Part No.:
0309200
3720693en - (00) Page 3.2.4 - 5

3.2.4 HAND TOOLS
Fig. 641514
Pos. 3.2.4.18
Wire Brush
Part No.:
0059644
Fig. 641515
Pos. 3.2.4.19
Measuring Tape
Part No.:
5m 0661813
Fig. 641547
Pos. 3.2.4.20
Ball peen hammer
Part No.:
1kg 0059687
Fig. 641572
Page 3.2.4 - 6 3720693en - (00)

3.2.5 MISCELLANEOUS
Pos. 3.2.5.01
Sledge Hammer
Part No.:
Weight 7kg 0059690
Fig.641563
Pos. 3.2.5.02
Crow Bar
Part No.:
1500mm 1477241
1250mm 2482520
Fig.641824
Pos. 3.2.5.03
Paint brush 2“
Part No.:
0014234
Fig.641536
3720695en – (02) Page 3.2.5 - 1

3.2.5 MISCELLANEOUS
Pos. 3.2.5.04
Air gun
Part No.:
Local
Fig.641561
Pos. 3.2.5.05
Air Grinder
Part No.:
Grinder
Cleaning Pads Local
Grinding bit
Fig.641578
Pos. 3.2.5.06
Air Hose 13x4m
Part No.:
For pneumatic tools 0530240
Fig.641535
Page 3.2.5 - 2 3720695en – (02)

3.2.5 MISCELLANEOUS
Pos. 3.2.5.07
Electric Angle Grinder
Part No.:
Diameter 5“ / 125 mm
Various disks for local
angle grinder
Fig.641552
Pos. 3.2.5.08
Extension Lead 10m
Part No.:
local
Fig.641573
3720695en – (02) Page 3.2.5 - 3

3.2.5 MISCELLANEOUS
Pos. 3.2.5.09
Control Body – Dye Penetrant Testing
Part No.:
See SM 2013-001 6004972
Fig.645720
Pos. 3.2.5.10
Comparison Body – Magnetic Powder Testing
Part No.:
See SM 2013-001 6004973
Fig.645721
Page 3.2.5 - 4 3720695en – (02)

3.2.5 MISCELLANEOUS
Pos. 3.2.5.11
UVA/LUX-Meter – Dye Penetrant & Magnetic Powder Testing
Part No.:
See SM 2013-001 6004974
Fig.645722
Pos. 3.2.5.12
Cleaner – Dye Penetrant Testing
500 ml
“Cold/Artic” Regions Part No.:
-30⁰C up to +10⁰C
See SM 2013-001 6004975
Fig.645718
3720695en – (02) Page 3.2.5 - 5

3.2.5 MISCELLANEOUS
Pos. 3.2.5.13
Developer – Dye Penetrant Testing
500 ml
“Cold/Artic” Regions
(-30⁰C up to +10⁰C) & Part No.:
& “Hot” Regions
(+10⁰C up to +50⁰C)
See SM 2013-001 6004976
Fig.645718
Pos. 3.2.5.14
Cleaner – Dye Penetrant Testing
500 ml
“Cold/Artic” Regions
(-30⁰C up to +10⁰C) & Part No.:
& “Hot” Regions
(+10⁰C up to +50⁰C)
See SM 2013-001 6004977
Fig.645718
Page 3.2.5 - 6 3720695en – (02)

3.2.5 MISCELLANEOUS
Pos. 3.2.5.15
Dye Penetrant – Dye Penetrant Testing
500 ml
“Hot” Regions Part No.:
(+10⁰C up to +50⁰C)
See SM 2013-001 6004978
Fig.645718
Pos. 3.2.5.16
Cleaner – Magnetic Powder Testing
500 ml
(+10⁰C up to +50⁰C)
See SM 2013-001 6004979
Fig.645719
3720695en – (02) Page 3.2.5 - 7

3.2.5 MISCELLANEOUS
Pos. 3.2.5.17
Underground – Magnetic Powder Testing
500 ml
(+10⁰C up to +50⁰C)
See SM 2013-001 6004980
Fig.645719
Pos. 3.2.5.18
Magnetic Powder Fluid – Magnetic Powder Testing
500 ml
(+10⁰C up to +50⁰C)
See SM 2013-001 6004981
Fig.645719
Page 3.2.5 - 8 3720695en – (02)

3.2.5 MISCELLANEOUS
Pos. 3.2.5.19
Hook wrench (1.3 ltr. diaphragm accumulator)
Part No.:
6100264
Fig. 646270
Pos. 3.2.5.20
Hook wrench (2.8 ltr. diaphragm accumulator)
Part No.:
6004214
Fig. 646270
3720695en – (02) Page 3.2.5 - 9

3.2.5 MISCELLANEOUS
Page 3.2.5 - 10 3720695en – (02)

3.2.6 MEASURING TOOLS
Pos. 3.2.6.01
PC-CAN USB Dongle
Part No.:
2482239
Fig. 642389
Pos. 3.2.6.02
PC-CAN Cable
Part No.:
3685323
Fig. 642390
Pos. 3.2.6.03
PC-Software
Part No.:
2768865
Fig. 642392
3720699en – (03) Page 3.2.6 - 1

Pos. 3.2.6.04
PC-Notebook with Software Win XP
Part No.:
Local
Fig. 641693
Pos. 3.2.6.05
3-Way heavy duty coolant test kit
Part No.:
1469685
Cummins engines only
Fig.641832
Page 3.2.6 - 2 3720699en – (03)

Pos. 3.2.6.06
Filling and testing Device for Accumulators
Part No.:
6003705
Adapter M28x1,5 – 7/8-14UNF

6003918
Filling and testing device 6003705
includes adapter 6003918
Adaptor for nitrogen bottles

GB / Australia 1441286
France 1441287
USA / Mexico 1441288
Fig. 646271
Pos. 3.2.6.07
Pressure Gauge Box
Part No.:
1476323
Contents:
2 x 600bar
1 x 250bar
1 x 60bar
Fig.630641
3720699en – (03) Page 3.2.6 - 3

Pos. 3.2.6.08
Oil-Analysis Set No. 1
Part No.:
Box of 1 6003611
Box of 6 1465077
Box of 12 6003624
Analysis of gear oil, hydraulic oil and
engine oil.
Accessories:
Part No.:
Hand Pump 1465079
Hose for Pump 1465080
Bild 641833
Pos. 3.2.6.09
Dial Gauge
Part No.:
2482692
100 mm Extension 2482693

60 mm Extension 2482694
Magnetic Base 2482695
Fig.641581
Pos. 3.2.6.10
Digital Pressure Check Equipment
Page 3.2.6 - 4 3720699en – (03)

Part No.:
6003400
Includes:
 Measuring Instrument
 Power Supply with adaptors
 2 Pressure Sensors (600bar) with
2,5m cables
 2 Fittings (minimess M16x2)
Fig.641825
Pos. 3.2.6.11
Pressure Sensor
Part No.:
60bar 6003401
600bar 6003399
Straight Fitting 6003798

90° Fitting 6003799
For use with Digital Pressure Check

Equipment
Fig.641826
3720699en – (03) Page 3.2.6 - 5

Pos. 3.2.6.12
Extension Cable
Part No.:
2,5m 6003363
5m 6003364
10m 6003365
25m 6003366

Equipment
Fig.641827
Pos. 3.2.6.13
Power Supply
Part No.:
6003410

Equipment
Fig.641828
Pos. 3.2.6.14
Stroke Gauge for Main Control Valves
Part No.:
RH40E / 6015,
RH90C / 6018,
3715535
RH120E / 6030,
RH340B / 6060B
RH170B / 6040,
RH200 / 6050,
3715545
RH340A / 6060A,
RH400 / 6090
Fig. 642780
Page 3.2.6 - 6 3720699en – (03)

Pos. 3.2.6.15
CAMP Test Equipment
Part No.:
RH120E / 6030,
RH340B / 6060B 6003905
RH400 / 6090
Fig. 645723
Pos. 3.2.6.16
Hydraulic Test Equipment
Part No.:
RH40E / 6015
RH90C / 6018
6020B
RH120E / 6030
6003979
RH170B / 6040
RH200 / 6050
RH340B / 6060B
RH400 / 6090
Fig. 645724
3720699en – (03) Page 3.2.6 - 7

Page 3.2.6 - 8 3720699en – (03)

3.2.7 SUPPORT
Pos. 3.2.7.01
Leaver Chain Hoist
Part No.:
Load bearing capacity
2482933
Max. 1,5t
0219531
Max. 3t
6004529
Max. 5t
Fig.641528
Pos. 3.2.7.02
Shackle
Part No.:
3 ton 2482519
4,75 ton 2482928
9,5ton 6004532
17ton 6004531
25ton 6004530
Fig.641579
Pos. 3.2.7.03
Lifting Eye Bolts
Thread size Part No.:
M10 2482683
M12 2482702
M14 2482681
M16 2482701
M20 2482968
M24 2482700
M30 2482698
M36 2482699
M48 2482697
M64 2482696
Fig.641831
3720696en - (04) Page 3.2.7 - 1

3.2.7 SUPPORT
Pos. 3.2.7.04
4 Leg Chain
Part No.
5t/10mm 6004533
Fig. 642663
Pos. 3.2.7.05
2 Leg Chain
Part No.
25t/22mm 6004536
Fig. 642662
Pos. 3.2.7.06
Nylon Rope
Part No.:
3/8”
½” local
5/8”
Fig.641548
Page 3.2.7 - 2 3720696en - (04)

3.2.7 SUPPORT
Pos. 3.2.7.07
Lifting Gear/Slings
Part No.:
1 ton, 2m 2168811
1 ton, 3m 2168812
1 ton, 4m 2168813
2 ton, 2m 2168814
2 ton, 3m 2168815
2 ton, 4m 2168816
2 ton, 6m 2168817
3 ton, 4m 2168818
3 ton, 6m 2168819
4 ton, 4m 2168820
4 ton, 6m 2168821
5 ton, 3m 6004527
5 ton, 5m 6004528
Fig.641580
Pos. 3.2.7.08
30t Porta Power Ram
Part No.:
Local
Fig.641577
Pos. 3.2.7.09
Hydraulic Hand Pump
Part No.:
800bar
6001915
¼” thread
For use with hydraulic cylinders (part

no. 6001918 and 6003597)
Fig.641834
3720696en - (04) Page 3.2.7 - 3

3.2.7 SUPPORT
Pos. 3.2.7.10
Hydraulic Cylinder
Part No.:
250kN
6001918
Diameter: 85mm
130kN
6003597
Diameter: 65mm
Fig.641821
Pos. 3.2.7.11
HP Hose for Hand Pump
Part No.:
800bar
¼” fitting 6001916
Length: 2m
Fig.641822
Pos. 3.2.7.12
Spirit Level 1m
Part No.:
2358109
Fig.641559
Page 3.2.7 - 4 3720696en - (04)

3.2.7 SUPPORT
Pos. 3.2.7.13
Hard Wood Blocks
Dimensions L x B x H Part No.:
1500x250x150
local
750x250x150
Fig.641540
Pos. 3.2.7.14
Wooden Pallets
Part No.:
local
Fig.641541
Pos. 3.2.7.15
Ladder 3m
Part No.:
local
Fig.641562
3720696en - (04) Page 3.2.7 - 5

3.2.7 SUPPORT
Pos. 3.2.7.16
Safety Harness
Part No.:
2482969
Fig.641538
Pos. 3.2.7.17
Gloves
Part No.:
local
Fig.641537
Pos. 3.2.7.18
Loctite O-Ring Set for gluing
Part No.:
0925395
Fig. 641835
Page 3.2.7 - 6 3720696en - (04)

3.2.7 SUPPORT
Pos. 3.2.7.19
O-Ring Set metric, Perbunan
Part No.:
Diameter 3 – 42 mm 1423537
Fig.641545
Pos. 3.2.7.20
O-Ring Set imperial, Perbunan
Part No.:
Diameter 2,9 –
1424013
43,82mm
Fig.641545
Pos. 3.2.7.21
Loctite O-Ring Set, Viton
Part No.:
Diameter 18 – 50mm 2482525
Fig.641545
3720696en - (04) Page 3.2.7 - 7

3.2.7 SUPPORT
Pos. 3.2.7.22
Seal Set for Hoses and Pipes
Part No.:
Diameter 3/4“ to 2“ 6002000
Fig.641560
Pos. 3.2.7.23
Plastic Tarp 5x6 m
Part No.:
2482970
Fig.641539
Pos. 3.2.7.24
Torch
Part No.:
local
Fig.641549
Page 3.2.7 - 8 3720696en - (04)

3.2.7 SUPPORT
Pos. 3.2.7.25
Empty Barrels 44Gal / 167L
Part No.:
local
Fig.641553
Pos. 3.2.7.26
Buckets
Part No.:
local
Fig.641575
Pos. 3.2.7.27
Hand Grease Pump
Part No.:
pump 6004583
Required only for RH40 / 6015 machines to fill

grease container
Fig.642779
3720696en - (04) Page 3.2.7 - 9

3.2.7 SUPPORT
Page 3.2.7 - 10 3720696en - (04)

3.2.8 CONSUMABLES
Pos. 3.2.8.01
Tubes of Omnifit
Part No.:
1991467
Fig.641554
Pos. 3.2.8.02
Assembly Spray for Pins
Part No.:
2764305
Fig.641555
Pos. 3.2.8.03
Loctite Master Gasket
Part No.:
Local
Fig. 641692
3720697en - (00) Page 3.2.8 - 1

3.2.8 CONSUMABLES
Pos. 3.2.8.04
Loctite Thread Lock
Part No.:
Local
Fig. 641691
Pos. 3.2.8.05
Paint Stripper
Part No.:
Local
Fig. 640096
Pos. 3.2.8.06
Solvent to remove Rust Inhibitor
Part No.:
Local
Fig.641557
Page 3.2.8 - 2 3720697en - (00)

3.2.8 CONSUMABLES
Pos. 3.2.8.07
Sandpaper fine
Part No.:
Local
Fig.641570
Pos. 3.2.8.08
Sandpaper coarse
Part No.:
Local
Fig.641570
Pos. 3.2.8.09
Bag of rags
Part No.:
Local
Fig.641576
3720697en - (00) Page 3.2.8 - 3

3.2.8 CONSUMABLES
Page 3.2.8 - 4 3720697en - (00)

3.2.9 SERVICE ADAPTORS
Pos. 3.2.9.01
Gear Oil refilling Adaptor
Part No.:
1960234
Fig. 640070
Pos. 3.2.9.02
Engine Oil refilling Adaptor
Part No.:
1960235
Fig. 640071
Pos. 3.2.9.03
Hydraulic Oil refilling Adaptor
Part No.:
1960236
Fig. 640072
3721419en - (00) Page 3.2.9 - 1

3.2.9 SERVICE ADAPTORS
Pos. 3.2.9.04
Coolant Water refilling Adaptor
Part No.:
2764855
Fig. 640074
Pos. 3.2.9.05
Grease refilling Adaptor
Part No.:
1960731
Fig. 640075
Pos. 3.2.9.06
Diesel / Fuel refilling Adaptor
Part No.:
1438372
Fig. 640076
Page 3.2.9 - 2 3721419en - (00)

08.2018
4. Undercarriage
6040

CONTENTS
4. UNDERCARRIAGE
4.1 Introduction....................................................................................... 4.1 - 1
4.1.1 Foreword ........................................................................... 4.1 - 1
4.1.2 Safety ................................................................................ 4.1 - 1
4.1.3 General .............................................................................. 4.1 - 5
4.2 Travel system.................................................................................... 4.2 - 1
4.2.1 General .............................................................................. 4.2 - 1
4.2.2 Components of travel system ............................................ 4.2 - 1
4.2.3 Wear limits ......................................................................... 4.2 - 4
4.3 Track chain ....................................................................................... 4.3 - 1
4.3.1 General .............................................................................. 4.3 - 1
4.3.2 Components of Track chain ............................................... 4.3 - 1
4.3.3 Assembly ........................................................................... 4.3 - 2
4.3.3.1 Opening the track chain .................................... 4.3 - 2
4.3.3.2 Closing the track chain ..................................... 4.3 - 3
4.4 Idler .................................................................................................... 4.4 - 1
4.4.1 General .............................................................................. 4.4 - 1
4.4.2 Components of the idler..................................................... 4.4 - 1
4.4.3 Assembly of the idler ......................................................... 4.4 - 3
4.5 Bottom roller ..................................................................................... 4.5 - 1
4.5.1 General .............................................................................. 4.5 - 1
4.5.2 Components of the bottom roller ....................................... 4.5 - 1
4.5.3 Bottom roller installation .................................................... 4.5 - 4
3720204en – (00) Page 4 - 1

CONTENTS
4.6 Top roller ........................................................................................... 4.6 - 1
4.6.1 General .............................................................................. 4.6 - 1
4.6.2 Components of the top roller ............................................. 4.6 - 1
4.6.3 Top roller installation.......................................................... 4.6 - 4
4.7 Sprocket ............................................................................................ 4.7 - 1
4.8 Travel gearbox – removal and installation ..................... see chapter 7.2
4.9 Track pads ....................................................................................... 4.9 – 1
4.10 Hydraulic track tensioning system .............................................. 4.10 – 1
4.10.1 General ........................................................................... 4.10 – 1
4.10.2 Components ................................................................... 4.10 – 1
4.10.3 Releasing the track tension ............................................ 4.10 – 4
4.10.4 Checking the accumulators ............................................. 4.10 - 4
4.11 Duo cone seals ............................................................................... 4.11 - 1
Page 4 - 2 3720204en – (00)

4.1 UNDERCARRIAGE
4.1 Introduction 4.1.2 Safety Instructions
4.1.1 Foreword Danger in case of non-observance of safety

instructions
The Service Manual contains important informa-
tion for personnel servicing the machine. Machine This Caterpillar hydraulic excava-
technical data listed in other machine documents tor has been built in accordance
are not always repeated in this book. with state-of-the-art standards and
the recognized safety rules.
The documentation of a Caterpillar mining machine
includes: However, operating the machine if
a fault is suspected or has oc-
 Operation and Maintenance Manual curred, or carrying out repair work
inexpertly
  endangers the lives of people in
 Service Manual contact with it
 damages the machine and other

The service manual does not contain technical property.
data on auxiliary units for the operation of specific
or optional equipment or data of individual devices. Stop the hydraulic excavator im-
The refilling quantities specified for consumables any damage to ensure the safety of
are approximate quantities which are intended as a the operator, other people or mate-
help for planning consumable requirements. rial property at the application area
of the excavator.
Each component is equipped with suitable check- All components of Caterpillar ma-
ing devices, e.g. a dipstick or checking plugs, per- chines are perfectly tuned to each
mitting the operator to check exactly the filling of other. Trouble-free operation and a
the components.
spare parts.
3849049en - (00) Page 4.1 - 1

4.1 UNDERCARRIAGE
Personnel
Personnel
The machine must not be started
by unauthorized people. Personal protective equipment and
safety working clothing:
Therefore secure and lock it.
Follow the accident prevention wear and safety gloves.
regulations.
Only specially trained and qualified ing when working on the machine.
personnel with the appropriate Loose, wide garments can catch on
technical knowledge can operate, machine parts and result in injury.
service or repair the hydraulic ex-
cavator. Personnel carrying out work at
If you lack such knowledge, ex- harnesses. Always put on a tested
perienced personnel, e.g. from harness which is equipped with fall
Caterpillar, are to give you detailed arrestors and safety lines.
instructions.
The personnel must have read and the work, e.g. marshallers, clearly
understood the Operation and define the responsibilities of each
Maintenance Manual and in par- assistant beforehand. The individ-
ticular the chapter ual responsibilities are to be care-
‘Fundamental Safety Instructions.’ fully observed to ensure safety.

Page 4.1 - 2 3849049en - (00)

4.1 UNDERCARRIAGE
Tools and devices Before opening systems and units

(e.g. pipes, coolers, hydraulic res-
Tools, hoists, slings, trestles and ervoirs and accumulators) depres-
other devices must be in a reliable, surize them properly.
safe state.
Metal splinters may cause injury on moving machine parts only
when you take in or out attachment when the drive unit is shut down
bolts. Therefore during this proce- and secured against inadvertent
dure use a brass or copper man- start.
When climbing onto or off the ma- protective devices.
forms and handrails provided for Before carrying out assembly work,
this purpose. the machine and the equipment
Always keep ladders, steps and tent movement, e.g. by placing the
platforms in a non-slip state. Re- working equipment on the ground.
immediately.
system:
Securing the working equip- Always observe the safety regula-
ment tions applicable to the product
when handling oils, greases and
Secure the machine and the work- other chemical substances.
and unauthorized start. Position Close open unused bores, pipe and
working equipment on the ground hose connections so that they are
in such a way that it cannot move impermeable to pressure.
when mechanical or hydraulic Refill the hydraulic system with
connections become detached. collected drain hydraulic oil only
Use hoists or other appropriate through the return flow filters. Dis-
support devices when you install, pose of waste oil without polluting
remove or displace any equipment the environment.
or component. Thus you prevent Observe the correct working se-
them from inadvertent movements, quence when fitting or replacing
slip or fall. components or equipment.
3849049en - (00) Page 4.1 - 3

4.1 UNDERCARRIAGE

Before carrying out works, espe-
cially on the electrical system, dur- Unauthorized conversions or modi-
ing which tools, spare parts, etc. fications of the hydraulic excavator
can contact electric cables, always are forbidden for reasons of safety.
Never modify the nominal pressure
value of pressure relief valves
erpillar. Do not remove the lead
Always replace defective, me- and hydraulic accumulators.
vice Manual contains no informa-
tion on such work. Re-commissioning

ables have at least the same tem- Before re-commissioning:
Be careful when handling acids,  Check all oil levels and correct
e.g. battery acid. Acid splashes them if necessary.
may injure the eyes and the skin.
 Carry out function checks of all
If the acid is splashed onto your repaired components.
skin, rinse it with plenty of clean
running water and seek medical  Check all functions of the exca-
care immediately. vator including brakes during a
If the acid is splashed in your eyes, test run. Release the hydraulic
rinse thoroughly with running wa- excavator for re-commissioning
ter and seek medical care immedi- only if all its functions operate
ately. properly.
Never smoke when handling flam-

mable liquids.
Be careful with open flames and
unprotected light. Not only fuel but
also other consumables often have
easily.
Page 4.1 - 4 3849049en - (00)

4.1 UNDERCARRIAGE
4.1.3 General
This Service Manual contains information in addi-

tion to the Operation and Maintenance Manual The Service Manual covers the information you
and the Spare Parts Catalog, to familiarise the need when handling your excavator. However,
personnel with the designated use, maintenance Caterpillar Global Mining HMS GmbH will be
and repair of the Caterpillar excavator. pleased to answer any questions you have on its
products. Please contact your local Caterpillar
The information in the Service Manual corre- dealer or your Caterpillar subsidiary.

They do not represent the actual design of the ma-
chine and are not to be used for manufacturing.

3849049en - (00) Page 4.1 - 5

4.1 UNDERCARRIAGE
Page 4.1 - 6 3849049en - (00)

4.2 TRAVEL SYSTEM
4.2 Travel system

4.2.1 General
The hydraulic excavator is equipped with a low-
maintenance undercarriage. Track pad and chain
link are forming one unit.
4.2.2 Components of travel system
Weight
Ref. no. Quantity Designation Further remarks [kg]
1 1 Carbody See chapter 4.2.2.1 26 780
2 1 Track frame See chapter 4.2.2.1 11 830
3 1 Track frame 11 830
50 2 Travel gearbox See chapter 7.2 7 600 each
51 2 Track tensioning system See chapter 4.4 4 150 each
52 14 Bottom roller See chapter 4.5 645 each
53 2 Support roller See chapter 4.6 445 each
54 94 Track link (2 x 47) See chapter 4.3
Track chain 1 200 mm: 505 each
55 2 Idler See chapter 4.4 2 645 each
56 2 Sprocket See chapter 4.7 2 170 each
57 4 Travel motor See chapter 7.2 143 each
58 72 Washer
59 72 Hex bolt M 30 x 220 – 12.9 Tightening torque = 2 250 Nm
Table 1
3849036en - (00) Page 4.2 - 1

4.2 TRAVEL SYSTEM
Fig. 1 Travel system – 2471551-02
Page 4.2 - 2 3849036en - (00)

4.2 TRAVEL SYSTEM
59
Fig. 2 Travel system – 3730806-01
3849036en - (00) Page 4.2 - 3

4.2 TRAVEL SYSTEM
4.2.2.1 Mounting track frames

Clean the contact surfaces between carbody and Tighten bolts pos. 9 and 10 with Plarad HPA 500
track frame with solvent from rust, paint and torquing tool, or similar.
grease to be metallically shiny.
Tighten bolts (9) at position a1, a2, a3 and a4 in
Apply adhesive (e.g. Omnifit) with approx. 10 mm fig. 4 hand tight, resp. until the track frame is in
clearance from the threaded holes to one of the contact with the superstructure.
contact surfaces. Ensure that no adhesive can be
forced into the threaded holes. Tighten bolts (10, Fig. 4) with a pre-torque of 600
Nm.
The threads and the heads of the mounting bolts
have to be slightly oiled and must not come into Tighten bolts pos. 9:
contact with the adhesive. Pre-torque = 1100 Nm
Turning angle = 90°
Tighten bolts pos. 10:

Start installation as soon as the
Pre-torque = 600 Nm
adhesive has been applied.
Turning angle = 60°
The adhesive starts hardening
when the metal surfaces have been
joined without any air being admit-
ted and is completed after approx.
48 hours at an ambient tempera-
ture of approx. 20°C.
The hardening process is initially
strongly delayed, so that the instal-
lation time can be extended to a
maximum of 8 hours.
At temperatures below -10°C, an
activator must be sprayed onto the
second joining surface - the sur-
face with no adhesive.
Page 4.2 - 4 3849036en - (00)

4.2 TRAVEL SYSTEM
Components of lower carriage
Ref. no. Quantity Designation Further remarks Weight [kg]
1 1 Carbody 26 780
4 2 Bracket
5 4 Plate
6 1 Safety grill
7 82 Bushing
8 32 Bushing
9 32 Hex. bolt M 36 x 350 - 12.9 See chapter 4.2.2.1
10 84 Hex. bolt M 30 x 190 - 12.9 See chapter 4.2.2.1
11 8 Hex. bolt M 16 x 50 - 8.8 - A3B Tightening torque = 195 Nm
13 8 Retaining washer
14 4 Plate
16 8 Washer
17 16 Bushing
21 4 Slide Strip
24 2 Bracket
25 2 Lid
27 8 Washer
28 4 Clip
29 4 Clip
30 4 Plate
31 8 Stud M 12 x 110 - 8.8
32 8 Hex. nut M12 – 8 - A3B
33 4 Insert
43 1 Cover
44 1 Cover
45 8 Bushing
46 8 Hex. bolt M 30 x 140 - 12.9 Tightening torque = 2250 Nm
47 Greasing system See chapter 11
Table 2
3849036en - (00) Page 4.2 - 5

4.2 TRAVEL SYSTEM
Fig. 3 Lower carriage – 3843474-01
Page 4.2 - 6 3849036en - (00)

4.2 TRAVEL SYSTEM
9, 10, 11,
15, 18, 26
Fig. 4 Mounting carbody and track frames – 3735961-01
3849036en - (00) Page 4.2 - 7

4.2 TRAVEL SYSTEM
13, 14, 15,

16
Fig. 5 Mounting carbody and track frames – 3680070-02
Page 4.2 - 8 3849036en - (00)

4.2 TRAVEL SYSTEM
4.2.3 Wear limits Track components must be replaced when they

have worn down to between 75 and 100%. Sudden
Wear on the track components is due to move- failure is otherwise pre-programmed.
ment, loading and ground contact, as well as to the
hardness (abrasiveness) of the ground. Careful and regular measurements are necessary
to determine the extent of wear and to be ready for
Wear can also be increased by the following fac- component exchange when it is necessary.
tors:
Before measuring components, clean them thor-
1. unstable position of excavator because of un- oughly. Measure at several points. It is not the
even ground; average, but the maximum wear value that is to be
taken as wear limit.
2. one-sided stressing of the tracks when turning
on the spot; Because the wear life between 75 and 100% is
low, components should be changed as a preven-
3. driving over obstacles; tive measure as soon as the 75% limit has been
reached. Exchange can take place while other
4. high amount of travelling of more than 7% of servicing is being carried out.
the operating hours.
3849036en - (00) Page 4.2 - 9

4.2 TRAVEL SYSTEM
Wear limits for travel system
Component Wear limits [mm]

N W W W W meas-
New 25 % 50 % 75 % 100 % ured
Track pad
415 417 420 423 427
Track chain (4 links)
1 660 1 668 1 680 1 692 1 708
Track pad A 140 138 135 131 126
B 312 304 292 276 256
C 52 46 37 25 10
Pad bush
Ø 102,5 103,5 105 106,5 108,5
Pad pin
Ø 102 101 99,5 98 96
Pad cam
226 222 216 207 195
126 122 116 107 95
Page 4.2 - 10 3849036en - (00)

4.2 TRAVEL SYSTEM
Component Wear limits [mm]

N W W W W meas-
New 25 % 50 % 75 % 100 % ured
Bottom roller
Ø 360 354 346 336 324
45 48 52 57 63
Top roller
Ø 360 354 345 335 322
51 54 58,5 63,5 70
Idler rim
Ø 1 286 1 281 1 275 1 267 1 258
62 64 67 71 76
Sprocket rim
Ø 1 278 1 273 1 267 1 259 1 250
62 65 67 72 76
Sprocket tooth
215 211 206 200 193
175 171 166 160 153
3849036en - (00) Page 4.2 - 11

4.2 TRAVEL SYSTEM
Page 4.2 - 12 3849036en - (00)

4.3 TRACK CHAIN
4.3 Track chain Proportionate weight transmitted through the

sprocket does not strain the pins and bushings
4.3.1 General connecting the pad-links.
The “combined pad-link” type track chain combines The track pins are full-floating.
a chain link and a track pad into one unit.
The drive forces are directly transferred from the
sprocket into the massive pad-link unit.
4.3.2 Components
The quantities are valid for 1 track chain.
Weight
Ref. No. Quantity Designation Further remarks
[kg]
1 42 Pad-link 462 each
2 336 Bushing 2 each
3 84 Pin 14 each
4 84 Cover plate 2,3 each
5 84 Circlip
Table 1
A A
1
2
3
4
5
2452540.SKD
Fig. 1 Track chain
2440560en - (00) – 01.98 Page 4.3 - 1

4.3 TRACK CHAIN
4.3.3 Assembly 2. First open the connection above the track link
which is to be removed. (Arrow A in Fig. 1).
4.3.3.1 Opening the track chain
The track chain can be opened as follows:
Avoid uncontrolled movement of
1. Position the excavator in such a way that the the track by fixing it with help of
chain link which is to be removed is positioned appropriate means, e.g. chain
at the lower section of the sprocket (Arrow A in hoists or forklift before it is
Fig.2). opened.
3. Remove both circlips (5, Fig. 1).

Before opening the track chain has
to be slackened in accordance with 4. Remove both cover plates (4, Fig. 1).
the operating instructions.
5. Remove both track pins (3, Fig. 1).
The ball valve in the line to the
track tensioning cylinder must be 6. Afterwards remove the other two track pins
closed to avoid the piston being accordingly.
completely pushed out of the bar-
rel when an engine is started.(see
chapter 4.10).
Secure against falling down!

When the chain is not engaged
with the sprocket the whole upper
section of the chain may roll off
from the idler and create injury and
damage!
Therefor uncontrolled rolling of the
chain has to be avoided by secur-
ing the chain by appropriate
means!
Page 4.3 - 2 2440560en - (00) – 01.98

4.3 TRACK CHAIN
A
2452502C.SKD
Fig. 2 Opening the track chain
4.3.3.2 Closing the track chain

1. Align the track chain so that the links which
are to be connected are positioned in front of
the sprocket (Fig. 2).
2. Clean bushings in the track link and the track

pins with degreaser.
3. Cover the track pins with a thin layer of as-

sembly paste part-no. 271 554.
4. Install both track pins, cover plates and cir-

clips.
5. Tension the track according to the ‘Operating

Instructions’.
2440560en - (00) – 01.98 Page 4.3 - 3

4.3 TRACK CHAIN
Page 4.3 - 4 2440560en - (00) – 01.98

4.4 IDLER
4.4. Idler With the idler the track is hydraulically tensioned

via spacer piece and track tensioning cylinder.
4.4.1 General
The idler is mounted in the two slider pieces, which
are guided in the track frame.
4.4.2 Components of the idler

The reference numbers are related to Fig. 1 and Fig. 2
Weight
Ref. no. Quantity Designation Further remarks
[kg]
1 1 Idler 2 288
2 2 Slider piece 238 each
3 1 Shaft 178
4 2 Disk
5 2 Labyrinth ring
6 2 Duo-cone seal
7 2 O-ring
8 4 Locking pin
9 2 Bushing
10 12 Dowel pin
11 2 Pin
12 1 Plug
13 1 Sealing ring
14 ----
15 ----
16 1 Push rod
17 4 Washer
18 4 Hex. bolt M30 x 170 – 8.8 Tightening torque Md = 1 350 Nm
19 4 Hex. bolt M24 x 160 – 8.8 Tightening torque Md = 670 Nm
20 1 Track tensioning cylinder
21 - 29 ----
30 Anti-seize paste Part-no. 271 554
31 0,6 kg Grease KPF2K - 30
Table 1
2461184en - (00) – 01.98 Page 4.4 - 1

4.4 IDLER
Fig. 1 Idler - 3657808-01
30
Fig. 2 Idler - 2763192-01
Page 4.4 - 2 2461184en - (00) – 01.98

4.4 IDLER
4.4.3 Assembly of the idler 3. Pick up idler shaft with lifting device (6, Fig. 3)
and install into the idler.
When assembling the idler the working sequence
has to be as follows:
1. Place idler onto suitable support (1, Fig. 1) and

completely press, respectively drive in bushing
(2, Fig. 1).
Fig. 3 Installation of idler shaft - 630425
4. Insert labyrinth ring into the groove in the idler

(5, Fig. 2).
The seal must not be pressed into the grove but
Fig. 1 Installation of bushings - 630423
move freely.
Grease the surface on both sides of the seal

2. Fit two halves of duo-cone seals (5, Fig. 2) into with high pressure grease (31, Fig. 2).
idler (see chapter 4.11 ‘Duo-cone seals’).
Grease must not penetrate into the

channels of the idler.
5. Grease seal ring (7, Fig. 4) and place into

slider piece (8, Fig. 4).
Fig. 2 Installation of duo-cone seal - 630424
Fig. 4 Installation of seal - 630426
2461184en - (00) – 01.98 Page 4.4 - 3

4.4 IDLER
6. Place disk (3, Fig. 5) with grease into slider 8. Clean indicated area of the idler shaft (arrow,
piece (8, Fig. 5) and secure by knocking in Fig. 2) with degreaser and cover with a thin
dowel pins (4, Fig. 5). layer of anti-seize paste part-no. 271 554.
Assemble the first slider piece (8, Fig. 7) and
the shaft (6, Fig. 7) with help of a lifting device.
Ensure that the slider piece is brought exactly
into position and the borings for the locking pins
(9 + 10, Fig. 8) in the slider piece and the shaft
are aligned.
Before assembling the duo-cone seal clean the

contact surface carefully and cover the contact
surface slightly with oil.
Do not oil the other areas of the duo-cone
seals..
Fig. 5 Installation of disc - 630427
7. Fit half of duo-cone seal (5, Fig. 6) into slider

piece (8, Fig. 6).
Fig. 7 Installation of slider piece - 630429
Fig. 6 Installation of duo-cone seal - 630428
Page 4.4 - 4 2461184en - (00) – 01.98

4.4 IDLER
9. Install the locking pins (9 + 10, Fig. 8). The

grove in the locking pin has to show into the di-
rection of the shaft.
Fig. 8 Installation of locking pins - 630430
10. Turn idler and fill idler housing with grease

according to Service Manual.
Fig. 9 Filling with g rease - 630431
For grease quantity and -quality refer to the ‘Ser-

vice Manual’.
11. Install second slider piece according to section

8.
2461184en - (00) – 01.98 Page 4.4 - 5

4.4 IDLER
Page 4.4 - 6 2461184en - (00) – 01.98

4.5 BOTTOM ROLLER
4.5 Bottom roller The majority of roller leaks is due to dirt that enters
through the labyrinth (see arrow B, fig. 2) and pen-
4.5.1 General etrates into the duo-cone seals. The roller can be
made fully operational by removing and cleaning it,
Bottom rollers have lifetime lubrication. They do and then filling it with fresh lubricant.
not require any maintenance until the wear limits
have been reached. Loose fastening bolts will immediately result in
leaks and further damage to the bottom rollers.
In order to assure the bottom rollers longevity,
sufficient axial clearance of the rollers between the
bearing caps must be ensured.
4.5.2 Components of the bottom roller

The parts listed in table 1 refer to fig.1 - 10.
Components of the bottom roller
Weight
[kg]
1 1 Roller body 466
2 2 Bearing Cap 73 each
3 2 Bushing 11 each
4 2 Thrust disc
5 2 Ring
6 2 Duo-cone seal
7 2 Plug used during operation
8 2 Sealing ring
9 2 Hex. bolt M 20 x 100 – 8.8 – A3B used for transport and storing
10 2 Sealing ring
11 2 Washer
13 1 Auxiliary bolt
14 2 O-ring
15 2 Plug used for transport and storing
17 4 Hex. bolt M 30 x 220 – 12.9 Tightening torque = 2 250 Nm
18 4 Washer
Table 1
3746422en - (00) Page 4.5 - 1

4.5 BOTTOM ROLLER
17
Fig. 1 Components of bottom roller – 3843031-02
A
Fig. 2 Bottom roller - 3700541-01
Page 4.5 - 2 3746422en - (00)

4.5 BOTTOM ROLLER
4.5.3 Bottom roller installation Installation
Transport and storing The rollers are sealed with duo-cone seals (6).
Function and assembly of duo-cone seals see
For storing and transportation roller and bearings chapter 4.11.
are screwed together with two bolts (9, fig. 3). The
boring for lubrication is closed with a plug (15, fig. Before assembling the bearing caps fill up sealing
4). gap above duo-cone seal with grease (G, fig. 5).
Fig. 5 G: fill up with grease 642790

B: If the roller is filled with oil no grease is
Fig. 3 Detail Z from fig. 2 3742528-03 permitted to flow into the bore B.
Storing and transport condition
 Clean contact surfaces (A, fig. 2) on frame

and bottom roller with cleaning agent down to
the shiny metal (no rust, paint or grease).
 Remove plug (15, fig. 4).
 Install O-rings (14, fig. 2) for grease channel.
 Position roller under the track frame. Threat in

mounting bolts (17, fig. 1) with washers (18).
The mounting bolts must be lightly oiled.
Tighten bolts hand tight.
 Remove items 8, 9, 10, 11 (fig. 3) on both

bearings.
 Press bearing with auxiliary bolt (fig. 6)

against connecting surfaces of the track
Fig. 4 Storing and transport condition – 3700541-02
frame.
** ATTENTION ** The bearings must lay at

the whole connecting surface of the track
frame without any axial tolerances.
3746422en - (00) Page 4.5 - 3

4.5 BOTTOM ROLLER
 Tighten bolts (17) with the required torque.  Remove plug from bearing cap. Make sure,
that transportation bore in roller (T, fig. 8)
Tightening torque Md = 2 250 Nm does not line up with with the bore of end cap.
This avoids damage of roller bore.
 Screw auxiliary bolt (13) into bearing end cap.

This pushes the roller into its end position (fig.
8). Take into consideration, that rubber rings
in the slide ring packing will keep the roller
from sliding into its end position.
 Once the roller has reached its end position,

set the dial gauge to zero (fig. 8).
 Remove the auxiliary bolt and close bore with

sealing ring (8) and plug (7).
 Insert the auxiliary bolt into the other bearing

end cap and turn it in, till the roller reaches the
other end position (fig. 9).
Fig. 6 Auxiliary bolt - 2157689
 Record the measurement of axial clearance
and where necessary make corrections.
In most cases the proper axial clearance can

Measuring axial clearance of roller be attained by first loosening and then retight-
ening the end cap bolts (fig. 10, pos. 17).
Axial clearance of the roller between the bearing
caps: If specified clearance on the rollers is not able
1,0 – 2,0 mm to be confirmed, remove roller and check
track frame to ensure, that there is no paint,
burrs or damage on the inside of the track
frame, where the roller end cap vertical sur-
face contacts the track frame.
If specified clearance on the roller is still not

able to be measured, contact your Caterpillar
Hex dealer.
 Remove auxiliary bolt.
 Check grease according to the service- and

operating instructions.
 Plug bearing with items 7 and 8.
 For rollers with central greasing system:
Check function of the central greasing system!

Fig. 7 A: Axial clearance 642791
B: Auxiliary bolt (pos. 13) fits here
 Find an appropriate place to fix the dial

gauge.
Page 4.5 - 4 3746422en - (00)

4.5 BOTTOM ROLLER
Fig. 8 Roller gets pushed to thrust washer by tightening auxiliary bolt. Here from left to right. 642792
13: Auxiliary bolt
A: Axial clearance
T: Transportation bore
U: Undercarriage sideframe
Fig. 9 Roller gets pushed to thrust washer by tightening auxiliary bolt. Here from right to left. 642793-01
3746422en - (00) Page 4.5 - 5

4.5 BOTTOM ROLLER
Page 4.5 - 6 3746422en - (00)

4.5 BOTTOM ROLLER
17
Fig. 10 Bottom roller - Installation – 3673416-02
3746422en - (00) Page 4.5 - 7

4.5 BOTTOM ROLLER
Page 4.5 - 8 3746422en - (00)

4.6 TOP ROLLER
4.6 Top roller  The roller can be made fully operational by

removing and cleaning it, and then filling it with
4.6.1 General fresh oil.
 Top rollers have long term lubrication. If in-  Loose fastening bolts will immediately result in
stalled the rollers are connected to the under- leaks and further damage to the rollers.
carriage central greasing system.
 The rollers are sealed with duo-cone seals (6).

Function and assembly of duo-cone seals -
see chapter 4.11.
 The majority of roller leaks is due to dirt that

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

The parts listed in table 1 refer to Fig.1, 2 and 3.
Components of the top roller
Weight
[kg]
1 1 Roller body  360 mm 321
2 2 Support 52 each
3 2 Bushing 6,5 each
4 2 Disk 1,4 each
5 2 O-Ring
6 2 Duo-cone seal
7 1 Plug
8 2 Sealing ring
9 ----
10 2 O-Ring
11 2 Plug
12 ----
13 4 Hex. bolt M 30 x 220 Tightening torque Md = 2 250 Nm
14 4 Washer
20 1 Securing device for transport
30 0,2 kg Grease
Table 1
3657719en - (00) Page 4.6 - 1

4.6 TOP ROLLER
Fig. 1 Top roller - 3659737a
13 A
Fig. 2 Top roller - 3648212a
Page 4.6 - 2 3657719en - (00)

4.6 TOP ROLLER
13
Fig.3 Top roller - Installation – 3673416-02
3657719en - (00) Page 4.6 - 3

4.6 TOP ROLLER
4.6.3 Top roller installation Press bearings against connecting surface of the
track frame.
Sequence of assembly for roller installation
 Tighten mounting bolts with torque according
 Position roller on the track frame and threat in to chapter 2.9 - ‘Tightening procedures’.
mounting bolts (13) with washers (14).
 Fill in oil according to the service- and operat-
 Remove securing device (20, Fig. 4). ing instructions and plug bearing with items 7
and 8.
Because of the securing device for  Fill oil container to the marked level
transport the roller body and the
supports have been pre-loaded.
Therefore it is important to press the
supports against the contact surface
of the frame before the mounting
bolts (13) are tightened. So the axial
clearance of 1,0 to 2,0 mm is
achieved.
The supports have to contact the

whole connecting surface of the
track frame without any axial toler-
ances.
Fig. 4 securing device for transport - 630821
Page 4.6 - 4 3657719en - (00)

4.7 SPROCKET
4.7 Sprocket  For Installation of the travel gearbox see

chapter 7.2 ‘Travel gearbox’.
The sprocket is bolted to the travel gearbox.
Weight
[kg]
1 1 Travel motor cover
3 48 Washer
4 48 Bolt M 30 x 2 x 240
5 1 Sprocket 2 070
6 48 Bolt M 30 x 2 x 260
7 48 Washer
8 16 Bolt M 20 x 60 Tightening torque Md = 400 Nm
9 16 Washer
10 2 Travel motor 150 each
11 1 Travel gearbox 3 800
Table 1
2452502C.SKD
Fig. 1 Opening of track
2461186en - (00) – 01.98 Page 4.7 - 1

4.7 SPROCKET
1
11
C
E
F
3,4
6,7 D 5
2452502F.SKD
3, 6
Fig. 2 Sprocket drive
4, 6, 8
Fig. 3 Travel gearbox and sprocket - 3659285-01
Page 4.7 - 2 2461186en - (00) – 01.98

4.7 SPROCKET
Removal and installation of the sprocket can be

done while the travel gearbox is installed in the
 Threads
track frame. Clean all threads from paint, rust and grease
and blow out with compressed air. Check for
The track has to be opened according to chapter damage and tap threads again if required.
4.3.
Avoid uncontrolled movement of  Adhesive

the track by fixing it with help of
appropriate means, e.g. chain When the sprocket has been prepared for in-
hoists or forklift before it is stallation, apply adhesive Part-no. 1 991 417
opened. to one of the contact surfaces (arrow E, Fig.
2).
Removal of the sprocket Apply the adhesive with ca. 10 mm clearance

from the threaded holes to ensure that no ad-
hesive can be forced into the threaded holes
 Pick up sprocket with lifting device. when the gearbox is set down.
 Unscrew all mounting bolts (4, Fig. 2) Penetration of adhesive into a threaded hole
leads to increased friction and thus to invali-
 Insert 4 special bolts
dation of the starting power data.
ISO 8765 - M 30 x 2 x 340, part-no. 2 765 752
into the holes of the sprocket.  Sprocket
The length of the bolt thread must be 225 mm.
 Screw in all 4 bolts equally to separate the
Pick up sprocket with lifting device.
Align sprocket and gearbox, insert all mount-
sprocket from the gearbox.
ing bolts and tighten hand-tight.
 Tightening of bolts
Installation of the sprocket
 Mounting bolts Start sprocket installation as soon

as the adhesive has been applied.
The threads and the heads of the mounting The adhesive starts hardening
bolts have to be slightly oiled and must not when the metal surfaces have been
come into contact with the adhesive. joined without any air being admit-
 Contact surface 48 hours at an ambient tempera-
Prior to installing the sprocket, all traces of The hardening process is initially
paint and grease must be removed from the strongly delayed, so that the instal-
contact surfaces between sprocket and travel lation time can be extended to a
gearbox with solvent Part-no. 216 405 (arrows maximum of 8 hours.
E and F, Fig. 2).
Check the contact area of sprocket and gear- At temperatures below -10°C, acti-
box carefully for mechanical damages. vator Part-no. 1 991 468 must be
The contact surface (arrow F, Fig. 2) must be sprayed onto the second joining
coated with mounting paste Part-no. 244 905. surface - the surface with no adhe-
sive.
2461186en - (00) – 01.98 Page 4.7 - 3

4.7 SPROCKET
After installing the sprocket, first
tighten all bolts (4, Fig. 3) crosswise to

900 Nm.
The sprocket is then in full contact and any ex-

cess adhesive is forced out.
The following procedure must then be observed

in clockwise direction (1st cycle):
 The 1st bolt is unscrewed completely.
 This bolt is pre-installed with a
joining torque of 550 Nm
 The bolt is then completely tightened

with an
additional turning angle of 150°
and marked in a suitable way (e.g. with

paint).
Every 2nd bolt (with odd nos. 3, 5, 7 etc.) is then

unscrewed and mounted with joining torque and
turning angle in the same way.
It is not permissible to loosen more

than one bolt at the same time.
All bolts of this connection must be
tightened within 8 hours maximum!
In the 2nd cycle, all bolts with even nos. (2, 4,

6 etc.) are then mounted by the same proce-
dure.
 Closing of track
Bring track to a suitable position (A, Fig. 1) by

moving the excavator and close track.
Page 4.7 - 4 2461186en - (00) – 01.98

4.8 TRAVEL GEARBOX - REMOVAL & INSTALLATION
4.8 Travel gearbox -

removal and installation
The removal and installation of the travel gearbox
is described in
chapter 7.2
2461035en - (00) Page 4.8 - 1

4.8 TRAVEL GEARBOX - REMOVAL & INSTALLATION
Page 4.8 - 2 2461035en - (00)

4.9 TRACK PAD
4.9 Track pad

The “combined pad-link” type track chain combines
a chain link and a track pad into one unit.
For further details see chapter 4.3 ‘Track chain‘.
2440562en - (00) – 01.98 Page 4.9 - 1

4.9 TRACK PAD
Page 4.9 - 2 2440562en - (00) – 01.98

4.10 HYDRAULIC TRACK TENSIONING SYSTEM
4.10 Hydraulic track tensioning system

4.10.1 General
Technical data:
Track tensioning pressure 60 bar
Setting of pressure relief valve: 330 bar
Nitrogen pre-charge of accumulator: 48 bar
4.10.2 Components of the track tensioning system

The reference numbers are related to Fig. 1; 2 & 3
Ref. no. Quantity Designation Further remarks Weight

[kg]
1 1 Idler-unit 3 620
2 1 Spacer piece 339
3 1 Tensioning cylinder 554
6 1 Accumulator 22
7 1 Hose
10 1 Cock
14 4 Hex. bolt M 24 x 160 Md = 670 Nm
15 4 Hex. bolt M 30 x 170 Md = 1 350 Nm
18 4 Hex. bolt M 8 x 20 Md = 23 Nm
22 4 Spring washer
28 2 Relief valve
29 1 Valve block
30 1 Filling and testing port
Table 1
2440563en - (00) – 01.98 Page 4.10 - 1

Fig. 1 Idler with track tensioning cylinder - 3657808-02
Fig. 2 Track tensioning system - 3663634-01
Page 4.10 - 2 2440563en - (00) – 01.98

2415503a.S K
22
30
18
13
6
7
10
14
3
2
15
1
14, 15, 18
Fig. 3 Idler with track tensioning system
2440563en - (00) – 01.98 Page 4.10 - 3

4.10.3 Releasing the track tension

 After completion of the repair close the pres-
Before carrying out repair work the tracks have sure relief valves (turn in completely).
to be slackened.
Each pressure relief valve (28, Fig. 4) is adjusted
Procedure: to 330 bar and sealed in this position.
The seal must not be removed and the pressure
 Shut down the engines setting of 330 bar must not be changed.
 Open both pressure relief valves (28, Fig. 4);

the track is slackening (each track is related to
a pressure relief valve).
Fig. 4 Track tensioning system
Attention! 4.10.4 Checking the accumulators

Tensioning of the tracks: The procedure how to check the accumulators is
described in chapter 8.6.4.8 ‘Track tensioning sys-
See operator’s manual. tem’.
Pressure setting:
See chapter 8.6

‘Checking and setting pressures’
Page 4.10 - 4 2440563en - (00) – 01.98

4.11 DUO-CONE SEALS
4.11 Duo-cone seals

Duo-cone seals (also referred to as steel-on-steel
seals) are used as shaft seals. The arrangement of
the seal is such that one steel ring, elastically
mounted in the fixed component, lies/runs axially
against a second steel ring that is also elastically
mounted, but this time in the rotating component.
Duo-cone seals are used in the excavator's bottom

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

damaged duo-cone seals.
Fig. 2 Duo-cone seals 630218

In case of leakages, the duo-cone
seals are to be changed immediately
and before installing the new duo- 3. Place one complete half (1) and (2) of the duo-
cone seals mating surfaces of both cone seal into/onto the rigid component and one
the rigid and the rotating compo- complete half into/onto the rotating component
nent(s) need to be inspected and (Fig. 3) - but without using any oil. Make sure
refurbished if necessary. that distance ‘’C’’ is equal all the way around the
Please contact Caterpillar Global seal.
Mining Service Department for in-
structions/guidelines.
Observe the following points when assembling

duo-cone seals:
1. The running surfaces ‘’A’’ of the steel rings (1,

Fig. 1) must be completely free of scratches
and scores. Clean all traces of oil and dust from
running surfaces "A" and seating bevels ‘’B’’. All
surfaces must be dry and free of rust, slag and
scale.
4. Before fitting the two machine components (rig-

id and rotating) together, carefully wipe the sur-
faces ’’A’’ of the steel rings (1) to remove any
foreign bodies or even finger-prints. Then apply
a drop of thin oil between the running surfaces,
but without allowing oil to get onto the other
parts.
Attention:
NEVER fit a new half of a duo-cone seal to a
used half. When re-assembling used duo-cone
2. Draw rubber seal (2) onto steel ring (1, Fig. 2).
The rubber ring (2). is correctly positioned when seals, make sure that pairs that were previously
it sits twist-free parallel to the surface of the installed together are kept together.
steel ring (1)..
2440564en - (01) Page 4.11 - 1

4.11 DUO-CONE SEALS
Page 4.11 - 2 2440564en - (01)

08.2018
5. Superstructure
6040

CONTENTS
5. SUPERSTRUCTURE
5.1 Introduction....................................................................................... 5.1 - 1
5.1.1 Foreword ........................................................................... 5.1 - 1
5.1.2 Safety ................................................................................ 5.1 - 1
5.1.3 General .............................................................................. 5.1 - 5
5.2 Swing ring ......................................................................................... 5.2 - 1
5.2.1 General .............................................................................. 5.2 - 1
5.2.2 Components of the swing ring ........................................... 5.2 - 2
5.2.3 Hardness gap, Soft spot .................................................... 5.2 - 3
5.2.4 Assembly swing ring – undercarriage ................................ 5.2 - 5
5.2.5 Assembly swing ring – superstructure ............................... 5.2 - 8
5.3 Engine / Motor installation ............................................................... 5.3 - 1
5.3.1 Engine mounting ................................................................ 5.3 - 1
5.3.2 Radiator installation ........................................................... 5.3 - 4
5.4 Engine / Motor coupling ................................................................... 5.4 - 1
5.5 Swing gearbox installation .............................................. see chapter 7.3
5.6 Pump gearbox installation ............................................... see chapter 7.4
5.7 Pump installation.............................................................. see chapter 8.7
5.8 Oil cooler installation ....................................................................... 5.8 - 1
5.9 Rotor installation .............................................................................. 5.9 - 1
3720205en – (00) Page 5 - 1

CONTENTS
Page 5 - 2 3720205en – (00)

5.1 SUPERSTRUCTURE – INTRODUCTION
5.1 Introduction 5.1.2 Safety Instructions

instructions
The Service Manual contains important informa-
tion for personnel servicing the machine. Machine This Caterpillar hydraulic excava-
technical data listed in other machine documents tor has been built in accordance
are not always repeated in this book. with state-of-the-art standards and
the recognized safety rules.
The documentation of a Caterpillar mining machine
includes: However, operating the machine if
 Operation and Maintenance Manual curred, or carrying out repair work
inexpertly
  endangers the lives of people in
 Service Manual contact with it

The service manual does not contain technical property.
data on auxiliary units for the operation of specific
or optional equipment or data of individual devices. Stop the hydraulic excavator im-
The refilling quantities specified for consumables any damage to ensure the safety of
are approximate quantities which are intended as a the operator, other people or mate-
help for planning consumable requirements. rial property at the application area
of the excavator.
Each component is equipped with suitable check- All components of Caterpillar ma-
ing devices, e.g. a dipstick or checking plugs, per- chines are perfectly tuned to each
mitting the operator to check exactly the filling of other. Trouble-free operation and a
the components.
spare parts.
3849050en - (00) Page 5.1 - 1

Personnel
Personnel
The machine must not be started
by unauthorized people. Personal protective equipment and
safety working clothing:
Therefore secure and lock it.
Follow the accident prevention wear and safety gloves.
regulations.
If you lack such knowledge, ex- harnesses. Always put on a tested
perienced personnel, e.g. from harness which is equipped with fall
instructions.
Maintenance Manual and in par- assistant beforehand. The individ-
ticular the chapter ual responsibilities are to be care-

Page 5.1 - 2 3849050en - (00)


safe state.
forms and handrails provided for Before carrying out assembly work,
this purpose. the machine and the equipment
Always keep ladders, steps and tent movement, e.g. by placing the
platforms in a non-slip state. Re- working equipment on the ground.
immediately.
system:
Securing the working equip- Always observe the safety regula-
ment tions applicable to the product
when handling oils, greases and
Secure the machine and the work- other chemical substances.
and unauthorized start. Position Close open unused bores, pipe and
working equipment on the ground hose connections so that they are
in such a way that it cannot move impermeable to pressure.
when mechanical or hydraulic Refill the hydraulic system with
connections become detached. collected drain hydraulic oil only
Use hoists or other appropriate through the return flow filters. Dis-
support devices when you install, pose of waste oil without polluting
remove or displace any equipment the environment.
or component. Thus you prevent Observe the correct working se-
them from inadvertent movements, quence when fitting or replacing
slip or fall. components or equipment.
3849050en - (00) Page 5.1 - 3


erpillar. Do not remove the lead
Always replace defective, me- and hydraulic accumulators.
vice Manual contains no informa-
tion on such work. Re-commissioning

ables have at least the same tem- Before re-commissioning:
If the acid is splashed onto your repaired components.
running water and seek medical  Check all functions of the exca-
care immediately. vator including brakes during a
If the acid is splashed in your eyes, test run. Release the hydraulic
rinse thoroughly with running wa- excavator for re-commissioning
ter and seek medical care immedi- only if all its functions operate
ately. properly.

mable liquids.
easily.
Page 5.1 - 4 3849050en - (00)

5.1.3 General
This Service Manual contains information in addi-

tion to the Operation and Maintenance Manual The Service Manual covers the information you
and the Spare Parts Catalog, to familiarise the need when handling your excavator. However,
personnel with the designated use, maintenance Caterpillar Global Mining HMS GmbH will be
and repair of the Caterpillar excavator. pleased to answer any questions you have on its
The information in the Service Manual corre- dealer or your Caterpillar subsidiary.

They do not represent the actual design of the ma-
chine and are not to be used for manufacturing.

3849050en - (00) Page 5.1 - 5

Page 5.1 - 6 3849050en - (00)

5.2 SWING RING
5.2 Swing ring Technical data
Total weight (without bolts): 6 850 kg

5.2.1 General
Outer diameter: 3 550 mm
This chapter applies to the RH170 / Height: 400 mm

6040 from DHX40022.
The swing ring is designed as a triple-race

combined axial/radial roller bearing.
The roller races are arranged in such a way that

the loads can be clearly defined for each row of
rollers.
Bolt types and tightening procedure for fitting of the swing ring
Swing ring - undercarriage Swing ring - superstructure

Bolt size M 36 x 400 M 36 x 380
Quality 12.9 12.9
Bolt surface oiled oiled
Quantity 96 96
Initial torque [Nm] 1 500 1 500
Pre-torque [Nm] 900 800
Plus turning angle of [°] 120 120
Inspection torque [Nm] 3 000 3 000
Table 1
The inspection torque permits to check the

It is N O T permitted to fit the
condition of the bolted joint.
swing ring or individual bolts of
A bolt that can be turned when the inspection
the ring with the inspection torque
torque is applied, is not correctly tightened. It must
and to put the machine into
then be loosened completely and refitted with the
operation in such condition.
pre-torque and the turning angle.
The condition of the bolt must be checked and a

new bolt used, if required.
Thereafter, it is absolutely
essential to recheck adjacent bolts
with the inspection torque.
2731953en - (02) Page 5.2 - 1

5.2 SWING RING
5.2.2 Components of the swing ring

The cross-section shows the design of the swing ring (Fig. 1).
"B"
8 4
"A" 2417331C.SKD
Fig. 1 components of the swing ring
The individual components of the swing ring are The swing ring is completely pre-assembled by the
listed in table 2. manufacturer. This means that the supporting ring
and the retaining ring are bolted together.
Components of the swing ring

[kg]
1 1 nose ring
2 1 supporting ring
3 1 retaining ring
4 row of axial rollers
5 row of axial rollers
6 row of radial rollers
7 1 seal
8 1 seal
Table 2
Page 5.2 - 2 2731953en - (02)

5.2 SWING RING
5.2.3 Hardness gap, ’’Soft spot’’ The two soft spot areas "S" on the supporting ring
(Pos. 2, Fig. 1 + 2) and the retaining ring (Pos. 3,
Swing rings have induction-hardened races. Fig. 1 + 2) are identified by the manufacturer. Both
Between the beginning and the end of the rings have been turned and bolted together in such
hardened race there is always an unhardened a way that the soft spots are in alignment.
area designed as "hardness gap area" (soft spot)
and identified by the letter "S" stamped into the The "S" markings on retaining ring
metal. The swing ring is to be installed in such a and supporting ring must be
way that the hardness slip areas "S" of the mounted at 90° to the RIGHT with
individual rings are positioned outside the main regard to the longitudinal axis of
area of load. the superstructure viewed in front
direction (Fig. 2).
The ’’S’’ marking on the nose ring

must be mounted acc. to Fig. 3 with
regard to the longitudinal axis of the
undercarriage.
Front
Fig. 2 Mounting position for hardness gap areas ‘’ S ‘ on supporting and retaining ring - 630650
Hardness gap area "S" on the nose ring (toothed ring) (Pos. 1, Fig. 2 + 3) must be aligned as shown
in fig. 3.
2731953en - (02) Page 5.2 - 3

5.2 SWING RING
Front
Fig. 3 Mounting position for ‘’S’’ on the nose ring - 630651
5.2.4 Assembly swing ring -

undercarriage  Contact surfaces
On a new excavator, the swing ring will already be The contact surfaces ("A", Fig. 1) of the
fitted to the carbody, when the machine leaves the undercarriage and the bolt must be checked for
factory. During site assembly of the machine only damage and thoroughly cleaned to remove
the superstructure has to be installed. paint and grease with diluting agent (Part-No. 1
201 408).
The contact surfaces must be metallically clean
(no rust), dry and grease-free.
If the swing ring has to be installed
onto the undercarriage, the
following procedure must be
strictly observed:  Threaded holes
All threaded holes in the carbody must be

completely cleaned and carefully checked for
 Fitting preparation the presence of dirt, paint residues, rust and
other visible defects. If necessary, the threads
Removal and installation of the swing ring must must be rethreaded.
be carried out after the superstructure has been
lifted off the machine.
 Condition of bolts
The threads of the fastening bolts and the

contact surfaces of the bolt heads must be
lightly oiled.
Page 5.2 - 4 2731953en - (02)

5.2 SWING RING
 Pre-assembly  Adhesive
Before applying adhesive on the carbody, the When the swing ring is ready for mounting
swing ring must be prepared for the assembly. apply a thin and uniform layer of adhesive
(Part-No. 1 991 467) on the whole contact
 Attach the swing ring to a lifting device (Fig. 4). surface ("A", Fig. 1) of the undercarriage using
To do so, insert four eye bolts M 36 (Part-No. 52 a paint roller, hard brush or a spatula.
695) spaced by 90° respectively into the
threaded holes provided. Apply the adhesive in such a way that approx.
10 mm around the threaded holes remain free
 Insert all bolts and washers required for from adhesive. The adhesive must not be
fastening the swing ring to the undercarriage squeezed into the threaded holes of the
into the swing ring (A, Fig. 4). undercarriage when the swing ring is placed on
the undercarriage.
 Insert all bolts and washers required for The penetration of adhesive into a threaded
fastening the superstructure onto the swing ring hole causes increased friction and will thus lead
and secure with nuts or cable binders to to incorrect tightening torque values.
prevent them from dropping out of the holes (B,
Fig. 4). The use of an adhesive permits the transfer of
radial forces three times as high as the normal
force.
The insertion of these bolts after mounting of the Since the adhesive is capable of transferring
swing ring on the undercarriage is time-consuming only small tension forces, the separation of the
and possible only if each bolt is passed one after glued swing ring from the superstructure and
the other through the assembly opening in the left- the undercarriage is no problem.
hand rear area of the central part of the
undercarriage.  Fitting
The ’’S’’ marking on the nose ring

must be mounted acc. to Fig. 3 with
regard to the longitudinal axis of the
undercarriage.
The swing ring must be fitted

immediately after application of the
adhesive.
Hardening of the adhesive begins
after joining the metal surfaces
under the exclusion of air and is
generally completed after approx.
48 hours at an ambient
Fig. 4 630660 temperature of 20 °C.
The hardening process begins only
after a considerable initial delay so
that the fitting operations may
extend over a period of 8 hours
maximum.
At temperatures below -10 °C it is
necessary to spray an activator
(P/N 1 991 468) on the second
contact surface, i.e. the one
without adhesive.
2731953en - (01) - 10.01 Page 5.2 - 5

5.2 SWING RING
After alignment of the swing ring with the

hardness slip area "S" in the correct position
 Replacing the seal
(Fig. 3) If the seal (27, Fig. 5) is to be replaced because
of damage, proceed as follows:
all bolts are first tightened crosswise with
an initial torque of 1 500 Nm
 remove the old seal;
to ensure that the swing ring is fully in contact
 check the area between retaining ring of the
with the opposite surface and that any adhesive
grease cover seal and undercarriage for
(Omnifit) applied too thickly is being squeezed
tightness and reseal with sealing compound
away.
(Part-No. 970 322), if required;
Continue to work clockwise and proceed as
follows:  drive the new seal with a blunt chisel into the
retaining ring and glue the ends with adhesive
(Part-No. 970 376).
 Loosen one bolt completely.
Attention
 The bolt is pre-tightened with a
If it becomes necessary to replace individual bolts
torque of 900 Nm
with the superstructure in place, the superstructure
base-plate is equipped with two fitting openings (I
 The bolt is then completely tightened and II in Fig. 5). These openings are closed with
with an covers (5, Fig. 5) to prevent dirt from penetrating
into the toothed area of the swing ring.
To replace a bolt, it is necessary to position the
and marked in an appropriate way (using superstructure in such a way that one of the fitting
paint, for instance). openings is exactly above the bolt head.
The bolts can only be removed and installed
Loosen the bolts one after another in the same through this fitting opening.
way and tighten with the indicated pre- (See also Fig. 1).
tightening torque and turning angle.
It is not allowed to loosen more

than one bolt at a time.
All bolts must be tightened within
a period of 8 hours maximum.
After completion of the assembly the outside

parting line between swing ring and carbody has to
be sealed with sealing compound Part-no. 970 322
(26, Fig. 5).
Finally the seal for the "grease cover" in the

carbody must be checked for perfect condition and
the cover placed into the carbody.
Page 5.2 - 6 2731953en - (02)

5.2 SWING RING
5.2.5 Assembly swing ring -  Adhesive

superstructure
When the superstructure is ready for mounting
apply a thin and uniform layer of adhesive
(Part-No. 1 991 467) on the whole contact
When fitting the superstructure
surface ("B", Fig. 1) of the swing ring using a
onto the swing ring, the following
paint roller, hard brush or a spatula.
procedure must be strictly
observed: Apply the adhesive in such a way that approx.
10 mm around the threaded holes remain free
from adhesive to prevent the adhesive from
 Condition of bolts being squeezed into the threaded holes when
the superstructure is placed on the swing ring.
The threads of the fastening bolts and the The penetration of adhesive into a threaded
contact surfaces of the bolt heads must be hole causes increased friction and will thus lead
to incorrect tightening torque values.
lightly oiled.
The use of an adhesive permits the transfer of
radial forces three times as high as the normal
 Contact surfaces force.
Since the adhesive is capable of transferring
The contact surfaces ("B" Fig. 1) of the only small tension forces, the separation of the
superstructure and the swing ring must be glued swing ring halves from the superstructure
checked for damage and thoroughly cleaned to and the undercarriage is no problem.
remove paint and grease with diluting agent
(Part-No. 1 201 408).
The contact surfaces must be metallically clean
(no rust), dry and grease-free.
 Fitting
 Threaded holes The "S" markings on retaining ring

and supporting ring must be
All threaded holes in the superstructure must mounted at 90° to the RIGHT with
be blown clean with compressed air and regard to the longitudinal axis of
carefully checked for the presence of dirt, paint the superstructure viewed in front
residues, rust and other visible defects. If direction (Fig. 2).
necessary, the threads must be rethreaded This is already determined by the
dowel pin.
 Back-Lash
Since the position of the swing ring with regard

to the superstructure is fixed by a dowel pin
(10, Fig. 5), an adjustment of the back-lash
between the swing ring teeth and the swing
gearbox pinion is not required.
To avoid damage to the swing ring teeth and

the gearbox pinion during installation of the
superstructure, it is recommended to loosen the
swing gearboxes and to lift and support them to
such an extent that the gearbox pinions do not
protrude over the superstructure base-plate.
2731953en - (01) - 10.01 Page 5.2 - 7

5.2 SWING RING
The superstructure must be fitted It is not allowed to loosen more than

immediately after application of the one bolt at a time.
adhesive.
All bolts must be tightened within a
Hardening of the adhesive begins period of 8 hours maximum.
after joining the metal surfaces
under the exclusion of air and is
generally completed after approx.
48 hours at an ambient
temperature of 20 °C. The
hardening process begins only  Installing the swing gearboxes
after a considerable initial delay so
that the fitting operations may The installation of the swing gearboxes is
extend over a period of 8 hours described in chapter 7.3 'Swing gearbox'.
maximum.
When inserting the swing gearbox pinion into
At temperatures below -10 °C it is the teeth of the swing ring it may be required to
necessary to spray an activator turn the toothed wheels to obtain a perfect
(Part-No. 1 991 468) on the second match of the hole patterns of the gearbox
contact surface, i.e. the one fastening bolts in the superstructure and the
without adhesive. swing gearbox after engagement of the pinion
in the swing ring teeth.
For this purpose, it is necessary to release the
After alignment of the swing ring with the spring-loaded multiple-disk brake of the swing
hardness slip area "S" in the correct position gearbox with a hand pump, to dismantle the
(Fig. 2) swing motor and to turn the gearbox input shaft
accordingly.
all bolts are first tightened crosswise with
an initial torque of 1 500 Nm The releasing pressure must be
monitored with help of a pressure
to ensure that the superstructure base-plate is gage and must be between 30 - 60
fully in contact with the opposite surface and bar.
that any adhesive (Omnifit) applied too thickly is
being squeezed away. Pressure must not exceed 60 bar,
this would cause damage of break
Continue to work clockwise and proceed as seals.
follows:
 Loosen one bolt completely. The "grease cover" must be fastened with the
retaining plates and the hex bolts (6, 18, 26,
 The bolt is pre-tightened with a Fig. 5) to the superstructure base-plate and
filled with grease in acc. with the servicing and
torque of 800 Nm inspection instructions.
 The bolt is then completely tightened

with an
and marked in an appropriate way (using

paint, for instance).
Loosen the bolts one after another in the same

way and tighten with the indicated pre-
tightening torque and turning angle.
Page 5.2 - 8 2731953en - (02)

5.2 SWING RING
 Connecting the central greasing system Attention
Finally, the lines of the central greasing system If it becomes necessary to replace individual bolts
must be connected in acc. with with the superstructure in place, the superstructure
must be positioned in such a way that the bolt in
chapter 11 'Central greasing system' question is at the rear in the middle between the
travelling gearboxes. A groove in the
undercarriage base-plate permits the removal and
and the system itself be checked for proper
the installation of the bolt.
operation to ensure adequate greasing of the
swing ring.
The fitting opening in the undercarriage base-plate
offers another possibility for replacement.
In this case, the superstructure must be positioned
in such a way that the fitting opening is at the rear
on the left side of the undercarriage base-plate
exactly below the bolt head.
2731953en - (01) - 10.01 Page 5.2 - 9

5.2 SWING RING
Fitting components for swing ring and swing gearboxes (Fig. 5)

[kg]
1 3 Swing gearbox
2 1 Swing ring 5890, 0
3 1 Swing ring cover
4 2 Seal 130X230
5 2 Cover 130X230
6 34 Plate
7 2 Plate 310X530
8 48 Plate
9 48 Plate
10 1 Pin ST50K
11 192 Washer C45
12 72 Washer C45
13 ----
14 192 Plate
15 96 Hex bolt - 12.9 LV M36x400
16 96 Hex bolt - 12.9 LV M36x380
17 72 Hex bolt - 10.9 LV M24x600
18 34 Hex bolt M10x30
19 20 Hex nut M10
20 8 Threaded bolt M10x20
21 3 Connecting piece M26x1.5
22 192 Lock washer
23 20 cm3 Adhesive Cyan-acrylate
24 2 kg Adhesive Omnifit Seal 54 H
25 1 000 cm3 Diluting agent
26 2 kg Sealing compound
27 9.5 m Seal PTFE
28 3 0-ring LV 460x6
Table 3
Page 5.2 - 10 2731953en - (02)

5.2 SWING RING
15, 16, 17
Fig. 5 Swing ring - installation
2731953en - (01) - 10.01 Page 5.2 - 11

5.2 SWING RING
Page 5.2 - 12 2731953en - (02)

5.3 ENGINE INSTALLATION
5.3 Engine installation
This section is valid for engine Caterpillar C 32.
5.3.1 Engine mounting

The components are listed in table 1. The numbers
refer to Fig. 2 and 3. Quantities are valid for 1 en-
gine.
The diesel engines are elastically mounted. The

elastic elements (6 & 7) are preloaded with the
bolts (8 & 9) and nuts (11). The preload is defined
by the length of the spacer (5).
The tightening torque of pos. 8, 9 & 10 is

Md = 490 Nm
Fig. 1 2 pairs of lock washers – 630918-01
Until coupling and pump gearbox are installed,
support the diesel engine on coupling side, e.g.
with timber or bracket.
Install the pairs of lock washers as shown in Fig. 1.
Check the required tightening torque regularly.

Check the components of the elastic mounting
regularly for damage. For check and maintenance
intervals see motor operation manual, section
‘maintenance schedule’.
3668684en - (01) – 08.11 Page 5.3 - 1

Components of the elastic mounting

[kg]
1 1 Mounting plate 88
2 2 Insert
3 8 Disc
4 8 Disc
5 8 Sleeve
6 8 Megiflex-disc
7 8 Megiflex-disc
8 4 Hex. bolt M 20 x 210 – 10.9 Tightening torque Md = 490 Nm
11 10 Hex. nut M 20
12 20 Pair of lock washer
13 1 Pump gearbox
14 1 Engine
Table 1 Quantities are valid for 1 engine.
8, 9, 10
Fig. 2 Engine mounting – 3720437-01
Page 5.3 - 2 3668684en - (01) – 08.11

8, 9, 10
Fig. 3 Engine mounting – 3690335-02
3668684en - (01) – 08.11 Page 5.3 - 3

5.3.2 Radiator installation Tightening torques
The components are listed in table 2. Quantities Pos. 12: Md = 350 Nm

are valid for 1 radiator. The numbers refer to fig. 4 Pos. 13: Md = 71 Nm
and fig. 10. Pos. 14 - 16: Md = 41 Nm
The radiators for the diesel engines are elastically Check the required tightening torque regularly.
mounted. The elastic elements (2) are preloaded Check the components of the elastic mounting
with the bolts (12). regularly for damage. For check and maintenance
intervals see motor operation manual, section
Install the radiator vertically without distortion. Dis- ‘maintenance schedule’.
tortion will reduce the service life. Adjust the radia-
tor at the upper elastic element (3) with bolt (11)
and nuts (17).
Components for radiator installation (Fig. 4 & 10)

[kg]
1 1 Radiator 255
2 2 Elastic element
3 2 Elastic element
4 2 Disc
5 2 Conical washer
6 2 Rounded washer
7 2 Bracket
8 7m Sponge rubber Glued on
9 1 Rubber mounting Glued on
10 2 Rubber mounting Glued on
11 2 Stud M 20 x 110
17 4 Hex. nut M 20
18 8 Hex. nut M 10
20 14 Disc
21 4 Disc
22 4 Disc
23 1 Earthing strip
Table 2 Quantities are valid for 1 engine.
Page 5.3 - 4 3668684en - (01) – 08.11

12, 13, 14, 8, 9, 10

15, 16
Fig. 5 Radiator mounting – 3669634a-01
3668684en - (01) – 08.11 Page 5.3 - 5

Fig. 6 Radiator installation: Mount filling- and ventlines continously rising. – 3669634a-02
Fig. 7 Radiator installation: Mount filling- and ventlines continously rising. – 3669634c-01
Page 5.3 - 6 3668684en - (01) – 08.11

Fig. 8 Radiator installation: Mount filling- and ventlines continously rising. – 3669634d-01
3668684en - (01) – 08.11 Page 5.3 - 7

Fig. 9 Radiator installation: Mount filling- and ventlines continously rising. – 3669634b-01
Page 5.3 - 8 3668684en - (01) – 08.11

12, 13, 14, 8, 9, 10

15, 16
Fig. 10 Radiator mounting – 3690348-02
3668684en - (01) – 08.11 Page 5.3 - 9

5.3.3 Radiator fan installation

The fans for the radiators of the diesel engines are
driven by hydraulic motors.
The components are listed in table 3. Quantities

are valid for 1 radiator. The numbers refer to fig. 11
- 13.
Tightening torques
Pos. 19: Md = 350 Nm

Pos. 20: Md = 170 Nm
Pos. 21: Md = 71 Nm
Pos. 22: Md = 20 Nm
Pos. 31: Md = 170 Nm
Pos. 33: Md = 195 Nm
Pos. 36: Md = 49 Nm
Check the required tightening torque regularly. For

check and maintenance intervals see motor opera-
tion manual, section ‘maintenance schedule’.
Page 5.3 - 10 3668684en - (01) – 08.11

Components for radiator fan installation (Fig. 11 - 13)

[kg]
1 1 Bracket 51
2 1 Hub
3 1 Sleeve
4 1 Plate
5 6 Sleeve
6-9 ----
10 1 Fan motor 26
11 1 Fan wheel 43
12 2 Roller bearing
13 1 Shaft nut
14 1 Securing washer
15 ----
16 1 Sealing
17 ----
18 1 Disc
19 1 Hex. bolt M 20 x 30 Tightening torque Md = 350 Nm
23 2 6kt Mutter M 16
24 2 Washer
25 6 Washer
26 16 Spacer
27 1 Grid 59
28 1 Label
29 - 30 ----
32 8 Hex. nut M 16
34 13 Spacer
35 1 Plate / Wall 135
36 4 Stud bolt M 12 x 25 Tightening torque Md = 49 Nm
37 4 Disc
38 4 Hex. nut M 12
39 1 Plate 10x30x1900 Glued on
Table 3 Quantities are valid for 1 fan.
3668684en - (01) – 08.11 Page 5.3 - 11

20, 21, 22,

30, 31
Fig. 11 Fan drive installation – 3669634e-01
Page 5.3 - 12 3668684en - (01) – 08.11

20, 21, 22
Fig. 12 Fan drive installation – 2416197-02
3668684en - (01) – 08.11 Page 5.3 - 13

20, 21, 22
Fig. 13 Fan drive installation – 2417369-01
Page 5.3 - 14 3668684en - (01) – 08.11

5.4 ENGINE COUPLING
5.4 Engine coupling

This section is valid for
- coupling part no. 2 768 547
- with engine Caterpillar C 32.
5.4.1 General
Between engine and pump gearbox an elastic
coupling is installed (1, fig. 1).
5.4.2 Components
The parts listed in table 1 refer to fig. 1 to fig. 6.
Tightening torque Weight

Ref. No. Quantity Designation
[Nm] [kg]
1 1 Coupling complete 33
1a 1 Outer ring
1b 1 Inner part
2 6 Cyl. head bolt 5/8-11UNC x 65 - 8.8 Md = 203
3 6 Washer
4 10 Rubber roller
5 1 Hex. bolt M 20 x 65 – 8.8 Md = 410
6 1 Plate
7 1 Assembly strap
Liquid thread adhesive
Table 1
3721425en - (01) – 09.11 Page 5.4 - 1

5.4 ENGINE COUPLING
Fig. 1 Engine coupling – 3669591-01
Page 5.4 - 2 3721425en – (01) – 09.11

5.4 ENGINE COUPLING
5.4.3 Dismantling
Remove pump gearbox with inner coupling part as
described in chapter 7.4 and 5.3.
At pulling pump gearbox apart, secure the rubber

rollers against falling down.
For dismantling the inner part of the coupling

loosen the bolt (fig. 5, pos. 5). Remove plate (6)
and inner part of the coupling (1b) off the shaft.
For dismantling the outer part of the coupling

loosen the screws (fig. 1, pos. 2).
5.4.4 Assembly
Measure the axial play in each direction of the
engine crankshaft to ensure the engine thrust
bearings are not loaded. Record the result.
Disassemble coupling for mounting. Push the inner

part (1b) with the rubber rollers (4) off the outer
Fig. 3 Secure the rubber rollers - 642702-03
part (1a).
Clean contact surfaces. Contact surfaces must be

metallically clean (no rust), dry and grease-free. Grease the gearbox shaft.
Mount outer part (1a) with slightly oiled bolts (2) Push inner part (1b) onto the pump gearbox shaft.
and washers (3) to the flywheel of the engine. Measure the distance “S” between shaft and inner
Tighten the bolts in several stages crosswise until part.
the required tightening torque is reached.
The required distance is 4,7 ± 0,5 mm (see fig. 6)
The tightening torque of pos. 2 is:
Md = 203 Nm Tighten the inner part and plate (6) with bolt (5).
Install bolt with liquid thread adhesive.
Insert the rubber rollers (4) into each of the sockets The tightening torque of pos. 5 is:
of the inner part (1b). Their largest diameter should Md = 410
lay at the deepest point of the pockets.
Secure the rubber rollers with the assembly strap

(7). If the assembly strap is not available use a
string or tape secured with a slip knot. Ensure that
the loose end is placed to the gearbox side.
Put the loose end of the assembly strap upwards.
3721425en - (01) – 09.11 Page 5.4 - 3

5.4 ENGINE COUPLING
Connecting inner and outer part Check correct mounting
For easy assembly moisten the pockets of the Rotate the complete assembly a few times to en-
outer part with soap solution (10% liquid soap with sure that there is no interference. If there is, the
90% water) or silicon spray. source must be identified and eliminated.
Push the pump gearbox with the inner part of the Motor damage can occur as a result of high axial
coupling into the outer part. Ensure that the arrows bearings of the crank shaft. Prior to comissioning
cast into both coupling parts are aligned (fig. 4). the system, ensure that the crank shaft has axial
Incorrect positioning of outer and inner part can play.
occur material damage.
Measure the axial play of the engine crankshaft
again. Measure in each direction to ensure the
engine thrust bearings are not loaded. Compare
with the result of first measuring before coupling
was fitted. The result should be the same.
On completion of assembly work,

all installation inspections pre-
scribed by the engine manufac-
turer (e.g. measurement of axial
play of the engine crankshaft) must
be carried out.
Fig. 4 Positioning of inner and outer part - 642703-03
Pass the loosen end of the assembly strap through

the upper hole of the gearbox bell housing.
When the rubber rollers are held in place by outer

and inner part of the coupling remove the assem-
bly strap (7).
Push inner and outer part further together.
Connect engine and pump gearbox as described in

chapter 7.4 and 5.3.
Page 5.4 - 4 3721425en – (01) – 09.11

5.4 ENGINE COUPLING
2, 5 5 6
3721425en - (01) – 09.11 Page 5.4 - 5

5.4 ENGINE COUPLING
2, 5 5 6
Fig. 6 Engine coupling – installation – 3705207-01
Page 5.4 - 6 3721425en – (01) – 09.11

5.5 SWING GEARBOX - REMOVAL & INSTALLATION
5.5 Swing gearbox -

The removal and installation of the swing gearbox
is described in
chapter 7.3
2471306en - (00) Page 5.5 - 1

5.5 SWING GEARBOX - REMOVAL & INSTALLATION
Page 5.5 - 2 2471306en - (00)

5.6 PUMP GEARBOX - REMOVAL & INSTALLATION
5.6 Pump gearbox -

The removal and installation of the pump gearbox
is described in
chapter 7.4
2471307en - (00) Page 5.6 - 1

5.6 PUMP GEARBOX - REMOVAL & INSTALLATION
Page 5.6 - 2 2471307en - (00)

5.7 HYDRAULIC PUMPS - INSTALLATION
5.7 Hydraulic pumps - instal-

lation
The installation of the hydraulic pumps is de-
scribed in
chapter 8.7
2461189en - (00) Page 5.7 - 1

5.7 HYDRAULIC PUMPS - INSTALLATION
Page 5.7 - 2 2461189en - (00)

5.8 OIL COOLER - INSTALLATION
5.8 Oil cooler – installation Always ensure, that the oil cooler
sets are free of oil leaks and dirt, to
5.8.1 General avoid overheating of the machine
because of plugged coolers.
There are 2 identical oil cooler sets installed in the
oil cooler module. Do not damage the aluminium core
of the coolers when using pressure
cleaners.
5.8.2 Hydraulic oil cooler

Components for oil cooler installation
(The items in table 1 are referring to Fig. 1, 2 & 3 and are related to one oil cooler set)

[kg]
1 1 Oil cooler module complete 6 200
2 ----
3 1 Hood 220
4 1 Fan unit 135
5 ----
6 ----
7 1 Plate
8 1 Bracket
9 1 Bracket
10 1 Hydraulic oil cooler 335
11 1 Bracket 50,5
12 2 Tensioning bolt
13 2 Rubber mounting
16 1 Guard grid
17 26 Sleeve
18 20 Washer
19 ----
20 1 Rubber seal
21 1 Rubber seal
22 ----
23 ----
27 ----
3657716en - (00) Page 5.8 - 1


[kg]
32 20 Hex. bolt M 24 x 210 – 10.9 Tightening torque Md = 1 020 Nm
33 ----
34 ----
35 8 Hex. nut M 10
36 12 Hex. nut M 16
37 4 Hex. nut M 12
38 16 Washer
39 4 Washer
40 8 Washer
41 2 Hex. nut M 20
Table 1
Page 5.8 - 2 3657716en - (00)

24, 25, 26, 28,

29, 30, 31
Fig. 1 Hydraulic oil cooler – installation – 2441315a
3657716en - (00) Page 5.8 - 3

Fig. 2 Hydraulic oil cooler – installation – 2712295a
Page 5.8 - 4 3657716en - (00)

24, 25, 26, 28,

29, 30, 31, 32
Fig. 3 Hydraulic oil cooler – installation – 2712295b
3657716en - (00) Page 5.8 - 5

5.8.3 Oil cooler fan installation

The fans for the hydraulic oil coolers are driven by
hydraulic motors.
Components for oil cooler fan installation (Fig. 4 & 5)

(Quantities are valid for 1 fan.)

[kg]
1 1 Bracket 50,5
2 1 Hub
3 1 Sleeve
4 1 Plate
5 6 Sleeve
6-9 ----
10 1 Fan motor 25,5
11 Fan 41,0
12 2 Roller bearing
13 1 Shaft nut
14 1 Locking plate
15 ----
16 1 Felt strip
17 - 19 ----
22 6 Hex. bolt M 8 x 20 – 8.8 Tightening torque Md = 20,5 Nm
23 2 Hex. nut M16
24 2 Washer
25 6 Washer
Table 2
Page 5.8 - 6 3657716en - (00)

20, 21, 22
Fig. 4 Fan drive mounting – 2441315b
3657716en - (00) Page 5.8 - 7

20, 21, 22
Fig. 5 Fan drive mounting – 2416197-01
Page 5.8 - 8 3657716en - (00)

5.9 ROTOR - INSTALLATION
5.9 Rotor - installation

See also chapter 8.4.
The hydraulic systems of superstructure and un-

dercarriage are connected by means of the rotor.
The rotor is mounted on the superstructure.
Weight
[kg]
1 1 Rotor 473
2 1 Control valve block, right 151
3 1 Control valve block, left 167
4 1 Brake valve block, right 20
5 1 Brake valve block, left 20
6 4 Valve
8 6 Sleeve
9 1 Retainer 51
Table 1
7, 11
Fig. 1 F: Front Rotor with travel valve blocks – 3663237-02
3746327en - (00) – 03.12 Page 5.9 - 1

5.9 ROTOR - INSTALLATION
Fig. 2 F: Front Rotor with travel valve blocks (superstructure) 3711361--02
7, 11
Fig. 3 Installation of the rotor
Page 5.9 - 2 3746327en - (00) – 03.12

08.2018
6. Drive Unit
6040

DRIVE UNIT
6. DRIVE UNIT
If required, engine or motor workshop manuals can

be ordered from Caterpillar Global Mining HMS
GmbH.
3720206en – (00) Page 6 - 1

DRIVE UNIT
Page 6 - 2 3720206en – (00)

08.2018
7. Gearboxes
6040

CONTENTS
7. GEARBOXES
7.1 Introduction....................................................................................... 7.1 - 1
7.1.1 Foreword ........................................................................... 7.1 - 1
7.1.2 Safety instructions ............................................................. 7.1 - 1
7.1.3 General .............................................................................. 7.1 - 5
7.1.4 Checking procedures ......................................................... 7.1 - 5
7.1.5 Hubs and bearings ............................................................ 7.1 - 6
7.1.6 Fitting of toroidal sealing rings ........................................... 7.1 - 8
7.2 Travel gearbox .................................................................................. 7.2 - 1
7.2.1 General .............................................................................. 7.2 - 1
7.2.2 Dismantling and installing the travel gearbox .................... 7.2 - 3
7.2.3 Disassembly- and Assembly Instructions .......................... 7.2 - 6
7.3 Swing gearbox .................................................................................. 7.3 - 1
7.3.1 General .............................................................................. 7.3 - 1
7.3.2 Dismantling and installing the swing gearbox .................... 7.3 - 2
7.4 Pump gearbox................................................................................... 7.4 - 1
7.4.1 General .............................................................................. 7.4 - 1
7.4.2 Dismantling and installing the pump gearbox .................... 7.4 - 2
3720207en – (00) Page 7 - 1

CONTENTS
Page 7 - 2 3720207en – (00)

7 GEARBOXES
7.1 Introduction 7.1.2 Safety instructions

instructions
This chapter contains important information on
gearboxes installed in Caterpillar excavators. This Caterpillar hydraulic
excavator has been built in
The assembly of a gearbox requires care and
accordance with state-of-the-art
cleanliness. Incorrectly installed components may
standards and the recognized
cause severe gearbox damage even in short
safety rules.
operation time.
However, operating the machine if
Wash gearbox housings clean with a detergent or a fault is suspected or has
diesel fuel if no detergent is available. Eliminate the occurred, or carrying out repair
damage to machined surfaces caused during work inexpertly
dismantling (e.g. scratches). Clean each part
before refitting and check for damage or wear and  endangers the lives of people in
replace, if required. Before pressing in shafts, contact with it;
bearings, etc., oil the both parts.
Never use open flame for warming property.
up bearings or seats.
Stop the hydraulic excavator
Use hot plates, heating stoves or
immediately if you suspect or
similar equipment instead.
notice any damage to ensure the
safety of the operator, other people
To ensure the proper assembly always re-fit parts
or material property at the
assembled in a warm condition after their cooling
application area of the excavator.
down.
All components of Caterpillar
machines are perfectly tuned to
each other. Trouble-free operation
and a long service life can only be
spare parts.
2440570en - (02) Page 7.1 - 1

7 GEARBOXES
Personnel Personnel
Therefore secure and lock it. Wear a safety helmet, safety
Follow the accident prevention footwear and safety gloves.
service or repair the hydraulic Personnel carrying out work at
excavator. greater heights must wear safety
If you lack such knowledge, harnesses. Always put on a tested
experienced personnel, e.g. from harness which is equipped with fall
instructions. If you need assistance to carry out
Maintenance Manual and in assistant beforehand. The
particular the chapter individual responsibilities are to be
carefully observed to ensure
‘Fundamental Safety Instructions.’ safety.
the start and shut down
procedures described in the
Manual.
Page 7.1 - 2 2440570en - (02)

7 GEARBOXES

(e.g. pipes, coolers, hydraulic
Tools, hoists, slings, trestles and reservoirs and accumulators)
other devices must be in a reliable, depressurize them properly.
safe state.
bolts. Therefore during this and secured against inadvertent
procedure use a brass or copper start.
mandrel and wear safety glasses.
When climbing onto or off the protective devices.
machine use only ladders, steps,
platforms and handrails provided Before carrying out assembly work,
for this purpose. the machine and the equipment
must be secured against
Always keep ladders, steps and inadvertent movement, e.g. by
platforms in a non-slip state. placing the working equipment on
Remove any oil, grease, earth, clay, the ground.
immediately.
Securing the working system:
equipment Always observe the safety
regulations applicable to the
Secure the machine and the product when handling oils,
working equipment against greases and other chemical
inadvertent and unauthorized start. substances.
Position working equipment on the
ground in such a way that it cannot Close open unused bores, pipe and
move when mechanical or hose connections so that they are
hydraulic connections become impermeable to pressure.
detached. Refill the hydraulic system with
Use hoists or other appropriate collected drain hydraulic oil only
support devices when you install, through the return flow filters.
remove or displace any equipment Dispose of waste oil without
or component. Thus you prevent polluting the environment.
them from inadvertent movements, Observe the correct working
slip or fall. sequence when fitting or replacing
2440570en - (02) Page 7.1 - 3

7 GEARBOXES
Before carrying out works, Modifications of the machine

especially on the electrical system,
during which tools, spare parts, Unauthorized conversions or
etc. can contact electric cables, modifications of the hydraulic
always disconnect the battery: first excavator are forbidden for
the negative pole and then the reasons of safety.
positive pole. When reconnecting
the battery, connect first the Never modify the nominal pressure
positive and then the negative value of pressure relief valves
pole. without explicit approval from
Caterpillar. Do not remove the lead
Always replace defect, seals from pressure relief valves
mechanically pre-stressed and hydraulic accumulators.
components. Never open them!
The Service Manual contains no
information on such work.
Re-commissioning
machine is high and the
consumables have at least the Before re-commissioning:
same temperature. Therefore take
care to avoid burns or scalds.  Grease all lubricating points.
If the acid is splashed onto your  Carry out function checks of all
skin, rinse it with plenty of clean repaired components.
care immediately.
 Check all functions of the
excavator including brakes
If the acid is splashed in your eyes, during a test run. Release the
rinse thoroughly with running hydraulic excavator for re-
water and seek medical care commissioning only if all its
immediately. functions operate properly.
Never smoke when handling
flammable liquids.
easily.
Page 7.1 - 4 2440570en - (02)

7 GEARBOXES
7.1.3 General 7.1.4 Check procedures
In addition to the Operation and Maintenance  Noise

Manual and the Spare Parts Catalog, this
Service Manual contains information enabling the Mechanical gearboxes produce noise during
user of the Caterpillar hydraulic excavator to operation. The amount of noise depends on
safely operate, maintain and repair the machine in gearbox loading and condition. Normal gearbox
accordance with the specifications. noise consists of a spectrum of many different
frequencies. The greater part of it is produced by
The information in the Service Manual roller bearings and toothed wheels. If the bearings
corresponds to the standard technical specification or toothed wheels are damaged, you can hear
of the machine when it was delivered. rumbling and knocking or bumps and impacts. To
check the noise and identify its cause you can use
All sketches and drawings show general principles. a simple stethoscope.
 Leaks
No reference is made to special versions.
Oil losses caused by leaks are dangerous for two
Special equipment is normally not considered. reasons: on the one hand, a lack of oil causes a
gearbox breakdown; on the other hand, it pollutes
Technical modifications, which are introduced after the environment.
in the machines which are already in operation. Therefore eliminate them immediately!
the Service Manual on the Caterpillar website. Leaks can occur at sealing surfaces, joints and, in
most cases, at shaft outlets.
The Service Manual covers the information you
need when handling your excavator. However, You can quickly detect leaks with the help of leak-
detecting sprays. For this purpose, pressurize the
Caterpillar Global Mining HMS GmbH will be
gearbox slightly with compressed air and apply a
pleased to answer any questions you have on its
leak-detecting spray to the surface to check. If air
bubbles appear, the component under check has
dealer or your Caterpillar subsidiary.
leaks.
Otherwise you can use oil absorbing contrasting

colours (e.g. Spanish white) which can detect even
the least amount of leaks. Larger amount of leaks
with the formation of droplets require immediate
corrective actions up to replacement of the seals.
2440570en - (02) Page 7.1 - 5

7 GEARBOXES
7.1.5 Removal and fitting procedures  Removal of hubs
 Removal of bearings Always apply the force "F" required for removal of a
hub (2, Fig. 2) from a housing (1) to the outer ring
Before removal of a bearing, clean the surfaces of the bearing with a properly fitting mandrel (4).
around it. Remove any bearing locking devices During the removal support the housing (1) with
(lock rings, screw locks, etc.). spacer blocks or a spacer bushing (3) as closely as
possible to the bearing. The spacers are to enable
To determine the tools and the dismantling the application of the reaction force "F 1" required
procedure and to find out how the bearing was for the movement of the hub to the housing (1).
installed, use the corresponding cross-sectional
drawing.
To easily remove outer bearing rings pressed in a

housing, heat the housing evenly.
To extract a bearing (5, Fig. 1) from a shaft (6), use

a special tool, e.g. a double- or triple-arm extractor
(7). Apply the force "F" required for extraction as
closely as possible to the bearing seat, i.e. to the
inner ring of the bearing. In this case, the reaction
force "F1" acts on the shaft (6) via the spindle of
the extractor (7).
Fig. 2 Removal of a hub – 630235
Fig. 1 Removal of a bearing – 630236
Page 7.1 - 6 2440570en - (02)

7 GEARBOXES
 Fitting bearings  Fitting hubs
Fit roller bearings so that after the assembly you When inserting a hub (2, Fig. 4) into a housing (1),
can see the component side with the inscription. ensure that the required fitting force "F" acts on the
outer ring of the bearing via a fitting mandrel (4).
The instructions for the removal of bearings on the Support the housing (1) as closely as possible to
previous page refer to the fitting of bearings as the bearing mounting point so that it absorbs the
well. reaction force "F 1".
When a bearing (11, Fig. 3) is mounted on a shaft

(12), the fitting force "F" acts on the inner ring of
the bearing via a fitting bushing (4). Support the
shaft end opposite to the mounting direction of the
bearing so that it absorbs the reaction force "F 1".
Fig. 4 Fitting a hub – 630237
Fig. 3 Fitting a bearing – 630239
2440570en - (02) Page 7.1 - 7

7 GEARBOXES
 Fitting o-ring seals 7.1.6 Fitting toroidal sealing rings in

gearboxes
When fitting o-ring seals, e.g., rotary shaft seals (9,
Fig. 5), into a housing (8) use a suitable mandrel or Toroidal sealing rings (seals) are supplied by
fitting bushing (10) to prevent any damage to the Caterpillar by the meter.
sealing element.
To install these seals proceed as follows:
1. Place a seal into a groove and cut it off with a

slight tolerance.
2. Cut one end of the seal straight (not

diagonally) using a sharp and clean knife free
of grease.
3. Make a straight cut at the second end to cut

the seal to length. Cut it off 1 to 2 mm shorter
to give the toroidal sealing ring a slight pre-
stress in the groove (after gluing) and to
prevent it from leaving the groove during the
assembly. Too much pre-stress causes
twisting of the ring during the assembly and
increases leaks.
4. Glue the toroidal sealing ring together with

butt ends using adhesive Caterpillar part no. 0
861 732.
Fig. 5 Fitting an o-ring seal – 630238
5. Press the glued ends together by hand and
hold them for at least 30 seconds.
Always prevent any contact of the

adhesive with the skin. Otherwise
you risk skin detachment.
6. Insert the toroidal sealing ring into the groove.
If you have to install bushings or similar parts

over the seal, grease it before the installation.
Page 7.1 - 8 2440570en - (02)

7.2 TRAVEL GEARBOX
7.2 Travel gearbox Weights

Travel gearbox appr. 3 810 kg
7.2.1 General Sprocket appr. 2 070 kg
Travel motor (1 unit) appr. 145 kg
Table 1
Tools, hoists, slings, trestles and
other devices must be in a reliable,
safe state. Technical data
Secure any equipment or compo- Gearbox type: GFT 800
nent which is to be mounted or Part-no. 2 763 213
dismantled or whose position is to Ratio: i = 284,8
be changed using hoists or appro- Table 2
priate slinging/supporting devices
to prevent them from moving, slip-
ping or falling inadvertently.
This section is valid for the travel gearboxes
Part-no. 2 763 213
The travel gearbox forms one structural unit to-

gether with the travel motors and the parking
brakes.
It is designed as a 3-stage planetary gear system.
Ref.-no. Quantity Designation further remarks Weight

[kg]
1 1 Sprocket
2 96 Washer
3 48 M30 x 2 x 260 - 12.9 See section 7.2.2
4 48 M30 x 2 x 240 - 12.9 See section 7.2.2
5 8 M20 x 60 - 8.8 Tightening torque Md = 350 Nm
6 8 Washer
7 4 Plug
8 2 Plug
9 1 Travel gearbox
10 2 Travel motor
11 2 Valve
12 1 Housing
13 1 Deflector plate
Table 3
3664244en - (01) Page 7.2 - 1

7.2 TRAVEL GEARBOX
7.2.2 Dismantling and installing the 6. Loosen bolts (4, Fig. 1) of sprocket.
travel gearbox
7. Screw lifting eye bolts M 36 into the holes
Dismantling the travel gearbox provided (8, Fig. 3) and take up sprocket in
crane. Remove bolts (4, Fig. 1). Remove the 4
1. Remove housing (12, Fig. 1). plugs (7, Fig. 3) and force off sprocket with 4
bolts M 30 x 2 x 240, (these are the mounting
2. Remove deflector (13, Fig. 2). bolts for the sprocket).
3. Slacken track on corresponding side (cf. Op- 8. Drain gearbox oil out of gearbox and pre-
erating Instructions). chambers (cf. Servicing Instructions).
4. Open track in area marked by arrow A (Fig. 9. Dismantle hydraulic lines of travel motors and
2). plug open connections.
Collect escaping oil in a suitable container.
Secure track against rolling off the 10. Remove bolts (5, Fig. 3) and remove travel
track frame after it has disengaged motors.
from the sprocket (e.g. by using
chain hoists). 11. Pick up gearbox with crane, remove bolts (3,
Fig. 1) and lift gearbox out of the frame.
5. Start up one engine and move the machine
carefully until the sprocket is exposed.
3, 4
Fig. 1 Drive unit – travel – 2452502a-02
Page 7.2 - 2 3664244en - (01)

7.2 TRAVEL GEARBOX
4
Fig. 2 Deflector – 2452502b-02
3664244en - (01) Page 7.2 - 3

7.2 TRAVEL GEARBOX
3, 4, 5 5
Fig. 3 Travel gearbox with sprocket – 3666475a
Installing the travel gearbox

Apply the adhesive with ca. 10 mm
Installation is done in reverse sequence. clearance from the threaded holes to
ensure that no adhesive can be
Special instructions: forced into the threaded holes when
the gearbox is set down.
1. Cleaning
Penetration of adhesive into a
threaded hole leads to increased
Prior to installing the travel gearbox, all traces
friction and thus to invalidation of
of paint and grease must be cleaned from the
the starting torque data.
contact surfaces between gearbox and under-
carriage frame with thinner P/N 216 405 (arrow
C, Fig. 1). Use of the adhesive will result in transmission
of a radial load corresponding to three times the
2. Adhesive normal value.
As the adhesive transmits only slight tensile
When the travel gearbox is ready for installa- forces, there is no difficulty in separating the
tion, an adhesive (P/N 1 991 467) is applied to components.
the entire contact surface (arrow C, Fig. 1) of
the track frame in a thin, uniform coating with a
paint roller, hard brush or plastic spatula.
Page 7.2 - 4 3664244en - (01)

7.2 TRAVEL GEARBOX
Start gearbox installation as soon It is not permissible for more than

as the adhesive has been applied. one bolt to be unscrewed at the
same time.
The adhesive starts hardening
when the metal surfaces have been All bolts of this connection must be
joined without any air being admit- tightened within 8 hours!
48 hours at an ambient tempera-
The hardening process is initially 6 etc.) are then mounted by the same proce-
strongly delayed, so that the instal- dure.
lation time can be extended to a
maximum of 8 hours. When installation has been completed, the joint
between the gearbox and the undercarriage
At temperatures below -10°C, acti- frame must be sealed with silicon sealant
vator Part-no. 1 991 468 must be Part-no. 1 960 354 (arrow D, Fig. 1).
sprayed onto the second joining
surface - the surface with no adhe- 4. Installation of sprocket
sive.
Prior to installing the sprocket, all traces of paint
3. Installation and grease must be removed from the contact
surfaces between sprocket and travel gearbox
After installing the travel gearbox, first with solvent Part-no. 216 405 (arrows E and F,
Fig. 1).
tighten all bolts (3, Fig. 1) crosswise to
The contact surface (arrow F, Fig. 1) must be
900 Nm coated with mounting paste Part-no. 244 905.
The gearbox is then in full contact and any ex- 5. Adhesive

cess adhesive is forced out.
When the sprocket has been prepared for in-
The following procedure must then be observed stallation, apply adhesive Part-no. 1 991 417 to
in clockwise direction (1st cycle): the contact surface (arrow E, Fig. 1) (cf. Pt. 2).
 The 1st bolt is unscrewed completely. 6. Installation
 This bolt is pre-installed with a After installing the sprocket, first
joining torque of 650 Nm tighten all bolts (4, Fig. 1) crosswise to
 The bolt is then completely tightened 900 Nm.

with an
The sprocket is then in full contact and any ex-
additional turning angle of 150° cess adhesive is forced out.
and marked in a suitable way (e.g. with The following procedure must then be observed
paint). in clockwise direction (1st cycle):
Every 2nd bolt with odd nos. (3, 5, 7 etc.) is then  The 1st bolt is unscrewed completely.
turning angle in the same way.  This bolt is pre-installed with a
joining torque of 550 Nm
 The bolt is then completely tightened

with an
3664244en - (01) Page 7.2 - 5

7.2 TRAVEL GEARBOX
additional turning angle of 150° 7. Installation of travel motor
and marked in a suitable way (e.g. with Mount the travel motors. Insert bolts (5, Fig. 3)
paint). with liquid bolt locking medium P/N 900 257
Every 2nd bolt with odd nos. (3, 5, 7 etc.) is then and tighten with the torque specified in table 3.
turning angle in the same way. Connect hydraulic lines.
8. Filling with oil

It is not permissible for more than
Fill up travel gearbox and pre-chambers with oil
one bolt to be unscrewed at the
as specified in the Operating Instructions.
same time.
All bolts of this connection must be 9. Closing the track
tightened within 8 hours!
Bring track to a suitable position by moving the
excavator and close track.
6 etc.) are then mounted by the same proce-
dure.
7.2.3 Disassembly & assembly in-
structions for the gearbox
Please refer to the attached manual
SN2763213 - RDE 77925-01-R/08.03
Page 7.2 - 6 3664244en - (01)

Demontage- Montageanleitung
Disassembly- Assembly Instructions RDE 77925-01-R/08.03
Fahrgetriebe / Propel Drive

Sach-Nr. / Part-No. 2763213
Inhaltsverzeichnis Table of Contents
Kapitel Seite Chapter Page
1. Einleitung 1. Preliminary Notes

1.1 Einführung 3 1.1 Introduction 3
1.2 Anziehdrehmomente 4 1.2 Tightening Torques 4
1.3 Werkzeuge und Zubehör 4 1.3 Tools and Accecories 4
1.4 Passungen 9 1.4 Fit´s 9
2. Teileliste 2. Parts List

Teileliste Getriebe 11 Parts List Gearbox 11
3. Zeichnungen 18 3. Drawings 18
4. Demontage 4. Disassembly
4.1 Demontage Allgemein 19 4.1 Disassembly General 19
4.2 Demontage Stirnradstufe 20 4.2 Disassembly Spur Gear Stage 20
4.3 Demontage Planetengetriebe 30 4.3 Disassembly Planetary Gear 30
5. Montage 5. Assembly
5.1 Montage Allgemein 36 5.1 Assembly General 36
5.2 Montage Planetengetriebe 37 5.2 Assembly Planetary Gear 37
5.3 Montage Stirnradstufe 48 5.3 Assembly Spur Gear Stage 48
5.4 Montage 59 5.4 Assembly 59
Stirnradstufe / Planetengetriebe Spur Gear Stage / Planetary Gearbox
6. Probelauf 6. Test Run

6.1 Prüfstandsaufbau 61 6.1 Test set-up 61
6.2 Ölversorgung 61 6.2 Lubrication 61
6.3 Drehzahl, Laufzeit und Prüflast 61 6.3 Speed, Running Time, Test Load 61
6.4 Thermische Werte 61 6.4 Thermal Parameters 61
6.5 Laufgeräusch 61 6.5 Running Noise 61
6.6 Dichtigkeitsprüfung 61 6.6 Tightness Testing 61
6.7 Funktionsprüfung der Bremsen 62 6.7 Hydraulic Brakes 62
(falls vorhanden) (if supplied)
6.8 Fremdkörper 62 6.8 Oil Contamination Test 62
Sach-Nr. / Part-No. 2763213 RDE 77925-01-R/08.03 00-2/62

Einleitung Preliminary Notes 1.
1.1 Einführung 1.1 Introduction

Beachten Sie unbedingt die Sicherheitsbe- The safety instructions and the appropriate ac-
stimmungen und die einschlägigen Unfallver- cident prevention instructions have absolutely
hütungsvorschriften! to be observed !.
Bauen Sie nur Originalersatzteile ein. Exclusively install original spares.
Lassen Sie das Öl ab. Drain the oil from the gearbox.
Verwenden Sie dabei geeignete Auffanggefäße. For this purpose use suitable containers.
Markieren Sie vor dem Trennen verschraubte und Mark all screwed and toothed parts before disas-
verzahnte Teile auf deren Lage und Position. sembling to ensure that all parts are in the same
running direction and position at reassembling.
Achten Sie darauf, daß kein Schmutz oder Fremd- Make sure that no dirt or foreign bodies are allowed
körper in das Getriebe gelangt. to enter the gearbox.
Ersetzen Sie beschädigte Teile sowie Dichtringe Replace damaged parts and all seals with new L+S
durch neue Teile. parts.
Erwärmen Sie Lager vor der Montage nur auf Prior to assembly heat up bearings. Make sure to
Heizplatten bzw. im Wärmeofen. use a warming plate or in a heating furnace exclu-
Niemals mit direkter Flamme erwärmen. sively. Never heat up with a direct flame.
Vor dem Einbau sind alle beweglichen Teile sowie Oil all moving parts and seals prior to assembly.
Dichtringe einzuölen.
Unter Umständen ist der Farbanstrich des Getrie- In the event the paint coat of the gearbox has been
bes durch das Zerlegen und Zusammenbauen be- damaged as a result of disassembly / assembly
schädigt. Erneuern Sie deshalb den Farbanstrich, work, touch up or renew the paint coat as necessa-
um das Getriebe gegen Korrosion zu schützen. ry to protect the gear against corrosion.
Führen Sie einen Probelauf des Getriebes durch. Carry out a test run of the gearbox.
(Beachten Sie hierzu Kapitel 6.) (See chapter 6.)
Urheberrecht Copyright
Das Urheberrecht an Zeichnungen und Bildern The copyright on drawings and pictures remains
verbleibt bei uns. Eine Zeichnung (Bild) darf nur zu with us. A drawing (picture) can solely be used for
den Zwecken benutzt werden, zu denen sie dem the purposes it has been transferred to the reci-
Empfänger anvertraut ist. Ohne unsere ausdrückli- pient. Drawings and pictures must not be handed
che schriftliche Genehmigung dürfen Zeichnungen over or disclosed to third parties without our ex-
und Bilder nicht an Dritte weitergegeben oder die- press consent in writing.
sen zugänglich gemacht werden.
Jede Vervielfältigung - auch von Einzelheiten - ist Any reproduction of a drawing in whole or part is
untersagt. prohibited.
Zuwiderhandlungen werden gerichtlich verfolgt. Contraventions will be prosecuted.
Hinweis! Note!
Die verwendeten Bilder müssen nicht der be- The photos may show other drive types than the
schriebenen Getriebetype entsprechen. described one.

1.2 Anziehdrehmomente 1.2 Tightening Torques
Standard-Anziehdrehmomente MA in Nm für ungeschmierte Schaftschrauben (µ = 0,13 bis 0,17) mit Regelgewinde ohne zu-
sätzliche Einzelangaben (s. LSN 945 0201)
Standard-tightening torque MA in Nm for unlubricated shoulder stud (µ = 0,13 bis 0,17) with standard thread without additional details
(LSN 945 0201)
Schraube M6 M8 M 10 M 12 M 14 M 16 M 20 M 24 M 27 M 30 M 33 M 36 M 39 M 42
screw
8.8 Dr. 8,5 21,1 42,2 73,6 114,8 176,6 358 618 903 1216 1687 2129 2757 3394
10.9 Dr. 12,4 30,4 60,8 104,0 166,8 255,1 510 873 1285 1736 2364 3021 3924 4836
Dr. = Drehmomentschlüssel (torque wrench)
1.3 Werkzeuge und Zubehör 1.3 Tool and Accessories
- Anzugsvorrichtung für Wellenmutter - Mounting device for shaft nut

- Drehmomentschlüssel SW - Torque Wrench
- Kupferbolzen Copper shaft
- Maulschlüssel SW - Open-enden spanner
- Abziehvorrichtung für Wälzlager - Bearing Puller
- Montagehilfe für Gleitringdichtung - Mounting device for face seal
- Meißel - Chisel
- Dorn - Punch
- Sicherungsringzangen - Tools for Snap Rings
- Plastik Hammer - Plastic Hammer
- Augenschrauben M12; M16 - Eye Bolts M12; M16
- Fett z.B. FAG L71V (K3N-30 DIN 51501) - Grease e.g. FAG L71V (K3N-30 DIN 51501)
- LOCTITE 7061 - LOCTITE 7061

Bild / fig. 1 Montagewerkzeug Pos. 44

Mounting Tool Item 44
+ 2x Mutter / nut M16

+ 2x Augenschraube / eye bolt M16




Bild / fig. 5
Montagewerkzeug Pos. 18


Hilfswerkzeug Montage Gleitringdichtung

Pos.43
Auxiliary mounting tool face seal item 43
Bild / fig. 7


1.4 Passungen 1.4 Fit´s

(siehe Bild 9) (note fig. 9)
Position Bohrung / Bore Welle / Shaft
A Ø 150 J6 Ø 85 k6
B Ø 140 J6 Ø 80 k6
C Ø 635,075 N7 Ø 447,725 n6
D Ø 635,075 N7 Ø 447,725 k6
E Ø 197,82 +0,075 Ø 140 j6

+0,049
F Ø 177 +0,075 Ø 110 j6

+0,049
G Ø 240 J6 Ø 160 m6
H Ø 240 J6 Ø 160 m6
I Ø 240 K6 Ø 160 k6
J Ø 86,74 +0,043 Ø 60 j6
+0,023

A B C D E F
G H J I
Bild / fig. 9

Teileliste Parts List 2.

Teileliste Parts List
Sach-Nr. / Part-No. 2763213 Sach-Nr. / Part-No. 2763213
Die im Anhang aufgeführten Positio- Some of the parts list items listed in
nen der Teileliste können zum Teil nur the appendix can only be obtained as
als Ersatzteil-Kits bezogen werden. spare parts kits.
Fragen Sie die entsprechenden Kits Please address your enquiries for the
über unseren Verkauf-Ersatzteile an. required kits to our spare parts sales
department.

30.07.2003 Teileliste / Parts List
Matnr./Material No :
Auftrag/Order :
Produkt/Product : 2763213
Zeichnungs-Nr./Drawing No :
Menge Pos. Benennung

Quantity Item Designation
1,000 000 Gehäuse

Housing
1,000 002 Tragachse

Spindle
1,000 003 Hohlrad

Ring gear
1,000 004 Hohlrad GFT

Ring gear
1,000 005 Deckel

Cover
1,000 006 Planetensteg

Planet carrier

Planet carrier

Planet carrier
5,000 009 Planetenrad

Planet gear

Planet gear

Planet gear
1,000 013 Sonnenrad

Sun gear
1,000 014 Sonnenrad

Sun gear
1,000 015 Sonnenradwelle

Sun gear shaft
2,000 016 Antriebswelle

Input shaft
1,000 017 Stirnrad

Spur wheel

Auftrag/Order :

1,000 018 Wellenmutter

Shaft nut
1,000 019 Mitnehmer

Coupler
2,000 020 Dichtungsring

Seal ring
1,000 021 Scheibe

Disk
1,000 022 Gehäusescheibe

Housing washer
1,000 023 Scheibe

Disk
1,000 024 Anlaufscheibe

Locating ring
1,000 027 Gehäuse

Housing
1,000 028 Flansch

Flange
1,000 029 Zwischenring

Spacer ring
2,000 030 Kegelrollenlager

Tapered roller bearing
5,000 031 Zylinderrollenlager

Cylindrical roller bearing


3,000 034 Rillenkugellager

Ball bearing

Auftrag/Order :




Locating ring

Locating ring
2,000 041 Zylinderstift

Cylindrical dowel pin
4,000 042 Zylinderschraube

Socket head cap screw
1,000 043 Gleitringdichtung

Face seal
2,000 044 Radialdichtring

Radial shaft seal ring
4,000 045 Radialdichtring


36,000 049 6kt-Schraube M 16x60

Hex head bolt
DIN 931
11,000 050 6kt-Schraube M 16x90

Hex head bolt
2,000 060 Sicherungsring

Snap ring

Auftrag/Order :



Snap ring

Snap ring

Snap ring

Snap ring

Snap ring

Snap ring

Snap ring

Snap ring

Snap ring

Snap ring
2,000 075 O-Ring

O-ring

Auftrag/Order :

2,000 076 O-Ring

O-ring
1,000 077 O-Ring 110x3

O-ring
2,400 078 Rundschnur

Chord
7,000 081 Verschlußschraube

Screw plug
7,000 082 Dichtring

Seal ring
1,000 083 Entlüfter

Vent
7,000 084 Dichtring

Seal ring

Screw plug
1,000 086 Dichtring

Seal ring
1,000 087 Zylinderstift

1,000 088 Scheibe

Disk
2,000 089 O-Ring

O-ring

Auftrag/Order :

2,000 090 6kt-Schraube

Hex head bolt
1,000 094 Dichtung

Gasket
2,000 096 Motorlaterne

Motor bell housing
2,000 097 O-Ring

O-ring

Screw plug

Screw plug
4,000 101 Dichtring

Seal ring

Zeichnungen Drawings 3.
Einbauzeichnung 2763213 Installation drawing 2763213

Ersatzteilzeichnung 2763213 Spare parts drawing 2763213
Unsachgemäße Handhabung beim Opening, disassembling and reas-

Öffnen, Zerlegen und Zusammen- sembling the equipment inexpertly
bauen kann zur Gefährdung von Per- may entail danger to persons, the
sonen, der Anlage und des Produktes plant and the product.
führen.
Derartige Arbeiten darf deshalb nur Such work must therefore be carried
Fachpersonal durchführen, das vom out only by expert personnel authori-
Hersteller ermächtigt und besonders zed and especially trained by the ma-
ausgebildet wurde nufacturer.
Für Schäden, gleich welcher Art, die The manufacturer will not assume lia-
durch Nichtbeachtung dieser Vor- bility for any kind of damage resulting
schrift entstehen, übernimmt der Her- from the noncompliance with the in-
steller keine Haftung. structions given in this operating in-
structions.

2763213
2763213
Demontage Disassembly 4.
4.1 Demontage Allgemein 4.1 Disassembly General
Getriebe nur im ausgebautem Zustand Make sure to remove the gearbox from
demontieren. the machine frame before disas-
sembling it.
Für die Demontage des Fahrgetriebes sind folgen- Prior to disassembly prepare the propel drive as
de Vorarbeiten erforderlich: follows:
Beachten Sie hierzu auch Kapitel 8 der Also observe chapter 8 of Operating
Betriebsanleitung. Instructions.
• Getriebeöl ablassen. Lösen Sie dafür

Verschlußschrauben (Pos. 81, 82, 83,
• Remove screw plugs (item 81, 82, 83,
84, 98) and drain oil. Use suitable oil
84, 98). Verwenden Sie dabei geeigne- drain pan.
te Auffanggefäße. Gear lube oil volume:
Ölinhalt: - planetary gear: approx. 22,45 gall
- spur gear stage: approx. 2,25 gall
- Planetengetriebe: ca. 85l
- motor mounting location: approx. ,013 gall
- Stirnradvorstufe: ca. 8,5l
- Motoreinbauraum: ca. 0,5l
• Hydraulikmotoren vom Getriebe ab-

bauen und Anschlüsse mit Hilfsdeckel
• Dismount hydraulic motors from gear-
box and seal ports with provisional
verschließen. cover.
Achten Sie beim Transport auf eine When handling the equipment make
ausreichende Tragkraft des Kranes. sure the carrying capacity of the crane
Getriebegewicht ohne Motoren is adequate.
ca. 3800 kg. Weight without motors appr. 8378 lbs.
• Stellen Sie sicher, daß das abgesetzte

Getriebe seine Lage nicht ändern
• Make sure the set down gearbox rests
immovably.
kann.

4.2 Demontage Stirnradgetriebe / Disassembly Spur Gear Stage
Lassen Sie das Öl ab (Pos. 98; 84). Verwenden

Sie dabei geeignete Auffanggefäße.
Hinweis !
Drain the oil from the gearbox (item 98; 84). For
this purpose use suitable containers.
Note !
Bild / fig 10
Motorbefestigungsschrauben lösen.
Hinweis !
Remove motor mounting bolts.
Note !
Bild / fig. 11
Hydromotor und O-Ring (Pos. 97) entfernen.
Hinweis !
Remove hydraulic motor and O-ring (item 97).
Note !
Bild / fig. 12
Zylinderschrauben (Pos. 61) lösen und entfernen.
Loosen and remove socket head cap screws (item

61).
Bild / fig. 13

Motorlaterne (Pos. 96) entfernen.
Remove motor bell housing (item 96).
Bild / fig. 14
O-Ring (Pos. 89) entfernen.
Remove o-ring (item 89).
Bild / fig. 15
Verschlußschraube (Pos. 81; 82) lösen und Öl ab-

lassen.
Ölauffangbehälter benutzen!
Remove screw plugs (item 81;82) and drain oil.

Use suitable oil drain pan.
Bild / fig. 16
6kt-Schrauben (Pos. 50) lösen und entfernen.
Loosen and remove hex head bolts (item 50).
Bild / fig. 17

Komplett montiertes Gehäuse (Pos. 27+28) ab-

bauen.
Dismantle complete mounted housing (item

27+28).
Bild / fig. 18
1x O-Ring (Pos. 76) entfernen.
Remove 1x o-ring (item 76).
Bild / fig. 19
Zylinderstifte (Pos. 41) austreiben.
Expel cylindrical dowel pins (item 41).
Bild / fig. 20

42).
Bild / fig. 21

Flansch (Pos. 28) aus Einpaß von Gehäuse (Pos.

27) entfernen.
Remove flange (item 28) out of fit from housing (i-

tem 27).
Bild / fig. 22
Hinweis !
Note !
Bild / fig. 23
Antriebswellen (Pos. 16) ausbauen.

Lagerinnenringe von Zylinderrollenlager (Pos.
35+36) verbleiben auf der Antriebswelle.
Hinweis !
Dismantle input shafts (item 16). The bearing inner
rings of cylindrical roller bearings (item 35+36) re-
mains on the input shaft.
Note !
Bild / fig. 24
1x Rillenkugellager (Pos. 34) von Stirnrad (Pos. 17)

abziehen.
Hinweis !
Pull off 1x ball bearing (item 34) from spur wheel
(item 17).
Note !
Bild / fig. 25

Stirnrad (Pos. 17) entfernen.
Hinweis !
Remove spur wheel (item 17).
Note !
Bild / fig. 26
Ggf. 2tes Rillenkugellager (Pos. 34) von Stinrad

(Pos. 17) abziehen.
Hinweis !
nd
If necessary pul- of 2 ball bearing (item 34) from
spur wheel (item 17).
Note !
Bild / fig. 27
Falls erforderlich Aussenringe mit Wälzkörpern der

Zylinderrollenlager (Pos. 35+36) aus den Aufnah-
mebohrungen entfernen.
Hinweis !
If necessary remove outer rings of bearings with
rolling elements from the cylindrical roller bearings
(item 35+36).
Note !
Bild / fig. 28
Sicherungsring (Pos. 60) entfernen.
Hinweis !
Remove snap ring (item 60).
Note !
Bild / fig. 29

Dichtungsring (Pos. 20) mit Wellendichtringen

(Pos. 45) ausbauen.
Dismantle the seal ring (item 20) with mounted ra-

dial shaft sealing rings (item 45).
Bild / fig. 30
Wellendichtringe (Pos. 45) aus Aufnahmebohrung

von Dichtungsring (Pos. 20) entfernen.
Hinweis !
Remove the shaft sealing rings (item 45) out of the
location hole of seal ring (item 20).
Note !
Bild / fig. 31
Bild / fig. 32
Sonnenrad (Pos. 14) entnehmen.
Remove sun gear (item 14).
Bild / fig. 33

Sicherungsring (Pos. 69) lösen.
Loosen snap ring (item 69).
Bild / fig. 34
Kompletten Planetensteg (Pos. 8) mit Scheibe

(Pos. 21) ausbauen.
Dismantle complete planetary carrier (item 8) with

disk (item 21).
Bild / fig. 35

Achtung!
Schrauben sind mit LOCTITE 270 gesichert. Vor
dem lösen ggf. mit Flamme erwärmen.

48).
Attention!
Bolts are fastened with LOCTITE 270. Heat with
flame prior to loosing.
Bild / fig. 36
Hohlrad (Pos. 4) ausbauen.
Dismantle ring gear (item 4).
Bild / fig. 37

Bild / fig. 38
Hilfswerkzeug (Bild 2) auf Mitnehmer (Pos. 19)

montieren und mit Sicherungsring (Pos. 69) befes-
tigen.
Mount a suitable fixture (fig. 2) onto coupler (item

19) and secure with snap ring (item 69).
Bild / fig. 39
Montiertes Hilfswerkzeug in Kran einhängen und

Mitnehmer (Pos. 19) unter Kettenspannung aus
Getriebe entfernen.
Hang suitable fixture onto a crane and create slight

string tension. Remove coupler (item 19) out of
gearbox.
Bild / fig. 40
Hilfswerkzeug entfernen.
Remove suitable fixture.
Bild / fig. 41

Rillenkugellager (Pos. 34) mit Abziehvorrichtung

von Mitnehmer (Pos. 19) abziehen.
Hinweis !
Pull off ball bearing (item 34) with a pulling-off devi-
ce from coupler (item 19).
Note !
Bild / fig. 42
Bild / fig. 43
Anlaufscheibe (Pos. 24) entfernen.
Remove locating ring (item 24).
Bild / fig. 44
Bild / fig. 45

Wellendichtringe (Pos. 44) aus Aufnahmenbohrung

von Tragachse (Pos. 1) ausbauen.
Dismantle the radial shaft sealings (item 44) out of

the location hole of spindle (item 1).
Bild / fig. 46
Sicherungring (Pos. 73) entfernen.
Remove the snap ring (item 73).
Bild / fig. 47
Planetenräder (Pos. 12) einschließlich der Zylinder-

rollenlager (Pos. 33) von Planetenbolzen mit Ab-
ziehvorrichtung abziehen.
Hinweis !
Pull-off the planet gears (item 12) included the
cylindrical roller bearings (item 33) from the plane-
tary-pins with a pulling-off device.
Note !
Bild / fig. 48
Scheibe (Pos. 21) entfernen.
Remove disk (item 21).
Bild / fig. 49

4.3 Demontage Planetengetriebe / Disassembly Planetary Gearbox
Verschlußschraube (Pos. 81; 82) lösen und Öl ab-

lassen.
Ölauffangbehälter benutzen!
Remove screw plugs (item 81;82) and drain oil.

Use suitable oil drain pan.
Bild / fig. 50
Deckelbefestigungsschrauben (Pos. 49) lösen.

ACHTUNG!
Schrauben sind mit LOCTITE 270 gesichert, vor
dem Lösen mit Flamme erwärmen.
Loosen cover fixing bolts (item 49).

ATTENTION!
Bolts are fastened with LOCTITE 270. Heat with
flame prior to loosing.
Bild / fig. 51
Abdrückgewinde für Deckel (Pos. 5) benutzen.
Hinweis !
Use threaded holes for cover (item 5).
Note !
Bild / fig. 52
2x Augenschrauben M16 in Deckel (Pos. 5) ein-

schrauben, in Kran einhängen und Deckel mit
O-Ring (Pos. 78) entfernen,
Insert 2x Eye Bolts M16 into cover (item 5), hang

onto crane and remove cover with o-ring (item 78).
Bild / fig. 53

Sonnenradwelle (Pos. 15) entnehmen.
Take out sun gear shaft (item 15).
Bild / fig. 54
Kompletten Planetenträger der Vorstufe entneh-

men.
Remove complet pre-stage.
Bild / fig. 55

ACHTUNG!
Evtl. müssen die Planetenräder abgezogen wer-
den.

ATTENTION!
If necessary pull-off the palnet gears.
Bild / fig. 56
Kompleten Planetensteg der Hauptstufe mit Siche-

rungsring (Pos. 68) und Scheibe (Pos. 23) ent-
nehmen.
Remove complete main planetary stage including

snap ring (item 68) and disk (item 23).
Bild / fig. 57

Bohren Sie im Bereich der Zylinderstifte (Pos. 87)

entsprechend der beiliegenden Skizze ein Loch in
die Wellenmutter (Pos. 18).
Start drilling one side of the shaft nut (item 18) clo-
se to one of the dowel pins (item 18) according to
the attached sketch.
Bild / fig. 58
Setzen Sie neben diese Bohrung eine weitere und

wiederholen Sie den Vorgang zum AußenØ der
Wellenmutter (Pos. 18) hin, bis diese Seite ausge-
Hinweis ! bohrt ist.
Wiederholen Sie die Arbeitsschritte um 180° ver-
setzt an der Wellenmutter.
Drill another hole next to the one you just comple-

Note ! ted and keep working your way towards the shaft
nut (item 18) outside diameter until that side is dril-
led out.
Go 180° degrees around the shaft nut and start the
processe over again.
Bild / fig. 59
Wellenmutter (Pos. 18) mit Hilfe eines Meißels im

Bereich der Ausbohrungen Sprengen und von der
Tragachse (Pos. 1) entfernen.
Hinweis !
Use a chisel to open up the shaft nut (item 18)
where you completed your drilling and remove it
from the spindle (item 1).
Note !
Bild / fig. 60
Reinigen Sie das Gewinde auf der Tragachse

(Pos. 1) mit einer Drahtbürste von allen Materia-
lien.
Hinweis !
Clean area from all materials and wire brush the

threads clean on the spindle (item 1).
Note !
Bild / fig. 61

3x Augenschrauben M16 in entsprechende Gewin-

de von Hohlrad (Pos. 3) eindrehen.
Insert 3x eye bolte M16 into matching threads of

ring gear (item 3).
Bild / fig. 62
Hohlrad (Pos. 3) in Kran einhängen und leichte

Kettenspannung erzeugen.
Hinweis !
Hang ring gear (item 3) crane and create slight
string tension.
Note !
Bild / fig. 63
Oberes Kegelrollenlager (Pos. 30) mit Flamme er-

wärmen.
Hinweis !
Heat upper tapered roller bearing (item 30) with
flame.
Note !
Bild / fig. 64
Hohlrad (Pos. 3) mit oberen Kegelrollenlager (Pos.

30) von Tragachse (Pos. 1) abziehen.
Remove the ring gear (item 3) with upper tapered

roller bearing (item 30) from the spindle (item 1).
Bild / fig. 65

Rollenkäfig des unteren Kegelrollenlagers (Pos.

30) gleichmäßig am Umfang mit Flamme erwär-
men.
Hinweis !
Heat roller cage of lower tapered roller bearing

(item 30) on ist circumference evenly.
Note !
Bild / fig. 66
Unteres Kegelrollenlager (Pos. 30) entfernen.
Remove lower tapered roller bearing (item 30).
Bild / fig. 67
Gleitringdichtungshälfte (Pos. 43) aus Tragachse

(Pos. 1) entfernen.
Remove the face seal half (item 43) from the

spindle (item 1).
Bild / fig. 68
Dichtung (Pos. 94) von Tragachse (Pos. 1) entfer-

nen.
Remove gasket (item 94) from the spindle (item 1).
Bild / fig. 69

Scheibe (Pos. 88) von Tragachse (Pos. 1) entfer-

nen.
Remove disk (item 88) from spindle (item 1).
Bild / fig. 70
Gleitringdichtungshälfte (Pos. 43) aus Hohlrad

(Pos. 3) entfernen.
Remove the face seal half (item 43) from the ring
gear (item 3).
Bild / fig. 71

Montage Assembly 5.
5.1 Montage Allgemein 5.1 Assembly General
Vor der Montage sind folgende Ver- Prior to assembly the following in-
schleißprüfungen erforderlich: spections of wear and tear are requi-
red:
• Prüfen Sie auf Verschleiß:

• Check for wear:
- axiale Anlaufflächen - axial contact faces
- Paßsitze - machined seats
- Gewindebohrungen - threaded holes
• Prüfen Sie alle Dichtflächen auf:

- Beschädigung
• Check all sealing faces for:
- damage
• Prüfen Sie die Lager auf:

• Check the bearings for:
- Verwendbarkeit (Spiel übermäßig) - usability (excessive clearance)
- visuelle Prüfung - visual appearance
• Prüfen Sie die Verzahnung auf:

• Check the gear teeth for:
- Zahnausbrüche - tooth breakage
- Pittings - pitting
- Rißbildung - cracks
- Gratbildung - burrs
- Verschleiß - wear
MET-L-CHEK / Rißprüfung:
1. Entfetten und reinigen der Prüfteile

(z.B. Spezialreiniger NPU).
1. Degrease and clean the parts to be
checked (e.g. special cleaner NPU).
2. Aufbringen des Eindringmittel

(z.B. DYE VP 30).
2. Apply penetrant fluid (e.g. DYE VP 30).
Reaction time approx. 5-30 minutes
Einwirkzeit ca. 5-30 Min. je nach Tem- depending on temperature and mate-
peratur und Werkstoff. rial.
3. Werkstück von Eindringmittel reini-

gen.
3. Clean off penetrant fluid from work
piece (e.g. with special cleaner NPU or
(z.B. mit Spezialreiniger NPU oder water). Allow surface to dry.
Wasser)
Oberfläche trocknen lassen.
4. Den Entwickler „weiß“, hauchdünn

auftragen. Nach einer kurzen Trocken-
4. Apply a very thin layer of developer
„white“. After a short drying time, the
zeit tritt aus den Fehlstellen das Ein- penetrant fluid (e.g. DYE VP 30) emer-
dringmittel (z.B. DYE VP 30) aus und ges from the defective spots and crea-
bildet mit dem weißen Entwickler ei- tes a red contrast to the white develo-
nen roten Kontrast. per.
5. Inspektion – rote Linien im weißen

Entwicklerfeld zeigen Risse oder Ü-
5. Inspection – red lines on the white de-
veloper field indicate cracks or over-
berlappungen an, während punktför- lappings, while point shaped colour
mige Farbaustritte als Poren zu werten patterns can be rated as blowholes
sind. and pores.

Montage Assembly 5.
5.2 Montage Planetengetriebe / Assembly Planetary Gearbox

Vor der Montage des Getriebes sind alle Teile
sorgfältig zu säubern.
Hinweis !
Note! Prior to gearbox assembly clean all parts carefully.
Bild / fig. 72
Aufnahmebohrung für die Gleitringdichtung (Pos.

43) in Tragachse (Pos. 1) und Hohlrad (Pos. 3)
Hinweis ! entfetten (z.B. LOCTITE 7061).
Note!
Degrease and dry the cavities for the face seal
(item 43) in the spindle (item 1) and in the ring gear
(item 3) (e.g. with LOCTITE 7061).
Bild / fig. 73
Gleitringdichtungs-O-Ring mit Spiritus benetzen.
Wet face seal o-ring with spirit of wine cleaner.
Bild / fig. 74
Die 2 Außenringe der Kegelrollenlager (Pos. 30) in

flüssigem Stickstoff auf –180°C abkühlen.
Use nitrogen to cool down the two outer rings of

tapered roller bearings (item 30) to approx.
–180°C.
Bild / fig. 75

Montage Assembly 5.
Scheibe (Pos. 88) auf Tragachse (Pos. 1) montie-

ren (auf richtige Einbaulage „Fase“ achten / Schei-
be bei Bedarf erwärmen).
Mount disk (item 88) onto spindle (item 1).

Observe correct installation position „chamfer“ /
heat disk if necessary.
Bild / fig. 76
Gleitringdichtungshälfte (Pos. 43) unter gleichmä-

ßigem Druck auf die Dichtfläche in die Aufnahme-
bohrung der Tragachse (Pos. 1) einsetzen.
Install one half of face seal (item 43) into cavity of

spindle (item 1) with even pressure around its cir-
cumference.
Bild / fig. 77
Mit geeignetem Hilfsmittel O-Ring der Gleitring-

dichtung in die entsprechende Aufnahmebohrung
einpressen.
Use a suitable device to press the face seal o-ring

into cavity of spindle.
Bild / fig. 78
Dichtung (Pos. 94) auf Tragachse (Pos. 1) montie-

ren.
Mount gasket (item 94) onto spindle (item 1).
Bild / fig. 79

Montage Assembly 5.
In Stickstoff abgekühlten Außenring von oberen

Kegelrollenlager (Pos. 30) in Hohlrad (Pos. 3) ein-
legen (auf richtige axiale Anlage prüfen).
After cooling-off with nitrogen, insert outer ring of

upper tapered roller bearing (item 30) into ring gear
(item 3) (check for proper axial seat).
Bild / fig. 80
Hohlrad um 180° wenden. Außenring von unteren

Kegelrollenlager in Hohlrad (Pos. 3) montieren (auf
richtige axiale Anlage prüfen).
Turn around ring gear about 180° . Insert outer ring

of lower tapered roller bearing into ring gear (item
3) (check for proper axial seat).
Bild / fig. 81
Gleitringdichtungshälfte (Pos. 43) unter gleichmä-

ßigem Druck auf die Dichtfläche in die Aufnah-
menbohrung des Hohlrades (Pos. 3) einsetzen.
Install one half of face seal (item 43) into cavity of

ring gear (item 3).
Bild / fig. 82
Innenring und Rollenkäfig vom unteren Kegelrol-

lenlager (Pos. 30) auf ca. 120°-130°C erwärmen
und auf Tragachse (Pos. 1) montieren (auf richtige
axiale Anlage prüfen).
Heat inner ring and roller cage of below tapered

roller bearing to approx. 120°-130°C and mount
onto spindle (item 1).
(Check for proper axial seat)
Bild / fig. 83

Montage Assembly 5.
Dichtung (Pos. 94) spannen.
Tension the gasket (item 94).
Bild / fig. 84
Dichtung (Pos. 94) einfetten.
Grease gasket (item 94).
Bild / fig. 85
Gleitflächen der Gleitringdichtung (Pos. 43) mit Öl-

film versehen.
Wet the sliding surfaces of the face seal (item 20)

with oil.
Bild / fig. 86
Hohlrad auf Tragachse (Pos. 1) aufsetzen.
Install ring gear onto spindle (item 1).
Bild / fig. 87

Montage Assembly 5.
Oberen Innenring mit Rollenkranz von Kegelrol-

lenlager (Pos. 30) auf ca. 120°-130°C erwärmen
und auf Tragachse (Pos. 1) montieren.
Vor weiterer Montage Abkühlzeit von ca. 15min.
einhalten.
Heat upper ring with roller cage of tapered roller

bearing (item 30) to approx. 120°-130°C and mount
onto spindle (item 1).
Allow cooling time of approx. 15 minutes before
continning assembly.
Bild / fig. 88
Gewinde der Tragachse (Pos. 1) und der Wellen-

mutter (Pos. 18) entfetten (z.B mit LOCTITE 7061).
Hinweis !
Note! Degrease threads of spindle (item 1) and shaft nut

(item 18) (e.g. with LOCTITE 7061).
Bild / fig. 89
Gewinde der Wellenmutter (Pos. 18) gleichmäßig

mit LOCTITE 638 bestreichen.
Evenly apply coat of LOCTITE 638 to thread of

shaft nut (item 18).
Bild / fig. 90
Wellenmutter (Pos. 18) mit Ringkerbe nach oben

(sichtbar) montieren.
Mount shaft nut (item 18) with groove on upper

side (visible).
Bild / fig. 91

Montage Assembly 5.
Wellenmutter (Pos. 18) von Hand mit Hilfsvorrich-

tung (Bild 5+6) voranziehen.
Pretighten shaft nut (item 18) by hand with a sui-

table device (fig. 5+6).
Bild / fig. 92
Vorrichtung zum Anziehen der Wellenmutter auf-

setzen.
Mount an adequate device to tighten the shaft nut.
Bild / fig. 93
ACHTUNG! Das Hohlrad ist während des Anziehvor-

ganges der Wellenmutter mehrfach in eine Richtung zu
drehen!
- Wellenmutter (Pos. 18) – mittels einer Vorrichtung mit ei-
Hinweis ! nem Anziehdrehmoment von 41000 Nm anziehen.
- Die anschließende Aushärtezeit für den Kleber beträgt
24 Std.
ATTENTION! While adjusting the bearing unit via the shaft

Note! nut the ring gear has to be turned in one direction several
times!
- Tighten shaft nut (item 18) – by using an adequate device
with a tightening torque of 41000 Nm
- The LOCTITE setting time equals 24 hours at room tempe-
rature.
Bild / fig. 94
Zylinderstift (Pos.87) einsetzen.
Insert cylindrical dowel pin (item 87).
Bild / fig. 95

Montage Assembly 5.
Planetenträger der Hauptstufe (Pos. 6) mit einge-

legter Scheibe (Pos. 23) in das Getriebe einsetzen.
Install planet carrier of main stage (item 6) with

mounted disk (item 23).
Bild / fig. 96
Neuen Sicherungsring (Pos. 68) so montieren das

die Sicherungsringaugen zwischen zwei Planeten-
bolzen stehen.
Mount a new snap ring (item 68) that the snap ring
eyes are between two planetary pins.
Bild / fig. 97
Aufnahmebohrung von Gehäusescheibe (Pos. 22)

mit LOCTITE 640 bestreichen und die in flüssigen
Stickstoff auf –180°C abgekühlte Scheibe mit
sichtbarer Ölschmiernut montieren.
Apply coat of LOCTITE 640 to the cavity of housing

washer (item 22). Use nitrogen to cool down
(-180°C) the washer and mount it with the lubricati-
on groove on upper side (visible).
Bild / fig. 98
Vormontierte Planetenräder (Pos. 9+31) auf ca.

120°-130°C erwärmen und auf die Planetenbolzen
von Planetensteg (Pos. 6) montieren.
Heat pre-assembled planet gears (item 9+31) to

approx. 120°-130°C and mount them onto the pla-
netary pins of planet carrier (item 6).
Bild / fig. 99

Montage Assembly 5.
Planetenräder mit neuen Sicherungsringen (Pos.

74) sichern.
Secure the planet gears with new snap rings

(item 74).
Bild / fig. 100
Komplett montierten Planetensteg der Vorstufe in-

klusive Sonnenrad (Pos. 13) in das Getriebe ein-
setzen.
st
Install completely pre-assembled 1 planet stage
including sun gear (item 13) into gear drive.
Bild / fig. 101
Sonnenradwelle (Pos. 15) einsetzen.
Install sun gear shaft (item 15).
Bild / fig. 102
Axialspiel prüfen:
Spiel zwischen Anlauffläche der Sonnenradwelle
Hinweis ! (Pos. 15) und dem Zwischenring (Pos. 29) vor der
Montage des Deckels (Pos. 5) prüfen.
(Sollwert 1-2 mm)
Note! Checking of axial clearance:

Determine clearance between contact face of sun
gear shaft (item 15) and spacer ring (item 29) by
measuring parts prior to assembly of cover
(item 5).
(Recommended clearance 1-2 mm)
Bild / fig. 103

Montage Assembly 5.
Neuen O-Ring (Pos. 78) in entsprechende Nut des

Deckels (Pos. 5) einlegen.
O-Ring und Gegenfläche im Hohlrad (Pos. 3) leicht
einölen.
Insert a new o-ring (item 78) into the o-ring groove

of cover (item 5).
Lubricate o-ring and opposite surface of ring gear.
Bild / fig. 104
Aufnahmebohrung von Anlaufscheibe (Pos. 40) mit

LOCTITE 640 bestreichen und die in flüssigen
Stickstoff auf –180°C abgekühlte Scheibe mit
sichtbarer Ölschmiernut montieren.
Apply coat of LOCTITE 640 to the cavity of locating

ring (item 40). Use nitrogen to cool down (-180°C)
the ring and mount it with the lubrication groove on
upper side. (visible)
Bild / fig. 105
Stirnfläche des Hohlrades (Deckelanschraubflä-

che) mit Flächendichtung z.B. LOCTITE 573 ein-
streichen.
Evenly apply coat of LOCTITE 573 to front side of

gear wheel (bolt-on surface of cover).
Bild / fig. 106
Deckel (Pos. 5) mit neuem O-Ring in den Einpaß

des Hohlrades (Pos. 3) einsetzen.
(Alternativ 3x Augenschrauben M16 zum Anhän-
gen verwenden)
Assemble cover (item 5) with new O-ring into fit of

ring gear (item 3).
(Alternatively, use 3x eye bolts M16 to hang up)
Bild / fig. 107

Montage Assembly 5.
Gewinde der Sechskantschrauben (Pos. 49)

gleichmäßig mit LOCTITE 270 bestreichen.
Evenly apply coat of LOCTITE 270 to threads of

hex head bolts (item 49).
Bild / fig. 108
Deckelbefestigungsschrauben (Pos. 49) in Gewin-

debohrungen von Hohlrad (Pos. 3) einsetzen und
mit erforderlichem Anzugsmoment anziehen.
Insert cover mounting bolts (item 49) into threaded

holes of ring gear (item 3) and tighten them to a
proper torque.
Bild / fig. 109
Abdrückgewindebohrungen im Deckel (Pos. 5) mit

Fett füllen (z.B. K3N-30 DIN 51502) und mit 6kt-
Schrauben (Pos. 91) verschließen.
Grease the forcing threaded holes at the cover

(item 5) (e.g. K3N-30 DIN 51502) and lock them
with hex head bolts (item 91).
Bild / fig. 110
Vor Inbetriebnahme Getriebe mit Öl auffüllen.

(Siehe hierzu Betriebsanleitung 4/6192/4001/0).
Hinweis !
Prior to putting into operation fill the drive with new

Note! oil.
(See Operating Instructions 4/6192/4001/0).
Bild / fig. 111

Montage Assembly 5.
Verschlußschrauben (Pos. 81) mit neuen Dichtun-

gen (Pos. 82) in Deckel (Pos. 5) einschrauben.
Install plugs (item 81) with new seal rings (item 82)
into cover (item 5).
Bild / fig. 112
Montage Zylinderrollenlager (Pos. 31) Hauptstufe:

Zylinderrollenlager (Pos. 31) aus Transportverpackung direkt in
die Aufnahmebohrung drücken.
Achtung!
- auf richtige Lage der Fase am Zylinderrollenlager achten.
- Kontrollieren ob der Sicherungsring vom Zylinderrollenla-
ger in die entsprechende Nut eingeschnappt ist
Assembly of cylindrical roller bearing (item 31) main stage:

Push cylindrical roller bearing (item 31) directly out of the
transport packing into locating hole of planet gear.
Attention!
- observe correct installation position of chamfer at the
cylindrical roller bearing
- make sure that the snap ring is in the right position of the
snap ring groove.
Bild / fig. 113
Montage Zylinderrollenlager (Pos. 32) Vorstufe:

- Sicherungsring (Pos. 65) einsetzen
- Anlaufscheibe (Pos. 39) einlegen
- Zylinderrollenlager (Pos. 32) aus Transportverpackung
direkt in die Aufnahmebohrung von Planetenrad (Pos. 10)
drücken
- 2te Anlaufscheibe einlegen
- mit Sicherungsring (Pos. 65) sichern
Assembly cylindrical roller bearing (item 32) pre-stage:

- install a new snap ring (item 65)
- insert a new locating ring (item 39)
- push cylindrical roller bearing (item 32) directly out of the
transport packing into the locating hole of the planet gear
(item 10)
- insert 2nd new locating ring
secure with a new snap ring (item 65)
Bild / fig. 114
Montage der Planetenräder und des Sonnenrades

(Vorstufe):
- Sonnenrad (Pos. 13) mit neuem Sicherungsring (Pos. 72)
Hinweis ! auf Planetensteg (Pos. 7) fixieren.
- Vormontierte Planetenräder (Pos. 10) auf ca. 120°-130°C
erwärmen und auf die Planetenbolzen montieren.
- Mit neuen Sicherungsringen (Pos. 71) sichern.
Note!
Assembly of planet gears and sun gear (1st stage):
- Fasten the sun gear (item 17) with a new snap ring (item
18) to the planet carrier (item 89).
- Heat on pre-assembled planet gears (item 10) onto 120-
130°C and mount them onto the planet bolts.
Bild / fig. 115
- Secure the gears with new snap rings (item 71).

Montage Assembly 5.
5.3 Montage Stirnradsrufe / Assembly Spur Gear Stage

Rillenkugellager (1x Pos. 34) auf ca. 120°-130°C
erwärmen und auf Mitnehmer (Pos. 19) montieren.
Abkühlzeit von ca. 60 min. beachten.
Heat ball bearing (1x item 34) to approx. 120°-

130°C and mount onto coupler (item 19). Observe
a time of refrigeration of approx. 60 min..
Bild / fig. 116
Rillenkugellager (2x Pos. 34) auf 120°-130°C er-

wärmen und auf Stirnrad (Pos. 17) montieren.
Abkühlzeit von ca. 60 min. beachten.
Heat ball bearings (2x item 34) to approx. 120°-

130°C and mount onto spur wheel (item 17).
Observe a time of refrigeration of approx. 60 min..
Bild / fig. 117
Lagerinnenring von Zylinderrollenlager (Pos. 35)

auf ca. 120°-130°C erwärmen und auf den ent-
sprechenden Paßsitz von Antriebswelle (Pos. 16)
montieren.
Heat bearing inner ring of cylindrical roller bearing

(item 35) to approx. 120°-130°C and mount onto
the equivalent fit of input shaft (item 16).
Bild / fig. 118
Aufnahmebohrung von Tragachse (Pos. 1) für

Wellendichtringe (Pos. 44) gleichmäßig mit
LOCTITE 573/574 bestreichen.
Evenly apply coat of LOCTITE 573/574 to the ca-

vity of shaft sealing rings (item 44) in spindle
(item 1).
Bild / fig. 119

Montage Assembly 5.
Neue Wellendichtringe (Pos. 44) einsetzen und mit

entsprechendem Hilfswerkzeug (Bild 1) zur Anlage
bringen.
Auf richtige Einbaulage der Dichtlippen achten!!
Insert new radial shaft sealing rings (item 44) and

mount them with a adequate device (fig. 1) for pro-
per axial seat.
Observe correct mounting position of sealing lips!!
Bild / fig. 120
Einbauraum zwischen den Dichtlippen mit Wälzla-

gerfett (K3N-30 DIN 51502) füllen.
Fill mounting space between sealing lips with roller

bearing grease (K3N-30 DIN 51502).
Bild / fig. 121
Neuen O-Ring (Pos. 77) in entsprechende O-Ring

Nut von Mitnehmer (Pos. 19) einsetzen.
O-Ring anschließend einölen.
Insert a new o-ring (item 77) into the adequate

o-ring groove of coupler (item 19).
Lubricate the o-ring.
Bild / fig. 122
Anlaufscheibe (Pos. 24) in Mitnehmer (Pos. 19 )

einsetzen und mit neuem Sicherungsring (Pos. 63)
sichern.
Insert locating ring (item 24) into coupler (item 19)

and secure with a new snap ring (item 63).
Bild / fig. 123

Montage Assembly 5.
Vormontierten Mitnehmer (Pos. 19) mit Hilfswerk-

zeug (siehe Bild 2) in Getriebe einsetzen.
Insert pre-assembled coupler (item 19) with moun-

ting tool (note fig. 2) into the drive.
Bild / fig. 124
Hilfswerkzeug aus Bild 124 entfernen und Mit-

nehmmer mit Hilfswerkzeug (siehe Bild 3) eintrei-
ben.
Remove mounting tool from fig. 124 and drive in

coupler with mounting tool (note fig. 3).
Bild / fig. 125
Sicherungsring (Pos. 62) in entsprechende Nut von

Tragachse (Pos. 1) einsetzen.
Insert a new snap ring (item 62) into suitable groo-

ve of spindle (item 1).
Bild / fig. 126
Hohlrad (Pos. 4) in entsprechende Aufnahmeboh-

rung von Tragachse (Pos. 1) einsetzen.
Install ring gear (item 4) into the suitable fit of

spindle (item 1).
Bild / fig. 127

Montage Assembly 5.
Gewinde der Zylinderschrauben (Pos. 48) gleich-

mäßig mit LOCTITE 270 bestreichen.
Evenly apply coat of LOCTITE 270 to threads of

socket head cap screws (item 148).
Bild / fig. 128
Zylinderschrauben (Pos. 48) in entsprechende

Gewindebohrungen von Tragachse (Pos. 1) ein-
setzen und mit erforderlichem Anzugsmoment an-
ziehen.
Install socket head cap screws (item 48) into threa-

ded holes of spindle (item 1) and tighten them to a
proper torque.
Bild / fig. 129
Scheibe (Pos. 21) in Planetensteg (Pos. 8) einle-

gen).
Insert disk (item 21) into planet carrier (item 8).
Bild / fig. 130
Montage Planetenrad (Pos. 12):

- Zylinderrollenlager (Pos. 33) montieren
- Anlaufscheibe (Pos. 40) einlegen
- Sicherungsring (Pos. 64) einsetzen
- Zylinderrollenlager (Pos. 33) montieren
Assembly of planet gear (item 12):

- mount cylindrical roller bearing (item 33)
- insert locating ring (item 40)
- install snap ring (item 64)
- mount cylindrical roller bearing (item 33)
Bild / fig. 131

Montage Assembly 5.
Vormontierte Planetenräder (Pos. 12) auf ca. 120°-

130°C erwärmen und auf die Planetenbolzen vom
Planetensteg (Pos. 8) montieren. Mit neuen Siche-
rungsringen (Pos. 73) sichern.
Heat pre-assembled planet gears (item 12) to ap-

prox. 120°-130°C and mount them onto the plane-
tary pins of planet carrier (item 8). Secure with
snap rings (item 73).
Bild / fig. 132
Vormontierten Planetensteg (Pos. 8) auf Mitneh-

mer (Pos. 19) fixieren und mit neuem Sicherungs-
ring (Pos. 69) sichern.
Fasten the pre-assembled planet carrier (item 8) to

the coupler (item 19) and secure with a new snap
ring (item 69).
Bild / fig. 133
Sonnenrad (Pos. 14) einsetzen.
Insert sun gear (item 14).
Bild / fig. 134
Wellendichtringe (Pos. 45) gleichmäßig mit

LOCTITE 573/574 bestreichen.
Evenly apply coat of LOCTITE 573/574 to the outer

ring of radial sealing (item 45).
Bild / fig. 135

Montage Assembly 5.
Mit entsprechenden Hilfsmittel (siehe Bild 4) in Aufnah-

mebohrung von Dichtungsring (Pos. 20 ) einsetzen.
Achtung!
Auf richtige Einbaulage der Dichtlippen achten.
Einbauraum zwischen den Dichtlippen mit Wälzlagerfett
(K3N-30 DIN 51502) füllen.
Insert radial shaft sealing rings (item 45) with mounting

tool (note fig. 4) into suitable fit of seal ring (item 20)
Attention!
Observe correct mounting position of sealing lips.
Fill mounting space between sealing lips with roller bea-
ring grease (K3N-30 DIN 51502).
Bild / fig. 136
Zylinderrollenlager (Pos. 36) in entsprechende Auf-

nahmebohrung von Flansch (Pos. 28) einsetzen.
Insert cylindrical roller bearing (item 36) into cavity

of flange (item 28).
Bild / fig. 137
Zylinderrollenlager (Pos. 36) verstemmen.
Caulk cylindrical roller bearing (item 36).
Bild / fig. 138
Komplett vormontiertes Stirnrad (Pos. 17) in Ge-

häuse (Pos. 27) einsetzen.
Install pre-assembled spur wheel (item 17) into

housing (item 27).
Bild / fig. 139

Montage Assembly 5.
Im Bereich der Gehäusebohrung für Pos. 85

LOCTITE 573/574 auftragen.
Apply LOCTITE 573/574 at the area of boring for

item 85.
Bild / fig. 140
O-Ring (Pos. 76) zwischen Gehäuse (Pos. 27) und

Flansch (Pos. 28) einlegen und Flansch in Auf-
nahmebohrung von Gehäuse einsetzen.
Insert a new o-ring (item 76) between housing

(item 27) and flange (item 28). Mount flange into
the fit of housing.
Bild / fig. 141
Flansch (Pos. 28) und Gehäuse (Pos. 27) mit Zy-

linderstift (Pos. 41) fixieren.
Fasten flange (item 28) and housing (item 27) with

cylindrical dowel pin (item 41).
Bild / fig. 142
Zylinderschrauben (Pos. 42) in Gewindebohrungen

von Gehäuse (Pos. 27) einsetzen und mit erforder-
lichem Anzugsmoment anziehen.
Insert socket head cap screws (item 42) into threa-

ded holes of housing (item 27) and tighten them to
a proper torque.
Bild / fig. 143

Montage Assembly 5.
Neuen O-Ring (Pos. 75) in entsprechende O-Ring

Nut von Gehäuse (Pos. 27) einsetzen.
Insert a new o-ring (item 75) into the suitable o-ring

groove of housing (item 27).
Bild / fig. 144
Antriebswelle (Pos. 16) mit montiertem Lagerin-

nenring in Gehäuse einsetzen.
Install the input shaft (item 16) with mounted bea-

ring inner ring into the housing.
Bild / fig. 145
Zylinderrollenlager (Pos. 35) in Gehäusebohrung

einsetzen.
Insert cylindrical roller bearing (item 35) into sui-

table boring of housing.
Bild / fig. 146
Aufnahmebohrung im Bereich des Dichtringes ein-

ölen.
Lubricate the cavity at the area of the seal ring.
Bild / fig. 147

Montage Assembly 5.
Vormontierten Dichtungsring (Pos. 21) in entspre-

chende Aufnahmebohrung von Gehäuse (Pos. 27)
einsetzen.
Mount the pre-assembled seal ring (item 21) into

the suitable cavity of housing (item 27).
Bild / fig. 148
Mit entsprechendem Hilfsmittel (siehe Bild 8)

Dichtungsring (Pos. 20) zur Anlage bringen.
Mount seal ring (item 20) with a suitable mounting

tool (note fig. 8) for proper axial seat.
Bild / fig. 149
Dichtungsring mit neuem Sicherungsring (Pos. 60)

sichern.
Secure seal ring with a new snap ring (item 60).
Bild / fig. 150
Neuen O-Ring (Pos. 89) auf Zentriersitz von Mo-

torlaterne (Pos. 96) aufziehen.
Mount a new o-ring (item 89) on the fit of motor bell

housing (item 1).
Bild / fig. 151

Montage Assembly 5.
Motorlaterne (Pos. 96) in Einpaß von Stirnradge-

häuse einsetzen.
Mount motor bell housing (item 96) into fit of spur

gear wheel housing.
Bild / fig. 152
Zylinderschraube (Pos. 61) in Gewindebohrung von

Gehäuse (Pos. 27) einsetzen und mit erforderli-
chem Anzugsmoment anziehen.
Insert socket head cap screws (item 61) into threa-

ded holes of housing (item 27) and tighten them to
proper seat.
Bild / fig. 153
Verschlußschrauben (Pos. 84; 98) in entsprechen-

de Gewindebohrungen einsetzen und mit entspre-
chendem Werzeug anziehen.
Insert srew plugs (item 84; 98) to the suitable

threaded holes and tighten them.
Bild / fig. 154
Hydromotor mit neuem O-Ring (Pos. 97) am Ge-

triebe anbauen.
Motor gehört nicht zum Lieferumfang BOSCH Rex-
Hinweis ! roth.
Assemble hydraulic motor with a new o-ring (item

Note ! 97) into gearbox.
Motor is not supplied by BOSCH Rexroth.
Bild / fig. 155

Montage Assembly 5.
Motorbefestigungsschrauben einschrauben und mit

erforderlichem Anzugsmoment anziehen.
Hinweis !
Insert the motor mounting bolts and tighten them to
proper torque.
Note !
Bild / fig. 156
Vor Inbetriebnahme Bremse mit Öl befüllen.
Hinweis ! Prior to putting into operation fill the brake with

new oil.
Note !
Bild / fig. 157

Montage Assembly 5.
5.4 Montage Stirnradstufe / Planetengetriebe

Assembly Spur Gear Stage / Planetary Gearbox
Dichtfläche Stirnradstufe / Tragachse mit LOCTITE

573 / 574 bestreichen.
Apply sealing surface of spur gear stage / spindle

with LOCTITE 573/574.
Bild / fig. 158
Komplett vormontierte Stirnradstufe (mit montierter

Bremse) in Kran einhängen und O-Ring (Pos. 76)
in entsprechende Nut von Flansch (Pos. 28) einle-
gen.
Hang complete pre-assembled spur gear stage

(with mounted brake) onto crane and insert o-ring
(item 76) into the suitable o-ring groove.
Bild / fig. 159
Komplett vormontierte Stirnradstufe (mit Bremse)

in entsprechende Aufnahmebohrung von Tragach-
se (Pos. 1) einsetzen.
Install complete pre-assembled spur gear stage

(with brake) into suitable fit of spindle (item 1).
Bild / fig. 160
6kt-Schrauben (Pos. 50) in Gewindebohrungen von

Tragachse (Pos. 1) einsetzen und mit erforderli-
chem Anzugsmoment anziehen.
Install hex head bolts (item 50) into threaded holes

of spindle (item 1) and tighten to proper torque.
Bild / fig. 161

Montage Assembly 5.
1x Entlüfter (Pos. 83) mit neuem Dichtring (Pos.

84) montieren.
Mount 1x vent (item 83) with a new sealing (item

84).
Bild / fig. 162
Verschlußschraube (Pos. 85) einsetzen.
Insert screw plug (item 85).
Bild / fig. 163
Vor Inbetriebnahme Stirnradstufe mit Öl befüllen.

(Siehe hierzu Betriebsanleitung 4/6192/4001/0)
Hinweis !
Prior to putting into operation fill the spur gear sta-
ge with new oil.
(note operating instructions 4/6192/4001/0)
Note !
Bild / fig. 164
Verschlußschrauben (Pos. 81) mit neuen Dichtun-

gen (Pos. 82) in Gehäuse (Pos. 27) einschrauben.
Screw into housing (item 27) screw plugs (item 81)

with new sealings (item 82).
Bild / fig. 165

Probelauf Test Run 6.
6.1 Prüfstandsaufbau 6.1 Test set up

Das Getriebe wird in der vorgesehenen Einbaulage The gearbox shall be mounted in its intended in-
aufgebaut und mit einem geeigneten Antriebsmotor stallation position and connected to a suitable dri-
angetrieben. Wenn das Betriebsverhalten des Ge- ving motor. If the operating performance of the
triebetyps bekannt ist, kann eine andere Prüflage gearbox type is known, it is possible to mount the
gewählt werden, wobei die Radialwellendichtringe, gearbox in another test position under the condition
bzw. Gleitringdichtungen unter Öl stehen müssen that the radial face seals and the axial seal are
(Luftkammerbildung beachten!). submerged in oil (check for air chambers!).
6.2 Ölversorgung 6.2 Lubrication

Die Getriebe werden wie in der Einbauzeichnung The gear units are to be filled with oil as shown on
vorgesehen mit Öl gefüllt. Bremsen mit seperater the installation drawing. Brakes which have sepa-
Ölfüllung sind vor dem Probelauf gemäß Einbau- rate oil fillings shall be filled with oil before test run.
zeichnung ebenfalls mit Öl zu befüllen. For oil fill, please use the lubricants listed in the o-
Zur Ölbefüllung verwenden Sie bitte die in der Be- perating instructions.
triebsanleitung angebenen Schmierstoffe.
6.3 Drehzahl, Laufzeit und Prüflast 6.3 Speed, Running Time, Test Load
Die Getriebe sind mit Höchstdrehzahl (nmax Getriebe The gear units are to be operated at max. speed
bzw. nmax Prüfstand) über 1 Stunde (je ½ Stunde pro (nmax of gearbox or nmax test bed) under no load for
Drehrichtung bei Getrieben mit wechselnder Dreh- one hour (half an hour in each direction of rotation
richtung) ohne Last zu fahren. in case of reverse gears).
Hierbei ist die Ölsumpftemperatur am Außendurch- Measure oil sump temperatures at outside diame-
messer des Hohlrades nach 30, 45 und 60 Minuten ter of ring gear and note them down after 30, 45
zu messen und zu protokollieren. and 60 minutes of operation.
6.4 Thermische Werte 6.4 Thermal Parameters

Die Ölsumpftemperatur soll nach Abschluß des The oil sump temperature measured after the 1-
1-stündigen Probelaufs 70°C nicht übersteigen. Die hour test run shall not exceed 70°C.
Temperatur nach 30 Minuten bei reduzierter Laufzeit The temperature measured after 30 minutes redu-
soll die Temperatur der Temperaturaufschreibung ced operating time shall not exceed the temperatu-
des ersten Getriebes um nicht mehr als 4°C über- re records of the first gearbox by more than 4°C.
schreiten. The temperatures measured at the external bea-
Die Temperaturen an außenliegenden Lagerstellen ring areas (if applicable) must be not exceed the oil
(soweit zutreffend) sollen die Ölsumpftemperaturen sump temperature by more than 10°C.
um nicht mehr als 10°C übersteigen.
6.5 Laufgeräusch 6.5 Running Noise

Das Laufgeräusch soll weich und gleichmäßig sein. The running noise under test conditions should be
Es dürfen keine harten, schlagenden oder pfeifende smooth and steady.
Geräusche vorhanden sein. Hard, knocking or howling noise produced by the
unit are inadmissible.
6.6 Dichtigkeitsprüfung 6.6 Tightness testing

Während des Probelaufs sind alle Dichtungen auf During the test run, make sure to check all seals
Undichtigkeiten hin zu beobachten, z.B.: for leakages, e.g.:
- Ein- und Auslaßschrauben - Inlet and drain plugs
- Entlüfter - Vent
- Dichtflächen an Hohlrädern und Deckeln - Sealing faces at ring gears and covers
- Wellendichtungen - Shaft seals

Probelauf Test Run 6.
6.7 Funktionsprüfung der Bremsen 6.7 Hydraulic Brakes

Die Bremsen werden durch eine pulsierende Prüfung A pulsating pressure test shall be performed on the
auf Funktion und Dichtigkeit geprüft: brakes to check the tightness and function:
- Prüfdruck: 60-80 bar - Test pressure: 60-80 bar
- Lüftzeit: 6-10 sek pro Kolbenhub - Releasing time: 6-10 sec. per piston stroke
- Prüfdauer: min. 15 Minuten - Testing time: 15 minutes minimum
6.8 Fremdkörper 6.8 Oil Contamination Test

Nach Durchführung des Probelaufs ist das ablaufen- After completing the test run, the oil shall be in-
de Getriebeöl auf Späne, Zunder, übermäßigen Ab- spected for scraps, scales and wear particles and
rieb zu beobachten. Auf Fremdkörper an Mag- other impurities. The magnetic plug and, if neces-
netstopfen und ggf. am Ölfilter ist zu achten. sary, the oil filter shall be checked.

7.3 SWING GEARBOX
7.3 Swing gearbox

7.3.1 General
Weight [kg]
This section is valid for the swing gearbox
Swing gearbox approx. 1 350 kg
Part-no. 3 692 960 Swing motor approx. 47 kg
3 692 970,
Table 1
3 692 990.
The swing gearbox with the swing motor and the Technical data
parking brake forms one structural unit. Gearbox type GFB 144 T2
It is designed as a 2-stage planetary gear system. Transmission ratio i = 49.28

Oil capacity 38 l
Table 2
3746565en - (00) Page 7.3 - 1

7.3 SWING GEARBOX
Dimensions of the swing gear box
mm
A 1 172
B 562
Table 3
Fig. 1 Swing gearbox – dimensions – 3745936_00_0_01_01b
Page 7.3 - 2 3746565en - (00)

7.3 SWING GEARBOX
7.3.2 Dismantling and installing the

swing gearbox
Dismantling the swing gearbox Installing the swing gearbox
1. Remove all traces of paint and grease from

1. Loosen all bolts with washers (3, 4 Fig. 3) contact surfaces of swing gearbox and super-
fastening the gearbox covers and remove the structure frame with a cleaner and check them
covers (9-14, Fig. 3). for damage. Contact metal surfaces must be
shiny, dry and free of grease.
2. Remove the brake line at parking brake unit
and close it. 2. Install O-ring (6, Fig. 2) onto gearbox housing.
3. Disconnect hydraulic and electric lines from 3. Pick up gearbox in lifting tackle, bring into
the swing gearbox and close them. installation position and set without displace-
ment.
4. Remove the swing motor.
4. Screw in bolts with washers (7, 8 Fig. 2) and
5. Loosen fastening bolts with washers (7, 8 Fig. tighten them crosswise.
2), lift up gearbox with lifting eye bolts in lifting
tackle and remove it. 5. Coat the drive pinion of the swing motor with
the lubricating paste (Omnifit) and install the
motor.
6. Connect the brake line and let the air out of

the brake oil system according to the instruc-
tions.
7. Install the covers (9 – 14, Fig. 3) and fix them

with bolts and washers (3, 4, Fig. 3).
Components of the swing gear box (Fig.1, 2)

[kg]
1 3 Swing gearbox with swing motor
2 2.3 m Edge protection 0.29
3 18 Hex. bolt M 8 x 30 – 8.8 Tightening torque M = 20.5 Nm 0.015
4 18 Washer 0.125
6 3 O-ring 0.02
7 72 Washer 0.008
8 72 Hex. bolt M 24 x 700 – 10.9 Tightening torque M = 850 Nm 2.52
9 1 Cover 4.30
10 1 Cover 4.70
11 1 Cover 4.30
12 1 Cover 4.70
13 1 Cover 4.20
14 1 Cover 4.70
Table 4
3746565en - (00) Page 7.3 - 3

7.3 SWING GEARBOX
8
Fig. 2 Swing gearbox - removal and installation – 3745936_00_0_01_01a
Page 7.3 - 4 3746565en - (00)

7.3 SWING GEARBOX
4
Fig. 3 Swing gearbox - covers – 3743239_01_1_01_01a
3746565en - (00) Page 7.3 - 5

7.3 SWING GEARBOX
7.3.3 Disassembly & Assembly in-

structions
Please refer to the attached manual:
SN 36929xx - RDE 77971-01-R/07.07
Page 7.3 - 6 3746565en - (00)

Demontage- Montageanleitung
Disassembly- Assembly Instructions
Schwenkgetriebe / Swing Drive RDE 77971-01-R/07.07
Sach-Nr. / Part-No. 3692960
3692970
3692990
RDE 77971-01-R/07.07 Sach-Nr. / Part-No. 2/48
3692960, 3692970, 3692990
Inhaltsverzeichnis • Table of Contents
Kapitel Chapter
1. Einleitung 1. Preliminary Notes

1.3 Schmieröl, Gewicht 1.3 Lube Oil, Weight
1.4 Werkzeuge und Zubehör 1.4 Tools and Accecories
1.5 Passungen 1.5 Fit´s
2. Zeichnungen 2. Drawings
3. Teileliste 3. Parts List

Teileliste Getriebe Parts List Gearbox
4. Demontage 4. Disassembly
4.2 Demontage Planetengetriebe / Bremse 4.2 Disassembly Planetary Gear / Brake
5. Montage 5. Assembly
5.2 Montage Planetengetriebe / Bremse 5.2 Assembly Planetary Gear / Brake
6. Probelauf 6. Test Run

6.1 Prüfstandsaufbau 6.1 Test set-up
6.3 Drehzahl, Laufzeit und Prüflast 6.3 Speed, Running Time, Test Load
6.6 Dichtigkeitsprüfung 6.6 Tightness Testing
6.7 Funktionsprüfung der Bremsen 6.7 Hydraulic Brakes
3692960, 3692970, 3692990
1. Einleitung • 1. Preliminary Notes

Mit diesem Symbol sind Gefahren für das This symbol signifies danger to the prod-
Produkt und die Gesamtanlage gekenn- uct and the overall plant.
zeichnet.
Dieses Symbol kennzeichnet Hinweise. This symbol calls attention to notes.
Zur Demontage; Montage des Getriebes For disassembly; assembly procedure of

werden die Ersatzteilzeichnung und die the gearbox, spare parts drawing and
Teileliste der entsprechenden Getriebe- parts list of the respective gearbox-type is
ausführung benötigt. required.
Beachten Sie unbedingt die Sicherheitsbe- The safety instructions and the appropriate accident
stimmungen und die einschlägigen Unfallver- prevention instructions have absolutely to be ob-
hütungsvorschriften ! served !
Bauen Sie nur Originalersatzteile ein. Exclusively install original spares.
Lassen Sie das Öl ab. Drain the oil from the gearbox.
Verwenden Sie dabei geeignete Auffanggefäße. For this purpose use suitable containers.
Achten Sie darauf, daß kein Schmutz oder Fremdkörper Make sure that no dirt or foreign bodies are allowed to
in das Getriebe gelangt. enter the gear box.
Beschädigte Teile, sowie Dichtringe, durch neue Teile Replace damaged parts and all seals with new L+S
ersetzen. parts.
Vor dem Einbau sind alle beweglichen Teile sowie Oil all moving parts and seals prior to assembly.
Dichtringe einzuölen.
Unter Umständen ist der Farbanstrich des Getriebes In the event the paint coat of the gear-box has been
durch das Zerlegen und Zusammenbauen beschädigt. damaged as a result of disassembly / assembly work
Erneuern Sie deshalb den Farbanstrich, um das Getrie- touch up or renew the paint coat as necessary to protect
be gegen Korrosion zu schützen. the gear against corrosion.
Führen Sie einen Probelauf des Getriebes durch. Carry out a test run of the gearbox.
Hinweis! Note!
Die verwendeten Bilder müssen nicht der beschriebe- The photos may show other drive types than the de-
nen Getriebetype entsprechen. scribed one.
3692960, 3692970, 3692990
Standard-Anziehdrehmomente MA in Nm für ungeschmierte Schaftschrauben (µ = 0,13 bis 0,17) mit Regelgewinde ohne zu-
sätzliche Einzelangaben (s. LSN 945 0201)
Standard-tightening torque MA in Nm for unlubricated shoulder stud (µ = 0,13 bis 0,17) with standard thread without additional details
(LSN 945 0201)
Schraube M6 M8 M 10 M 12 M 14 M 16 M 20 M 24 M 27 M 30 M 33 M 36 M 39 M 42
screw
8.8 Dr. 8,5 21,1 42,2 73,6 114,8 176,6 358 618 903 1216 1687 2129 2757 3394
10.9 Dr. 12,4 30,4 60,8 104,0 166,8 255,1 510 873 1285 1736 2364 3021 3924 4836
1.3 Schmieröl; Gewicht 1.3 Lube Oil; Weight

Gewicht ca. 990 kg Weight approx. 990 kg
Getriebeölmenge ca. 38 Liter Gear lube oil volume approx. 38 liters
Schmieröl CLP 320 LSN 1410-8 Lube oil CLP 320 LSN 1410-8
1.4 Werkzeuge und Zubehör 1.4 Tool and Accessories

- Drehmomentschlüssel - Torque Wrench
- Abziehvorrichtung für Wälzlager - Bearing Puller
- Sicherungsringzangen - Tools for Snap Rings
- Plastik Hammer - Plastic Hammer
- Wälzlagerfett K3N 30 DIN 51502 - Roller bearing grease K3N 30 DIN 51502
- LOCTITE 573/574 - LOCTITE 573/574

3692960, 3692970, 3692990

Mounting Tool item 125
Bild / fig. 1a Bild / fig. 1b
Bild / fig. 1c
3692960, 3692970, 3692990

Mounting Tool item 180
Bild / fig. 3 Montagewerkzeug Pos. 502, 509

Mounting Tool item 502, 509
3692960, 3692970, 3692990
1.5 Passungen (siehe Bild 4) 1.5 Fit´s (note fig. 4)
Position Bohrung / Bore Welle / Shaft
A Ø 400 J7 Ø 220 p6
B Ø 360 J7 Ø 200 n6
C + 0,059
Ø 133,2 Ø 85 j6
+ 0,037
D + 0,053
Ø 89,9 Ø 65 j6
+ 0,038
A B C D
Bild / fig. 4
3692960, 3692970, 3692990
2. Zeichnungen • 2. Drawings
2. Zeichnungen 2. Drawings
Einbauzeichnung Installation drawing
Ersatzteilzeichnung Spare parts drawing





3692960, 3692970, 3692990
3. Teilelisten • 3. Parts Lists
3. Teilelisten 3. Parts Lists

Teileliste Parts List
Sach-Nr. Part-No.
3692960, 3692970, 3692990 3692960, 3692970, 3692990
Auftrag/Order :
Menge Pos. Benennung .

1,000 102 Hohlrad GFB 144 T

Ring gear
1,000 103 Tragrohr GFB 144 T

Cartridge
1,000 104 Sonnenrad z=15 GFB 144

Sun gear
1,000 106 Abtriebswelle z=13 GFB 144

Output shaft
1,000 107 Planetensteg GFB 144 T

Planet carrier
1,000 108 Planetensteg GFB 144

Planet carrier
3,000 110 Planetenrad z=48 GFB 144

Planet gear

Planet gear
1,000 113 Zwischenring GFB 144 T

Spacer ring
1,000 114 Sonnenradwelle z=15 GFB 144

Sun gear shaft
3,000 118 Zylinderrollenlager F-209297

DIN 5412
8,000 119 Zylinderrollenlager RSL 182217

DIN 5412
1,000 120 Pendelrollenlager 23244 MB

Spherical roller bearing
DIN 635
1,000 121 Zylinderrollenlager NJ 240 EM

DIN 5412
2,000 125 Radialdichtring 240x270x15 C

DIN 3760
Seite / Page 1/6

Auftrag/Order :

1,000 126 O-Ring 470x4

O-ring
DIN 3771
1,000 128 Nilosring 22244 AV

Nilos ring
1,000 129 Sicherungsring 90x3

Snap ring
DIN 471

Snap ring
DIN 471
3,000 131 Sicherungsring 65x2,5

Snap ring
DIN 471
8,000 134 Anlaufscheibe F 90401

Locating ring

Snap ring
DIN 471

Snap ring
DIN 472
1,000 139 Verschlussschraube M 24x1,5

Screw plug
DIN 908
1,000 140 Winkel A4, 1/2'

Angle
GF-NR. 92
1,000 142 Dichtring A 24x29x2

Seal ring
DIN 7603
4,000 151 Zylinderschraube M 20x270

DIN 912

DIN 912
Seite / Page 2/6

Auftrag/Order :

1,000 175 Ring GFB 144 T

Ring
1,000 179 Flanschabdeckung GPN 640 fuer 1 1/4"

Flange cover
1,000 180 Huelse GFB 144 T

Sleeve
2,000 181 O-Ring 215x5

O-ring
DIN 3771
1,000 198 Hydromotor A2FM 200/63W-VAB010

Hydraulic motor

DIN 912
1,000 206 Rohrklemme S 12

Pipe clamp
112A-PA-DP-AS
1,000 300 Flansch GFB 144 T

Flange
4,000 313 Stopfen GPN 700 M20

Plug
1,000 326 Verschlussschraube G 1/2

Screw plug
DIN 910
1,000 327 Dichtring A 21x26x1,5

Seal ring
DIN 7603
1,000 331 Entluefter G 1/2

Vent
1019-14-00
1,000 332 Peilstab G 1/2 x 400

Dipstick
LSN 627 1005
1,000 333 Dichtring A 21x26x1,5

Seal ring
DIN 7603
Seite / Page 3/6

Auftrag/Order :

1,000 345 Schmiernippel R 1/8 A

Grease nippel
DIN 71412
1,000 355 Schwimmer 16x50 GFB 144 T

Float gauge
1,000 356 Adapter M12x1 - M22x1,5 Kunststoff

Adapter
1,000 357 Stopfen GPN 300 F 5

Plug
1,000 400 Verschraubung GAI 12PL/R1/2

Fitting
1,000 401 Verschraubung GE 12 PL/M14x1,5

Fitting
1,000 402 Rohr 12x1,5x285 lg.

Pipe
1,000 403 Halteblech GFB 144 T

Locking plate
2,000 409 6kt-Schraube M 6x40 A2C

Hex head bolt
ISO 4014
1,000 411 O-Ring 470x4

O-ring
DIN 3771
1,000 501 Lamellentraeger GFB 144

Disk housing
1,000 502 Kolben GFY100/GFB60

Piston
1,000 503 Motorflansch GFB 144

Motor flange
1,000 504 Scheibe * GFB 84/117

Disk
7,000 505 Innenlamelle 3070-740-23-005

Inner disk
Seite / Page 4/6

Auftrag/Order :

8,000 506 Aussenlamelle LD 411 6039

Outer disk
C60/HS 45
25,000 507 Druckfeder 2,5x11,5x54

Pressure spring
DIN 2098

Snap ring
DIN 472
25,000 509 Druckfeder 1,6x6,5x54

Pressure spring
DIN 2098
1,000 510 O-Ring 200x3

O-ring
DIN 3771
1,000 511 O-Ring 160x3

O-ring
DIN 3771
1,000 512 Quadring 4363 446 A

Piston seal
2,000 513 Stuetzring 168,5x178x1,4 P

Supporting ring
1,000 514 Quadring 4362 446 A

Piston seal
2,000 515 Stuetzring 156,5x166x1,4 P

Supporting ring

DIN 912
1,000 517 Stopfen GPN 710 R 1/4'

Plug
12,000 519 6kt-Schraube M 10x25

Hex head bolt
DIN 933
Seite / Page 5/6

Auftrag/Order :


Snap ring
DIN 472
1,000 521 Scheibe GFY100/GFB60

Disk
1,000 524 O-Ring 335x3

O-ring
DIN 3771

Screw plug
DIN 910
1,000 527 Dichtring A 21x26x1,5

Seal ring
DIN 7603
1,000 353 Naeherungsschalter magn. M12x1

Proximity switch
Seite / Page 6/6

Auftrag/Order :


Ring gear

Cartridge

Sun gear

Output shaft

Planet carrier

Planet carrier

Planet gear

Planet gear

Spacer ring

Sun gear shaft

DIN 5412

DIN 5412

DIN 635

DIN 5412

DIN 3760
Seite / Page 1/6

Auftrag/Order :

1,000 126 O-Ring 470x4

O-ring
DIN 3771
1,000 128 Nilosring 22244 AV

Nilos ring

Snap ring
DIN 471

Snap ring
DIN 471

Snap ring
DIN 471

Locating ring

Snap ring
DIN 471

Snap ring
DIN 472

Screw plug
DIN 908
1,000 140 Winkel A4, 1/2'

Angle
GF-NR. 92

Seal ring
DIN 7603

DIN 912

DIN 912
Seite / Page 2/6

Auftrag/Order :

1,000 175 Ring GFB 144 T

Ring
1,000 179 Flanschabdeckung GPN 640 fuer 1 1/4"

Flange cover
1,000 180 Huelse GFB 144 T

Sleeve
2,000 181 O-Ring 215x5

O-ring
DIN 3771
1,000 197 6kt-Schraube M 16x55

Hex head bolt
DIN 931
1,000 198 Hydromotor A2FM 180/61W-VAB010

Hydraulic motor

Hex head bolt
DIN 933
1,000 206 Rohrklemme S 12

Pipe clamp
112A-PA-DP-AS

Flange
4,000 313 Stopfen GPN 700 M20

Plug

Screw plug
DIN 910
1,000 327 Dichtring A 21x26x1,5

Seal ring
DIN 7603
1,000 331 Entluefter G 1/2

Vent
1019-14-00
1,000 332 Peilstab G 1/2 x 400

Dipstick
LSN 627 1005
Seite / Page 3/6

Auftrag/Order :

1,000 333 Dichtring A 21x26x1,5

Seal ring
DIN 7603

Grease nippel
DIN 71412

Float gauge

Adapter
1,000 357 Stopfen GPN 300 F 5

Plug

Fitting

Fitting
1,000 402 Rohr 12x1,5x285 lg.

Pipe
1,000 403 Halteblech GFB 144 T

Locking plate
1,000 405 Scheibe A 17

Disk
DIN 125
2,000 409 6kt-Schraube M 6x40 A2C

Hex head bolt
ISO 4014
1,000 411 O-Ring 470x4

O-ring
DIN 3771

Disk housing

Piston
Seite / Page 4/6

Auftrag/Order :

1,000 503 Motorflansch GFB 144

Motor flange
1,000 504 Scheibe * GFB 84/117

Disk
7,000 505 Innenlamelle 3070-740-23-005

Inner disk

Outer disk
C60/HS 45
25,000 507 Druckfeder 2,5x11,5x54

Pressure spring
DIN 2098

Snap ring
DIN 472
25,000 509 Druckfeder 1,6x6,5x54

Pressure spring
DIN 2098
1,000 510 O-Ring 180x3

O-ring
DIN 3771
1,000 511 O-Ring 160x3

O-ring
DIN 3771
1,000 512 Quadring 4363 446 A

Piston seal
2,000 513 Stuetzring 168,5x178x1,4 P

Supporting ring
1,000 514 Quadring 4362 446 A

Piston seal
2,000 515 Stuetzring 156,5x166x1,4 P

Supporting ring

DIN 912
Seite / Page 5/6

Auftrag/Order :

1,000 517 Stopfen GPN 710 R 1/4'

Plug
12,000 519 6kt-Schraube M 10x25

Hex head bolt
DIN 933

Snap ring
DIN 472

Disk
1,000 524 O-Ring 335x3

O-ring
DIN 3771

Screw plug
DIN 910
1,000 527 Dichtring A 21x26x1,5

Seal ring
DIN 7603

Proximity switch
Seite / Page 6/6

Auftrag/Order :


Ring gear

Cartridge

Sun gear

Output shaft

Planet carrier

Planet carrier

Planet gear

Planet gear

Spacer ring

Sun gear shaft

DIN 5412

DIN 5412

DIN 635

DIN 5412

DIN 3760
Seite / Page 1/6

Auftrag/Order :

1,000 126 O-Ring 470x4

O-ring
DIN 3771
1,000 128 Nilosring 22244 AV

Nilos ring

Snap ring
DIN 471

Snap ring
DIN 471

Snap ring
DIN 471

Locating ring

Snap ring
DIN 471

Snap ring
DIN 472

Screw plug
DIN 908

Seal ring
DIN 7603

DIN 912

DIN 912
1,000 175 Ring GFB 144 T

Ring
Seite / Page 2/6

Auftrag/Order :

1,000 180 Huelse GFB 144 T

Sleeve
2,000 181 O-Ring 215x5

O-ring
DIN 3771

Flange
1,000 301 Deckel GFB 144 T2

Cover
4,000 313 Stopfen GPN 700 M20

Plug

Screw plug
DIN 910
1,000 327 Dichtring A 21x26x1,5

Seal ring
DIN 7603
1,000 334 Dichtring A 14x18x1,5

Seal ring
DIN 7603
1,000 335 Verschlussschraube M 14x1,5 A

Screw plug
DIN 7604

Grease nippel
DIN 71412

Float gauge

Adapter
1,000 357 Stopfen GPN 300 F 5

Plug

Fitting
Seite / Page 3/6

Auftrag/Order :


Fitting
1,000 402 Rohr 12x1,5x285 lg.

Pipe
1,000 411 O-Ring 470x4

O-ring
DIN 3771

Disk housing

Piston
1,000 504 Scheibe * GFB 84/117

Disk
7,000 505 Innenlamelle 3070-740-23-005

Inner disk

Outer disk
C60/HS 45
25,000 507 Druckfeder 2,5x11,5x54

Pressure spring
DIN 2098

Snap ring
DIN 472
25,000 509 Druckfeder 1,6x6,5x54

Pressure spring
DIN 2098
1,000 511 O-Ring 160x3

O-ring
DIN 3771
1,000 512 Quadring 4363 446 A

Piston seal
2,000 513 Stuetzring 168,5x178x1,4 P

Supporting ring
Seite / Page 4/6

Auftrag/Order :

1,000 514 Quadring 4362 446 A

Piston seal
2,000 515 Stuetzring 156,5x166x1,4 P

Supporting ring

DIN 912
1,000 517 Stopfen GPN 710 R 1/4'

Plug
12,000 519 6kt-Schraube M 10x25

Hex head bolt
DIN 933

Snap ring
DIN 472

Disk
1,000 524 O-Ring 335x3

O-ring
DIN 3771

Screw plug
DIN 910
1,000 527 Dichtring A 21x26x1,5

Seal ring
DIN 7603

Hex head bolt
DIN 931

Hex head bolt
DIN 933

DIN 912
Seite / Page 5/6

Auftrag/Order :

1,000 332 Peilstab G 1/2 x 400 16572844

Dipstick
LSN 627 1005
1,000 333 Dichtring A 21x26x1,5

Seal ring
DIN 7603

Proximity switch
1,000 406 Verschraubung M14x1,5 GFB 144 BescS

Fitting
1,000 510 O-Ring 180x3

O-ring
DIN 3771
1,000 510 O-Ring 200x3

O-ring
DIN 3771
Seite / Page 6/6

3692960, 3692970, 3692990
4. Demontage • 4. Disassembly

Getriebe nur im ausgebautem Zustand Make sure to remove the gearbox from the
demontieren. machine frame before disassembling it.
Für die Demontage des Schwenkgetriebes sind folgen- Prior to disassembly prepare the swing drive as follows:
de Vorarbeiten erforderlich:
Beachten Sie hierzu auch Kapitel 8 der Also observe chapter 8 of Operating In-
Betriebsanleitungen structions
• Getriebeöl ablassen. Lösen Sie dafür

Verschlußschrauben (Pos. 139+142). Ver- • Remove screw plugs (items 139+142) and
drain oil. Use suitable oil drain pan.
wenden Sie dabei geeignete Auffanggefä- Gear lube oil volume:
ße. - planetary gear: approx. 38 l
Ölinhalt:
- Planetengetriebe: ca. 38l
• Hydraulikmotoren vom Getriebe abbauen

und Anschlüsse mit Hilfsdeckel verschlie- • Dismount hydraulic motors from gearbox
and seal ports with provisional cover.
ßen.
Achten Sie beim Transport auf eine aus- When handling the equipment make sure
reichende Tragkraft des Kranes. the carrying capacity of the crane is ade-
Getriebegewicht mit Motor: quate.
ca. 990 kg. Weight with motor appr. 2182,5lbs.
• Stellen Sie sicher, daß das abgesetzte

Getriebe seine Lage nicht ändern kann. • Make sure the set down gearbox rests
immovably.
3692960, 3692970, 3692990
4.2 Demontage Planetengetriebe / Bremse

Disassembly Planetary Gearbox / Brake
Verschlußschrauben (Pos. 139+142) lösen und Öl ab-
lassen.
Fangen Sie Altöl in geeigneten Behältern auf und ent-
sorgen Sie es unter Beachtung der entsprechenden
Vorschriften.
Remove screw plugs (item 139+142) and drain oil.

Collect spent oil in suitable containers and dispose of
the oil line with the respective regulations.
Bild / fig. 5
Motorbefestigungsschrauben (Pos. 199+197) lösen.
Remove motor mounting bolts (items 199+197).
Bild / fig. 6
6kt-Schrauben (Pos. 409) lösen.
Remove hex head bolts (items 409).
Bild / fig. 7
Rohrklemme (Pos. 206) entfernen.
Remove pipe clamp (item 206).
Bild / fig. 8
3692960, 3692970, 3692990
Halteblech (Pos. 403) entfernen.
Remove locking plate (item 403).
Bild / fig. 9
Hydromotor (Pos. 198) mit O-Ring (Pos. 510) entfernen.
Motorgewicht: ca. 66kg
Remove hydraulic motor (item 198) with o-ring (item

510).
Weight of motor: appr. 66kg
Bild / fig. 10
Befestigungsschrauben (Pos. 151) lösen.
Remove mounting bolts (items 151).
Bild / fig. 11
Komplett montierten Peilstab entfernen.
Remove complete assembled dipstick.
Bild / fig. 12
3692960, 3692970, 3692990
Komplett montierten Lamellenträger mit Flansch (Pos.

300) und O-Ring (Pos. 411) entfernen.
Remove complete assembled disk housing with flange

(item 300) and o-ring (item 411).
Bild / fig. 13
Sonnenradwelle (Pos. 114) entfernen.
Remove sun gear shaft (item 114).
Bild / fig. 14
Komplett montierten Planetensteg der Vorstufe entneh-
men.
st
Remove completely pre-assembled 1 planet stage.
Bild / fig. 15
1x Sicherungsring (Pos. 130) lösen.
Remove 1x snap ring (item 130).
Bild / fig. 16
3692960, 3692970, 3692990
Hohlrad (Pos. 102) entfernen.
Remove ring gear (item 102).
Bild / fig. 17
1x Planetenrad (Pos. 111) abziehen.
Pull off 1x planet gear (item 111).
Bild / fig. 18
Bild / fig. 19
Planetensteg (Pos. 108) der Hauptstufe entnehmen.
Remove planet carrier main stage (item 108).
Bild / fig. 20
3692960, 3692970, 3692990
Bild / fig. 21
Loosen and remove socket head cap screws (item 174).
Bild / fig. 22
Ring (Pos. 175) entfernen.
Remove ring (item 175).
Bild / fig. 23
Mit entsprechender Vorrichtung Abtriebswelle (Pos. 106)

aus Tragrohr (Pos. 103) drücken.
Press out output shaft (item 106) out of cartridge (item

103) with an adequate tool.
Bild / fig. 24
3692960, 3692970, 3692990
Tragrohr (Pos. 103) abnehmen.
Take off cartridge (item 103).
Bild / fig. 25
Mit entsprechender Vorrichtung Pendelrollenlager (Pos.

120) von Abtriebswelle(Pos. 106) entfernen.
Remove spherical roller bearing (item 120) from output

shaft (item 106) with an adequate tool.
Bild / fig. 26
Nilos Ring (Pos. 128) von Abtriebswelle (Pos. 106) ent-

fernen.
Remove Nilos ring (item 128) from output shaft (item

106).
Bild / fig. 27
Zylinderrollenlager (Pos. 121) aus Tragrohr (Pos. 103)

entnehmen.
Remove cylindrical roller bearing (item 120) out of car-

tridge (item 108).
Bild / fig. 28
3692960, 3692970, 3692990
Mit geeignetem Hilfsmittel Wellendichtringe (Pos. 125)

aus Tragrohr (Pos. 103) entfernen.
Remove radial shaft sealing rings (item 125) with an

adequate tool out of cartridge (item 103).
Bild / fig. 29
Zwischenring (Pos. 113) abheben.
Take off spacer ring (item 113).
Bild / fig. 30
Loosen and remove socket head cap screws (item 516).
Bild / fig. 31
Motorflansch (Pos. 503) und O-Ring (Pos. 511) entfer-

nen.
Remove motor flange (item 503) with o-ring (item 511).
Bild / fig. 32
3692960, 3692970, 3692990
6kt-Schrauben (Pos. 519) lösen und entfernen.
Loosen and remove hex head bolts (item 519).
Bild / fig. 33
Lamellenträger (Pos. 501) von Flansch (Pos. 300) ab-

heben.
Remove disk housing (item 501) out of flange (item

300).
Bild / fig. 34
Bild / fig. 35
Mit geeigneter Vorrichtung Scheibe (Pos. 521) bis zum

Anschlag gegen die Federn (Pos. 507+509) drücken.
Press disk (item 521) firmly against springs (item

507+509) with a suitable fixture.
Bild / fig. 36
3692960, 3692970, 3692990
Vorrichtung entfernen.
Remove fixture.
Bild / fig. 37
Bild / fig. 38
Scheibe (Pos. 521) entfernen.
Bild / fig. 39
Federn (Pos. 507+509) entfernen.
Remove springs (items 507+509).
Bild / fig. 40
3692960, 3692970, 3692990
Kolben (Pos. 502) mit Quadring (Pos. 512) und Stützrin-

gen (Pos. 513) entfernen. (Kolben ggf. mit Luftdruck
beaufschlagen. Benutzen Sie hierzu den Bremslüftan-
schluss G1/4 (siehe Einbauzeichnung).
Remove piston (item 502) with piston seal (item 512)

and supporting rings (item 513). If necessary pressurize
piston with air. For this purpose brake release port G1/4
(see installation drawing).
Bild / fig. 41
Lamellenpaket (Pos. 505+506) herausnehmen.
Remove brake disks (item 505+506).
Bild / fig. 42
Quadring (Pos. 514) und Stützringe (Pos. 515) aus

Lamellenträger (Pos. 501) entfernen.
Remove piston seal (item 514) and supporting rings

(item 515) out of disk housing (item 501).
Bild / fig. 43
Quadring (Pos. 512) und Stützringe (Pos. 513) aus

Kolben entfernen.
Remove piston seal (item 512) as well as supporting

rings (item 513) out of piston.
Bild / fig. 44
3692960, 3692970, 3692990
Zur weiteren Demontage der Bremse stellen Sie den

Lamellenträger auf die Flanschanschlussfläche.
For further disassembly storage the disc housing on the

flange surface.
Bild / fig. 45
Bild / fig. 46
Scheibe (Pos. 504) entnehmen.
Bild / fig. 47
Demontage Baugruppe Planetenträger Vorstufe

Disassembly of planet carrier assembly input stage

Bild / fig. 48
3692960, 3692970, 3692990

Planetenräder (Pos. 110) mit Hilfswerkzeug z.B. Ab-

Pull planet gears (item 110) with a suitable fixture e.g. a
puller.
Bild / fig. 49

Sicherungsring (Pos. 129) lösen und Planetensteg (Pos.
107) abheben.

Remove snap ring (item 129) and lift off planet carrier
(item 107).
Bild / fig. 50
Demontage Baugruppe Planetenträger Hauptstufe

Disassembly of planet carrier assembly main stage

Bild / fig. 51
Demontage Baugruppe Planetenträger Hauptstufe

Planetenräder (Pos. 111) mit Hilfswerkzeug z.B. Ab-
Disassembly of planet carrier assembly main stage

Pull planet gears (item 111) with a suitable fixture e.g. a
puller.
Bild / fig. 52
3692960, 3692970, 3692990
Ggf. Entlüfter (Pos. 331) entfernen.
If necessary remove vent (item 331).
Bild / fig. 53
3692960, 3692970, 3692990
5. Montage • 5. Assembly

VORSICHT ! CAUTION!
Gefahr von Personen- oder Sachschäden! Risk of Personal Injury or Damage to Prop-
erty!
Durch das Verwenden von metrischen und
amerikanischen Gewinden wie z.B. UN oder As both metric and US threads, such as UN
UNF Gewinden an unseren Produkten kann or UNF threads, are used on our products,
es zu Verwechslungen und somit zu Beschä- there is a risk of confusion that may lead to
digungen des Produkts und/oder zu Verlet- damage to equipment and/or personal injury.
zungen von Personen kommen.
• Stellen Sie sicher, dass <das Pro- • Prior to starting up the prod-
dukt/die Anlage> durch qualifizier- uct/equipment, make sure that it
tes Personal korrekt montiert has been correctly assembled and
wurde, bevor Sie <das Produkt/die installed by qualified personnel.
Anlage> in Betrieb nehmen.
• The product/equipment must not
• Das Produkt darf nur montiert und be assembled/installed and
in Betrieb genommen werden started up, unless documents are
wenn Dokumente wie z.B das available, e.g. technical data-
Technische Datenblatt oder die sheets or installation drawings,
Einbauzeichnung des Produkts which clearly show the thread
vorliegen aus denen die Gewinde- types and sizes.
arten und -größen ersichtlich
sind.
Vor der Montage sind folgende Ver- Prior to assembly the following inspec-
schleißprüfungen erforderlich: tions of wear and tear are required:
• Prüfen Sie auf Verschleiß:

- axiale Anlaufflächen
• Check for wear:
- axial contact faces
- Paßsitze - machined seats
- Gewindebohrungen - threaded holes
• Prüfen Sie alle Dichtflächen auf:

- Beschädigung • Check all sealing faces for:
- damage
• Prüfen Sie die Lager auf:

- Verwendbarkeit (Spiel übermäßig)
• Check the bearings for:
- usability (excessive clearance)
- visuelle Prüfung - visual appearance
• Prüfen Sie die Verzahnung auf:

- Zahnausbrüche
• Check the gear teeth for:
- tooth breakage
- Pittings - pitting
- Rißbildung - cracks
- Gratbildung - burrs
- Verschleiß - wear
3692960, 3692970, 3692990
MET-L-CHEK / Rißprüfung:
1. Entfetten und reinigen der Prüfteile
(z.B. Spezialreiniger NPU).
1. Degrease and clean the parts to be che-
cked (e.g. special cleaner NPU).
2. Aufbringen des Eindringmittel

(z.B. DYE VP 30).
2. Apply penetrant fluid (e.g. DYE VP 30).
Reaction time approx. 5-30 minutes de-
Einwirkzeit ca. 5-30 Min. je nach Tempera- pending on temperature and material.
tur und Werkstoff.
3. Werkstück von Eindringmittel reinigen.

(z.B. mit Spezialreiniger NPU oder Wasser)
3. Clean off penetrant fluid from work piece
(e.g. with special cleaner NPU or water).
Oberfläche trocknen lassen. Allow surface to dry.
4. Den Entwickler „weiß“, hauchdünn auftra-

gen. Nach einer kurzen Trockenzeit tritt
4. Apply a very thin layer of developer „whi-
te“. After a short drying time, the penetrant
aus den Fehlstellen das Eindringmittel fluid (e.g. DYE VP 30) emerges from the
(z.B. DYE VP 30) aus und bildet mit dem defective spots and creates a red contrast
weißen Entwickler einen roten Kontrast. to the white developer.
5. Inspektion – rote Linien im weißen Ent-

wicklerfeld zeigen Risse oder Überlap-
5. Inspection – red lines on the white devel-
oper field indicate cracks or overlappings,
pungen an, während punktförmige Farb- while point shaped colour patterns can be
austritte als Poren zu werten sind. rated as blowholes and pores.
3692960, 3692970, 3692990
5.2 Montage Planetengetriebe / Bremse

Assembly Planetary Gearbox / Brake
Vor der Montage des Getriebes sind alle Teile zu säu-
bern.
ACHTUNG!
Die anschließende Aushärtezeit für den Kleber (z.B.
LOCTITE) beträgt ca 24 Std. bei einer Temperatur von
20°C.
Clean all parts before assembly of the gearbox.

ATTENTION!
The LOCTITE setting time equals 24 hours at ambient
temperature of 20°C.
Bild / fig. 54
Anlagefläche von Zwischenring (Pos.113) mit LOCTITE
270 bestreichen.
Evenly apply coat of LOCTITE 270 to contact surface of

spacer ring (item 113).
Bild / fig. 55
Zwischenring (Pos.113) auf Abtriebswelle (Pos.106)
montieren. Auf richtige Einbaulage des Zwischenrings
achten.
Mount spacer ring (item 113) on output shaft (item 106).

Observe correct installation position.
Bild / fig. 56
Nilosring (Pos. 128) mit Fett (K3N 30 DIN 51502) füllen
und auf die Antriebswelle montieren.
Grease Nilos ring (item128) with grease (K3N 30 DIN

51502) and mount it on the output shaft (item 106).
Bild / fig. 57
3692960, 3692970, 3692990
Rollenkranz von Pendelrollenlager (Pos. 120) mit Wälz-

lagerfett (K3N 30 DIN 51502) fetten.
Grease roller cage of spherical roller bearing (item 120)

with roller bearing grease (K3N 30 DIN 51502).
Bild / fig. 58
Pendelrollenlager (Pos. 120) auf max. 120°-130°C er-

wärmen und auf Abtriebswelle (Pos. 106) montieren.
Abkühlzeit von ca. 60 Minuten beachten!
Heat spherical roller bearing (item 120) to max. 120°-

130°C and mount onto output shaft (item 106).
Observe a time of refrigeration of approx. 60 min!
Bild / fig. 59
Hülse (Pos. 180) auf max. 120°-130°C erwärmen und

neue O-Ringe (Pos. 181) in entsprechende O-Ring Nut
von Hülse (Pos. 180) einlegen.
ACHTUNG!
Entsprechende Sicherheitshandschuhe tragen.
Heat sleeve (item 180) onto max. 120°-130°C and

mount new o-rings (item 181) into the suitable o-ring
grooves of sleeve (item 180).
CAUTION!
Wear suitable safety gloves.
Bild / fig. 60
Hülse (Pos. 180) mit entsprechendem Hilfswerkzeug auf

Abtriebswelle (Pos. 106) auftreiben.
Mount sleeve (item 180) with an adequate tool onto

output shaft (item 106).
Bild / fig. 61
3692960, 3692970, 3692990
Nochmals Wälzlagerfett (K3N 30 DIN 51502) im Bereich

Pendelrollenlager (Pos. 120) auftragen.
Grease again the area of spherical roller bearing (item

120) with roller bearing grease (K3N 30 DIN 51502).
Bild / fig. 62
Aussendurchmesser der Wellendichtringe (Pos. 125)

gleichmäßig mit LOCTITE 573/574 bestreichen.
Evenly apply coat of LOCTITE 573/574 to the outer ring

of radial sealing sing (item 125).
Bild / fig. 63
Neue Wellendichtringe (Pos. 125) in Tragrohr (Pos. 103)

einsetzen und mit entsprechendem Hilfswerkzeug auf
Anlage bringen.
Auf richtige Einbaulage der Dichtlippe achten!
Insert new radial shaft sealing rings (item 125) into car-
tridge (item 103) and mount them with an adequate tool
for proper axial seat.
Observe correct mounting position of sealing lip!
Bild / fig. 64
Einbauraum zwischen den Dichtlippen zu ca. 30% mit

Wälzlagerfett (K3N 30 DIN 51502) füllen.
Fill mounting space between sealing lips with appr. 30%

roller bearing grease (K3N 30) DIN 51502).
Bild / fig. 65
3692960, 3692970, 3692990
Vormontiertes Tragrohr (Pos. 103) auf Abtriebswelle

(Pos. 106) montieren.
Mount pre-assembled cartridge (item 103) on output

shaft (item 106).
Bild / fig. 66
Aussenring mit Rollenkranz von Zylinderrollenlager

(Pos. 121) in Bohrung von Tragrohr (Pos. 103) montie-
ren.
Mount outer ring with roller cage of cylindrical roller

bearing (item 121) into cartridge (item 103).
Bild / fig. 67
Lagerinnering von Zylinderrollenlager (Pos. 121) auf

entsprechenden Paßsitz von Abtriebswelle (Pos. 106)
montieren (Innenring nicht gegen die Rollen drücken).
ACHTUNG!
Während der Montage vom Lagerinnenring ist das Trag-
rohr in eine Richtung zu drehen.
Mount inner ring of cylindrical roller bearing (item 121)

onto the equivalent fit of output shaft (item 106 (do not
spinn the inner ring against the roles)
ATTENTION!
While mounting the inner ring of cylindrical roller bearing
turn the cartridge in one direction.
Bild / fig. 68
Gewinde der Zylinderschrauben (Pos. 174) gleichmäßig

mit LOCTITE 270 bestreichen.
Evenly apply coat of LOCTITE 270 to threads of socket

head cap screws (item 174).
Bild / fig. 69
3692960, 3692970, 3692990
Ring (Pos.175) montieren.
Mount ring (item 175).
Bild / fig. 70
Zylinderschrauben (Pos. 174) in entsprechende Gewin-

debohrungen von Tragrohr (Pos. 103) einsetzen und mit
erforderlichem Anzugsmoment anziehen.
Install socket head cap screws (item 174) into threaded

holes of cartridge (item 103) and tighten them to a re-
quired torque.
Bild / fig. 71
Planetensteg (Pos. 108) einsetzen.
Insert planet carrier (item 108).
Bild / fig. 72
Mit Sicherungsring (Pos. 135) sichern.
Secure with snap ring (item 135).
Bild / fig. 73
3692960, 3692970, 3692990
Neuen O-Ring (Pos. 126) auf Zentriersitz von Tragrohr

(Pos. 103) aufziehen.
O-Ring leicht einfetten.
Mount a new o-ring (item 126) on the fit of cartridge

(item 103).
Grease o-ring lightly.
Bild / fig. 74
Montage der Zylinderrollenlager (Pos. 119):

Zylinderrollenlager (Pos. 119) aus der Transportverpa-
ckung direkt in die Aufnahmebohrung von Planetenrad
(Pos. 111) drücken.
Assembly of cylindrical roller bearing (item 119:

Push cylindrical roller bearing (item 119) directly out of
transport packing into the locating hole of the planet
gear (item 111).
Bild / fig. 75
Anlaufscheibe (Pos. 134) einsetzen.
Insert locating ring (item 134).
Bild / fig. 76
Neuen Sicherungsring (Pos. 136) einsetzen.
Insert a new snap ring (item 136).
Bild / fig. 77
3692960, 3692970, 3692990
Zweite Anlaufscheibe (Pos. 134) einsetzen).
nd
Insert 2 locating ring (item 134).
Bild / fig. 78
Zweites Zylinderrollenlager (Pos. 119) aus der Trans-

portverpackung direkt in die Aufnahmebohrung von
Planetenrad (Pos. 111) drücken.
nd
Push 2 cylindrical roller bearing (item 119) directly out
of transport packing into the locating hole of the planet
gear (item 111).
Bild / fig. 79
Vormontiertes Planetenrad (Pos. 111) auf ca. 120°-

130°C erwärmen.
Heat pre-assembled planet gear (item 111) to approx.

120°-130°C.
Bild / fig. 80
Bei der Montage des vormontierten Planetenrades ist

darauf zu achten das der größere Planetenlagerradius
zum Planetensteg zeigt.
Observe during assembly of the pre-assembled planet

gear that the larger radius on the bearing bore is orien-
tated towards the planet carrier.
Bild / fig. 81
3692960, 3692970, 3692990
Vormontiertes Planetenrad auf den Planetenbolzen von

Planetensteg (Pos. 108) montieren.
Mount pre-assembled planet gear onto the planetary pin

of planet carrier (item 108).
Bild / fig. 82
Planetenrad mit neuen Sicherungsring (Pos. 130) si-

chern.
Secure the planet gear with new snap ring (item 130).
Bild / fig. 83
Hohlrad (Pos. 102) auf Zentriersitz von Tragrohr (Pos.

103) montieren.
Mount ring gear (item 102) onto the fit of cartridge (item
103).
Bild / fig. 84
Sonnenrad (Pos. 104) in Innenverzahnung von Plane-

tensteg (Pos. 107) einsetzen.
Insert sun gear (item 104) into internal teeth of planet

carrier (item 107).
Bild / fig. 85
3692960, 3692970, 3692990
Sonnenrad mit neuem Sicherungsring (Pos. 129) si-

chern.
Secure sun gear with a new snap ring (item 129).
Bild / fig. 86
Vormontierten Planetensteg der Vorstufe in das Getrie-

be einsetzen.
Install pre-assembled input planet stage into the swing

drive.
Bild / fig. 87
Montage Zylinderrollenlager (Pos. 118)

Zylinderrollenlager (Pos. 118) aus der Transportverpackung
direkt in die Aufnahmebohrung drücken.
Achtung!
Kontrollieren Sie ob der Sicherungsring vom Zylinderrollenlager
in die entsprechende Nut eingeschnappt ist.
Assembly of cylindrical roller bearing (item 118)

Push cylindrical roller bearing (item 118) directly out of the
transport packing into the locating hole of planet gear.
Caution!
Make sure that the snap ring is in the right position of the snap
ring groove.
Bild / fig. 88
Vormontierte Planetenräder (Pos. 110) auf ca. 120°-

130°C erwärmen.
Heat pre-assembled planet gears (item 110) to approx.

120°-130°C.
Bild / fig. 89
3692960, 3692970, 3692990
Bei der Montage des vormontierten Planetenrades ist

darauf zu achten das der größere Planetenlagerradius
zum Planetensteg zeigt.
Observe during assembly of the pre-assembled planet

gear that the larger radius on the bearing bore is orien-
tated towards the planet carrier.
Bild / fig. 90
Vormontierte Planetenräder (Pos. 110) auf den Plane-

tenbolzen von Planetensteg (Pos. 107) montieren.
Mount pre-assembled planet gears (item 110) onto the

planetary pins of planet carrier (item 107).
Bild / fig. 91
Planetenräder mit neuen Sicherungsringen (Pos. 131)

sichern.
Secure the planet gears with new snap rings (item 131).
Bild / fig. 92
Im Bereich der Bohrung für den Peilstab LOCTITE

573/574 auftragen.
Apply LOCTITE 573/574 at the area of dipstick boring.
Bild / fig. 93
3692960, 3692970, 3692990
Neuen O-Ring (Pos. 411) auf Zentriersitz von Flansch

(Pos. 300) aufziehen.
Mount a new o-ring (item 411) onto the fit of flange (item
300).
Bild / fig. 94
Flansch (Pos. 300) in Einpass von Hohlrad (Pos. 102)

einpassen.
Mount flange (item 300) into fit of ring gear (item 102).
Bild / fig. 95
Achtung!
Vor dem Verschrauben von Flansch (Pos. 300) und
Hohlrad (Pos. 102) auf richtige Lage der Bohrungen
zueinander achten.
Caution!
Observe.that the borings of flange (item 300) and ring
gear (item 102) are in the right position.
Bild / fig. 96
Befestigungsschrauben (Pos. 151) für Hohlrad und

Flansch in Gewindebohrungen von Tragrohr (Pos. 103)
einsetzen und mit erforderlichem Anzugsmoment anzie-
hen.
Insert socket head cap screws (item 151) into threaded

holes of cartridge (item 103). Tighten them to a required
torque.
Bild / fig. 97
3692960, 3692970, 3692990
Sonnenradwelle (Pos. 114) einsetzen.
Install sun gear shaft (item 114).
Bild / fig. 98
Stellen Sie den Lamellenträger (Pos. 501) zur Montage

der Scheibe (Pos. 504) und des Sicherungringes (Pos.
508) auf die Getriebeanschlußfläche.
Storage the disc housing (item 501) for mounting of disc

(item 504) and snap ring (item 508) onto the gearbox
surface.
Bild / fig. 99
Scheibe (Pos. 504) einlegen.
Install disk (item 504).
Bild / fig. 100
Neuen Sicherungsring (Pos. 508) montieren und auf

richtigen Sitz prüfen.
Assemble a new snap ring (item 508) and check for

proper seat.
Bild / fig. 101

3692960, 3692970, 3692990
Zur weiteren Montage der Bremse stellen Sie den La-

mellenträger auf die Motoranschlussfläche.
For further assembly of brake storage the disc housing

onto the motor surface.
Bild / fig. 102
Neue Stützringe (Pos. 515) in Lamellenträger (Pos. 501)

einsetzen. Neuen Quadring (Pos. 514) zwischen die
Stützringe montieren. Leicht einölen.
Set in new supporting rings (item 515) into the disk

housing (item 501). Assemble a new piston seal (item
514) between supporting rings.
Lubricate contact areas with gear oil lightly
Bild / fig. 103
Neue Lamellen (Pos. 506+505) in richtiger Reihenfolge

einlegen. (siehe Skizze)
Insert new brake disks (item 506+505) in correct order.

(note sketch)
Bild / fig. 104
Federn, Dichtelemente und Gegenflächen der Dichtele-

mente sind für die Montage leicht einzuölen. Bevor die
Quadringe montiert werden müssen beide Stützringe
eingebaut werden.
Lubricate springs, piston seals, supporting rings as well

as their contact areas lightly with gear oil assemble
supporting rings prior to piston seals.
Bild / fig. 105

3692960, 3692970, 3692990
Kolbeneinheit bestehend aus (Pos. 502, 512, 513) in

Lamellenträger (Pos. 501) einsetzen.
Insert piston assembly consisting of (item 502, 512, 513)

into disk housing (item 501).
Bild / fig. 108
Kolben mit Hilfswerkzeug zur Anlage bringen.
Bring piston with an adequate tool to stop face.
Bild / fig. 109
Neue Federn (Pos. 507+509) in richtiger Anordnung in

den Kolben (Pos. 502) einsetzen.
Insert new springs (item 507+509) in correct order into

piston (item 502).
Bild / fig. 110
Scheibe (Pos. 521) und Sicherungsring (Pos. 520) ein-

legen.
Install disk (item 521) and snap ring (item 520).
Bild / fig. 111

3692960, 3692970, 3692990
Mit geeigneter Vorrichtung Scheibe (Pos. 521) bis zum

Anschlag gegen die Federn (Pos. 507+509) drücken.
Neuen Sicherungsring (Pos. 520) montieren und auf
richtigen Sitz prüfen.
Press disk (item 521) firmly against springs (item

507+509) with a suitable fixture. Assemble the new snap
ring (item 520) and check for proper seat.
Bild / fig. 112
Vorrichtung entfernen.
Remove fixture.
Bild / fig. 113
Neuen O-Ring (Pos. 524) in entsprechende Nut von

Lamellenträger (Pos. 501) einlegen.
Insert a new o-ring (item 524) into the o-ring groove of

disk housing (item 501).
Bild / fig. 114
Komplett vormontierte Bremse in Kran einhängen und

Bremse mit Druck beaufschlagen (ca. 50 bar). (Brems-
lüftanschluss siehe Einbauzeichnung.)
Verwenden Sie hierzu z.B. „LUKAS“ als Hilfswerkzeug.
Insert pre-mounted brake into crane and impinge on

brake with pressure (approx. 50 bar). Brake release
connection acc. to installation drawing. Use "LUKAS"
f.ex. as auxiliary tool
Bild / fig. 115

3692960, 3692970, 3692990
Achtung!
Beim Anbau der vormontierten Lamellenhaltebremse
Einbaulage beachten (Stellung Ölablaß/Bremslüft-
anschluss siehe Einbauzeichnung)
Caution!
Observe installation position of pre-mounted disk brake
during assembly. Position oil drain / brake release con-
nection acc. to installation drawing.
Bild / fig. 116
Komplett vormontierte Bremse in Einpass von Flansch

(Pos. 300) einsetzen. „LUKAS“ entlüften und entfernen.
Mount complete pre-assembled brake into the fit of

flange (item 300). Bleed and remove „LUKAS“
Bild / fig. 117
Befestigungsschrauben (Pos. 519) für den Lamellenträ-

ger in die Gewindebohrungen von Flansch (Pos. 300)
einsetzen und mit erforderlichem Anzugsmoment anzie-
hen.
Insert hex head bolts (Item 519) for disk housing into
threaded holes of flange (item 300) and tighten them to
required torque.
Bild / fig. 118
Neuen O-Ring (Pos. 511) auf Zentriersitz von Motor-

flansch (Pos. 503) aufziehen.
Mount a new o-ring (item 511) onto the fit of motor flan-
ge (item 503).
Bild / fig. 119

3692960, 3692970, 3692990
Motorflansch (Pos. 503) in Einpass von Lamellenträger

(Pos. 501) einpassen.
Mount motor flange (item 503) into fit of disk housing

(item 501).
Bild / fig. 120
Gewinde der Zylinderschrauben (Pos. 516) gleichmäßig

mit LOCTITE 270 bestreichen und in Gewindebohrun-
gen von Lamellenträger (Pos. 501) einsetzen.
Evenly apply coat of LOCTITE 270 to the thread of so-

cket head cap screws (item 516) and insert screws into
threaded holes of disk housing (item 501).
Bild / fig. 121
Zylinderschrauben (Pos. 516) mit erforderlichem An-

zugsmoment anziehen.
Tighten socket head cap screws (item 516) to a required

torque.
Bild / fig. 122
Bremslüftanschluss mit Stopfen (Pos. 517) verschlie-

ßen.
Lock brake release port with plug (item 517).
Bild / fig. 123

3692960, 3692970, 3692990
Verschlußschraube (Pos. 526) mit neuem Dichtring

(Pos. 527) in Lamellenträger (Pos. 501) einschrauben
und mit entsprechendem Werkzeug anziehen.
Screw into disk housing (item 501) screw plug (item

526) with a new seal ring (item 527) and tighten them
with an adequate tool.
Bild / fig. 124
Schmiernippel (Pos. 345) in Tragrohr (Pos. 103) ein-

schrauben und mit entsprechendem Werkzeug anzie-
hen.
Insert grease nipple (item 345 into cartridge (item 103)

and tighten them with an adequate tool
Bild / fig. 125
Verschlußschraube (Pos. 139) für Ölablaß mit neuem

Dichtring (Pos. 142) in Tragrohr (Pos. 103) einschrau-
ben und mit entsprechendem Werkzeug anziehen.
Screw into cartridge (item 103) screw plug for oil-outlet

(item 139) with a new seal ring (item 142) and tighten
them with an adequate tool.
Bild / fig. 126
Gewinde am Winkel (Pos. 140) bzw. Gewindebohrung

am Motorflansch (Pos. 503) entfetten (z.B. mit LOCTITE
7061).
Degrease thread of angle (item 140) resp. threaded hole

at the motor flange (item 503) (with e.g. LOCTITE 7061).
Bild / fig. 127

3692960, 3692970, 3692990
Gewinde am Winkel (Pos. 140) gleichmäßig mit

LOCTITE 586 bestreichen und in die entsprechende
Gewindebohrung vom Motorflansch (Pos. 503) ein-
schrauben.
Evenly apply coat of LOCTITE 586 to thread of angle

(item 140) and insert angle into suitable thread hole of
motor flange (item 503).
Bild / fig. 128
Gewinde am Entlüfter (Pos. 331) gleichmäßig mit

LOCTITE 586 bestreichen.
Evenly apply coat of LOCTITE 586 to thread of vent

(item 331).
Bild / fig. 129
Entlüfter (Pos. 331) in Winkel (Pos. 140) einschrauben

und mit entsprechendem Werkzeug anziehen.
Insert vent (item 331) into angle (item 140) and tighten
them with an adequate tool.
Bild / fig. 130
Gewinde des komplett vormontierten Peilstabes (Pos.

406) gleichmäßig mit LOCTITE 586 bestreichen.
Evenly apply coat of LOCTITE 586 to threads of the

complete assembled dipstick (item 406).
Bild / fig. 131

3692960, 3692970, 3692990
Komplett vormontierten Peilstab montieren.
Mount complete pre-assembled dipstick.
Bild / fig. 132
O-Ring (Pos. 510) auf Zentriersitz von Hydromotor (Pos.

198) aufziehen.
Mount o-ring (item 510) onto the fit of hydraulic motor

(item 198).
Bild / fig. 133
Hydromotor (Pos. 198) in den Einpass von Motorflansch

(Pos. 503) einsetzen.
Motorgewicht: 66kg
Mount hydraulic motor (item 198) into the fit of motor

flange (item 503).
Weight of motor: 66kg
Bild / fig. 134

3692960, 3692970, 3692990
Achtung!
Bei der Montage der Motorbefestigungsschrauben muss
das Halteblech (Pos. 403) mitmontiert werden.
Caution!
When mounting the motor fixation screws, the holding
plate must be mounted too.
Bild / fig. 135
Rohrklemme (Pos. 206) mit 6kt-Schrauben (Pos. 409)

an Halteblech (Pos. 403) anschrauben und mit entspre-
chendem Werkzeug anziehen.
Mount pipe clamp (item 206) with the hex head bolts
(item 409) to the locking plate (item 403) and tighten
them with a adequate tool..
Bild / fig. 136
Motorbefestigungsschrauben (Pos. 197 oder 199) in

Gewindebohrungen von Motorflansch (Pos. 503) einset-
zen und mit erforderlichem Anzugsmoment anziehen.
Insert motor mounting bolts (item 197 or 199) into threa-

ded holes of motor flange (item 503) and tighten them to
required torque.
Bild / fig. 137
Vor Inbetriebnahme Öl auffüllen und die mit neuen Dich-

tungen (Pos. 327) versehenen Verschlußschrauben
(Pos. 326) anziehen.
(siehe hierzu entsprechende Betriebsanleitung der Ge-
triebetype)
Prior to commissioning fill the swing drive with new oil to

recommended level. Install plugs (item 326) with new
seal rings (item 327).
(observe the resp. operating instructions of the gearbox
type)
Bild / fig. 138

3692960, 3692970, 3692990
6.1 Prüfstandsaufbau 6.1 Test set up

Das Getriebe wird in der vorgesehenen Einbaulage auf- The gearbox shall be mounted in its intended installation
gebaut und mit einem geeigneten Antriebsmotor angetrie- position and connected to a suitable driving motor. If the
ben. Wenn das Betriebsverhalten des Getriebetyps be- operating performance of the gearbox type is known, it
kannt ist, kann eine andere Prüflage gewählt werden, is possible to mount the gearbox in another test position
wobei die Radialwellendichtringe, bzw. Gleitringdichtun- under the condition that the radial face seals and the
gen unter Öl stehen müssen (Luftkammerbildung beach- axial seal are submerged in oil (check for air cham-
ten!). bers!).

Die Getriebe werden wie in der Einbauzeichnung vorge- The gear units are to be filled with oil as shown on the
sehen mit Öl gefüllt. Bremsen mit seperater Ölfüllung sind installation drawing. Brakes which have separate oil
vor dem Probelauf gemäß Einbauzeichnung ebenfalls mit fillings shall be filled with oil before test run.
Öl zu befüllen. For oil fill, please use the lubricants listed in the operat-
Zur Ölbefüllung verwenden Sie bitte die in der Betriebsan- ing instructions.
leitung angebenen Schmierstoffe.
6.3 Drehzahl, Laufzeit und 6.3 Speed, Running Time,

Prüflast Test Load
Die Getriebe sind mit Höchstdrehzahl (nmax Getriebe bzw. The gear units are to be operated at max. speed (nmax of
nmax Prüfstand) über 1 Stunde (je ½ Stunde pro Drehrich- gearbox or nmax test bed) under no load for one hour
tung bei Getrieben mit wechselnder Drehrichtung) ohne (half an hour in each direction of rotation in case of
Last zu fahren. reverse gears).
Hierbei ist die Ölsumpftemperatur am Außendurchmesser Measure oil sump temperatures at outside diameter of
des Hohlrades nach 30, 45 und 60 Minuten zu messen ring gear and note them down after 30, 45 and 60 min-
und zu protokollieren. utes of operation.

Die Ölsumpftemperatur soll nach Abschluß des The oil sump temperature measured after the 1-hour
1-stündigen Probelaufs 70°C nicht übersteigen. Die Tem- test run shall not exceed 70°C.
peratur nach 30 Minuten bei reduzierter Laufzeit soll die The temperature measured after 30 minutes reduced
Temperatur der Temperaturaufschreibung des ersten operating time shall not exceed the temperature records
Getriebes um nicht mehr als 4°C überschreiten. of the first gearbox by more than 4°C.
Die Temperaturen an außenliegenden Lagerstellen (so- The temperatures measured at the external bearing
weit zutreffend) sollen die Ölsumpftemperaturen um nicht areas (if applicable) must be not exceed the oil sump
mehr als 10°C übersteigen. temperature by more than 10°C.

Das Laufgeräusch soll weich und gleichmäßig sein. The running noise under test conditions should be
Es dürfen keine harten, schlagenden oder pfeifende Ge- smooth and steady.
räusche vorhanden sein. Hard, knocking or howling noise produced by the unit
are inadmissible.
6.6 Dichtigkeitsprüfung 6.6 Tightness testing

Während des Probelaufs sind alle Dichtungen auf Undich- During the test run, make sure to check all seals for
tigkeiten hin zu beobachten, z.B.: leakages, e.g.:
- Ein- und Auslaßschrauben - Inlet and drain plugs
- Entlüfter - Vent
- Dichtflächen an Hohlrädern und Deckeln - Sealing faces at ring gears and covers
- Wellendichtungen - Shaft seals
3692960, 3692970, 3692990
6.7 Funktionsprüfung der 6.7 Hydraulic Brakes

Bremsen
Die Bremsen werden durch eine pulsierende Prüfung auf A pulsating pressure test shall be performed on the
Funktion und Dichtigkeit geprüft: brakes to check the tightness and function:
- Prüfdruck: 60-80 bar - Test pressure: 60-80 bar
- Lüftzeit: 6-10 sek pro Kolbenhub - Releasing time: 6-10 sec. per piston stroke
- Prüfdauer: min. 15 Minuten - Testing time: 15 minutes minimum

Nach Durchführung des Probelaufs ist das ablaufende After completing the test run, the oil shall be inspected
Getriebeöl auf Späne, Zunder, übermäßigen Abrieb zu for scraps, scales and wear particles and other impuri-
beobachten. Auf Fremdkörper an Magnetstopfen und ggf. ties. The magnetic plug and, if necessary, the oil filter
am Ölfilter ist zu achten. shall be checked.
7.4 PUMP GEARBOX
7.4 Pump gearbox

7.4.1 General
This section is valid for pump gearboxes
Weight
part no. 2 707 787 Pump gearbox without pumps approx. 1 200 kg
3 686 883 Pump gearbox with pumps approx. 2 300 kg
3 736 803
Table 2
The pump gearbox forms one structural unit to-

gether with the main-, swing-, cooling-, and servo
pumps. It is designed as a spur gear system. Dimensions of the pump gearbox (Fig. 1)
[mm]
Technical data A 1 590
Gearbox type: 4343.XX B 1 316
Input RPM: 1 800 C 518,5
RPM of main pumps: 1 490 Table 3
RPM of swing pumps: 2 645

Ratio for cooling pumps: 1 994
Direction of rotation: right
(view onto input shaft)
Oil capacity: approx. 55 l
Table 1
Fig. 1 Dimensions of the pump gearbox – 3736803-02
3664245en - (02) Page 7.4 - 1

7.4 PUMP GEARBOX
7.4.2 Dismantling and installing the 2. If necessary support diesel engine on super-
pump gearbox structure frame, e.g. with timber or bracket
(arrow A, fig. 2).
The diesel engine and pump gearbox are resil-
iently mounted together on the superstructure The engine must be securely sup-
frame by means of the bearing. ported on the frame.
Dismantling the pump gearbox

3. Unscrew bolts (1, fig. 2) between gearbox
1. Remove hydraulic lines and pumps, collecting flange and diesel engine.
escaping hydraulic oil in suitable vessels.
4. Unscrew bolts between engine coupling and
Close exposed hose and pipe connections, flywheel (see chapter 5.4 – Coupling assem-
open bores and housing carefully to prevent bly).
dirt from penetrating.
5. Connect gearbox at eyes with appropriate
Disconnect electric cables from gearbox and lifting tackle (crane).
pumps and secure to prevent short-circuiting.
6. Unscrew bolts between gearbox and super-
structure frame (see chapter 5.3 – Engine
mounting).
7. Remove gearbox with coupling from engine

and lift out.
Components for pump gearbox mounting (fig. 2)
Weight
[kg]
Tightening torque
1 16 Hex. bolt ½” 13 UNC 2B x 1½” - 8.8 – A3B
Md = 86 Nm
Table 1 Quantities are valid for 1 pump gearbox.
Page 7.4 - 2 3664245en - (02)

7.4 PUMP GEARBOX
Fig. 2 Pump gearbox – dismantling and assembly – 3843462a
3664245en - (02) Page 7.4 - 3

7.4 PUMP GEARBOX
Installation of the pump gearbox 7.4.3 Disassembly & Assembly in-

structions
1. Clean the contact surface of pump gearbox
and superstructure carefully. The surfaces Please refer to the attached manual:
must be metallically clean (no rust), dry and
grease-free. Part no. 2 707 787 – 4343.03
2. Check Megiflex-discs, replace if necessary Part no. 3 686 883 – 4343.04

(see chapter 5.3 – Engine installation).
Part no. 3 736 803 – 4343.07
3. Install coupling onto the input shaft of the
pump gearbox (see chapter 5.4 – Engine
coupling).
4. Position the pump gearbox on the superstruc-

ture. Fasten the slightly oiled bolts finger tight
(see chapter 5.3).
5. Tighten bolts between engine coupling and

flywheel (see chapter 5.4).
6. Connect engine and pump gearbox with

slightly oiled bolts (1, fig. 2) and tighten with
the required torque.
Tightening torque = 86 Nm
7. Tighten the pump gearbox on the superstruc-

ture with the required torque (see chapter
5.3).
6. Connect hydraulic lines and electric cables.

Remove support parts.
7. Check oil level in pump gearbox.
8. Bleed air from the hydraulic pumps (see

chapter 8.2).
On completion of assembly work,

all installation inspections pre-
scribed by the engine manufac-
turer (e.g. measurement of axial
play of crank shaft) must be car-
ried out.
Page 7.4 - 4 3664245en - (02)

SERVICE MANUAL
4343.03 – 4343.07 (RH 170)

Bucyrus SN: 2707787 / 3686883 / 3736801 /
3736802 / 3736803
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
Inhaltsverzeichnis – Table of contents
Sicherheit – Safety .........................................................................................................3

Einleitung – Introduction ................................................................................................5
Einführung – Introduction ...............................................................................................6
Anziehdrehmomente – Tightening torque ......................................................................7
Werkzeuge – Tools ........................................................................................................7
Montageanleitung allgemein – General assembly instructions .................................... 10
Montageanleitung – General Aassembly instructions Type 4343.03 – 4343.07 ......... 11
Demontageanleitung allgemein – General disassembly instructions ........................... 23
Demontageanleitung - Disassembly instructions Type 4343 ....................................... 24
Problemanalyse – Troubleshooting ............................................................................. 28
Anlagen – Enclosures .................................................................................................. 29
2
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
Sicherheit-safety
Bei der Montage bzw. Demontage des Pumpenverteilergetriebes Typ 4343 sind die folgenden
Sicherheitshinweise zur Vermeidung von Personen-, Sach- und Umweltschäden unbedingt zu
beachten:
During assembly and disassembly of pump drive type 4343 the following safety instructions to
prevent personal injury, damage to property and environmental damage or loss must be absolutely
observed:
Mögliche
Gefahr(en) / Maßnahmen
Beschreibung / Description
Potential / Measures
Danger(s)
Gefahr von Verbrennungen durch den Umgang mit erhitzten

Bauteilen. Tragen Sie beim Umgang mit heißen Teilen
immer geeignete Schutzhandschuhe.
Danger of burns due to the handling of heated components.
Warnung vor heißen
Oberflächen
Always wear suitable protective gloves when handling hot
parts.
Beware of hot surfaces
Gefahr von Handverletzungen z.B. durch scharfe Kanten,

herab- und/ oder herunterfallende Bauteile. Tragen Sie
geeignete Schutzhandschuhe zum Schutz vor
Handverletzungen.
Gefahr von Danger of hand injury e.g. due to sharp edges, falling down
Handverletzungen components. Wear suitable protective gloves as a protection
Beware of hand injury against hand injury.
Quetschgefahr durch umstürzendes Getriebes. Sichern Sie

das Getriebe gegen Umfallen. Tragen Sie Schutzschuhe.
Danger of being crushed due to upset of the gearbox.
Quetschgefahr Secure the gearbox aginst tipping over. Wear safety shoes.
Danger of being
crushed
Achten Sie beim Transport des Getriebes mittels Kran

darauf, dass der Kran und die verwendeten Anschlagmittel
über ausreichende Tragfähigkeit verfügen und in
einwandfreiem Zustand sind. Halten Sie sich nicht unter
schwebenden Lasten auf.
Gefahr durch Pay attention during transportation of the gearbox by means
schwebende Lasten of a crane that the crane and the used lifting accessories
Overhead load hazard hava a sufficient lifting capacity. Do not remain under
suspended loads.
3
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
Beim Umgang mit hydraulischen Vorrichtungen bestehen

Quetschgefahren und Gefahren durch platzende
Hydraulikschläuche. Verwenden Sie nur einwandfreie
hydraulische Vorrichtungen und beachten Sie die
Bedienungsanleitung des Herstellers.
Gefahrstelle When handling hydraulic devices there is danger due to
Hazard area hydraulic oil. Only use correct devices and observe the
manufacturer’s instructions.
Beachten Sie die beim Umgang mit Chemikalien (Fett,

Kleber, Öle, etc.) üblichen Sicherheitshinweise und tragen
Sie ggf. geforderte Persönliche Schutzausrüstung.
Gesundheitsschädliche When handling chemicals (fat, adhesive, oil, etc.) observe

Stoffe the usual safety instructions and wear the demanded
Materials harmful to personal protection equipment, if necessary.
health
Gefährdung der Umwelt durch auslaufendes Getriebeöl.

Verwenden Sie geeignete Auffangwannen. Nehmen Sie
verschüttetes oder ausgelaufenes Öl mit
flüssigkeitsbindendem Material auf und führen Sie es der
sachgerechten Entsorgung zu.
Endangerment of the environment by leaking gear oil. Use
suitable collecting trays. Take up burie or run out oil with
liquid-binding material and arrange for proper disposal.
Rutschgefahr durch ausgelaufenes Getriebeöl. Nehmen Sie

verschüttetes oder ausgelaufenes Öl mit
flüssigkeitsbindendem Material auf und führen Sie es der
sachgerechten Entsorgung zu.
Rutschgefahr Slip hazard by leaking gear oil. Take up buried or run-out oil
Slip hazard with liquid-binding material and arrange for proper disposal.
4
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
Einleitung – Introduction
Urheberrecht Copyright
Das Urheberrecht an Zeichnungen und Bildern The copyright at drawings and pictures remains
verbleibt bei uns. Eine Zeichnung (Bild) darf nur zu with us. A drawing (picture) may be used only for
den Zwecken benutzt werden, zu denen sie dem the purposes, for which it is entrusted to the
Empfänger anvertraut ist. Ohne unsere recipient. Without our written permission drawings
ausdrückliche schriftliche Genehmigung dürfen and pictures must not be made available to third
Zeichnungen und Bilder nicht an Dritte persons. Each duplication – also of details – is
weitergegeben oder diesen zugänglich gemacht forbidden.
werden. Jede Vervielfältigung – auch von
Contravention will be prosecuted. Spare parts must
Einzelheiten – ist untersagt.
meet the technical requirements committed by
Zuwiderhandlungen werden gerichtlich verfolgt. Stiebel. This is always secured with the
Ersatzteile müssen den von Stiebel festgelegten manufacturer original spare parts.
technischen Anforderungen genügen. Dies ist bei
Indicate the following data when placing an order:
Hersteller Originalersatzteilen immer gewährleistet.
Geben Sie bei einer Bestellung folgende Daten an:
 the article no. / drawing no. (DIN no.)
 the gearbox serial no.
 die Artikel-Nr. / Zeichnungs-DIN-Nr.
 You find these numbers on the nameplate
 die Getriebe-Nr. which is attached to each product.
 Sie finden diese Nummern auf dem  the drawing no.
Typenschild, das an jedem Produkt
 the item no.
angebracht ist.
 the exact description
 die Zeichnungsnummer
 the part no.
 die Positionsnummer
 You find these numbers in the parts list.
 die genaue Benennung
 the number of pieces of the requested
 die Teil-Nr.
spare parts
 Sie finden diese Nummern in der Teileliste.
 the requested way of dispatch (e.g.
 die Stückzahl der gewünschten Ersatzteile express shipment, freight, airfreight,
 die gewünschte Versandart (z.B. courier service, etc.)
Expressgut, Frachtgut, Luftfracht,
Kurierdienst, usw.)
5
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
Einführung / Introduction
Einführung Introduction
Die vorliegende Anleitung beschreibt die Montage The available instructions describe the assembly
bzw. Demontage des Pumpenverteilergetriebes and disassembly of pump drive type 4343.03-
Typ 4343.03- 4343.07. 4343.07.
Beachten Sie die Hinweise auf der Observe the references on the assembly drawing
Anbauzeichnung A4343. A4343.
Für die Durchführung der Demontage und Montage The manufacturer does not assume liability for
des Pumpenverteilergetriebes durch Dritte third party assembly or disassembly of the pump
übernimmt der Hersteller keine Gewährleistung. drive.
Alle Einzelpositionen und deren Lage sind auf der All items and their positions are shown on the
Ersatzteilzeichnung E4343 dargestellt. spare part drawing E4343.
Mit diesem Symbol sind Gefahren für With this symbol dangers for bodies and
Körper und Gesundheit gekennzeichnet. health are characterized.
Mit diesem Symbol sind Gefahren für das With this symobl dangers for the product
Produkt und die Gesamtanlage and the entire plant are characterized.
gekennzeichnet.
Absolutely consider the safety
Beachten Sie unbedingt die regulations and the relevant rules for the
Sicherheitsbestimmungen und die einschlägigen prevention of accidents! Consider for this the
Unfallverhütungsvorschriften! Beachten Sie hierzu operating instructions for pump drives.
die allgemeine Bedienungsanleitung für
Pumpenverteilergetriebe.
 Attach only original spare parts.
 Use suitable collection receptacles when
 Bauen Sie nur Originalersatzteile ein. draining oil.
 Verwenden Sie geeignete Auffanggefäße  Mark before the separation bolted and
beim Ölablassen. toothed parts on their positions.
 Markieren Sie vor dem Trennen  Make sure that no dirt or foreign
verschraubte und verzahnte Teile auf substance gets into the gearbox.
deren Lage und Position.
 Replace damaged parts, O-rings, seal
 Achten Sie darauf, dass kein Schmutz oder rings and end caps by new parts.
Fremdkörper in das Getriebe gelangt.
 Warm up bearings and gear wheels
 Ersetzen Sie beschädigte Teile, O-Ringe, before assembling only on hot plates or
Dichtringe und Verschlusskappen durch in the furnace. Never warm up with direct
neue Teile. flame. All fixing bolts must be secured
 Erwärmen Sie Lager und Zahnräder vor with Loctite 573.
der Montage nur auf Heizplatten bzw. im  Before the installation all movably parts
Wärmeofen. Niemals mit direkter Flamme and seal rings are to be oiled.
erwärmen. Alle Befestigungsschrauben
 Sometimes the coat of paint of the
müssen mit Loctite 573 gesichert sein. gearbox is damaged by dismantling and
 Vor dem Einbau sind alle beweglichen re-assembling. Renew therefore the coat
Teile sowie Dichtringe einzuölen. of paint in order to protect the gearbox
 Unter Umständen ist der Farbanstrich des from corrosion.
Getriebes durch das Zerlegen und  Carry out a test run of the gearbox.
Zusammenbauen beschädigt. Erneuern
Sie deshalb den Farbanstrich, um das
Getriebe gegen Korrosion zu schützen.
 Führen Sie einen Probelauf des Getriebes
durch.
6
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
Anziehdrehmomente / Tightening torque

Standard-Anziehdrehmomente M A in Nm für ungeschmierte Schaftschrauben ( = 0,14)
mit Regelgewinde ohne zusätzliche Einzelangaben (s. LSN 945 0201)
Standard-tightening torque MA in Nm for unlubricated shoulder stud ( = 0,14) with standard thread
without additional details (LSN 945 0201)
Schraube
M6 M8 M 10 M 12 M 14 M 16 M 20 M 24 M 27 M 30
Screw
8.8 Dr. 10 25 49 85 135 210 425 730 1100 1450
10.9 Dr. 15 36 72 125 200 310 610 1050 1550 2100
Werkzeuge – Tools
 Drehmomentschlüssel: SW17; SW19; SW22;  Torque wrench: SW17; SW19;
SW24; SW27; SW30 SW22; SW24; SW27; SW30
 Maulschlüssel: SW17; SW19; SW22; SW24;  Combination wrench: SW17; SW19;
SW27; SW30; SW41 SW22; SW24; SW27; SW30; SW41
 Imbus: SW 10; SW 12; SW14; SW17  Imbus: SW 10; SW 12; SW14;
 Hydraulische Abziehvorrichtung SW17
 Pumpe; Zylinder (250 + 400 KN)  Hydraulic extractor
 Schlagdorn für RWDR  Pump; cylinder (250 + 400 KN)
 Schlagdorne für Kugellager  breaker plate Ø 50; Ø 230
 Einpressplatten für RWDR + Lager  bolt spacer Ø 230
 Zweiarmabzieher 88010 Gr. 3; 4  Two-armed extractor 88010 Gr. 3; 4
 Zweiarmabzieher 88150 Gr. 2  Two-armed extractor 88150 Gr. 2
 Durchschlag: 6; 8; 10; 12  Punch: 6; 8; 10; 12
 Gasbrenner  Gas burner
 Loctite 0270  Loctite 0270
 Loctite 0573  Loctite 0573
 Reiniger (Noba)  Detergent (Noba)
 MET-L-Check / Rissprüfung  MET-L-Check / Check for cracks
zum Beispiel: e.g.:
 Spezialreiniger NPV  Special detergent NPV
 Eindringmittel DYE VP30  Penetration substance DYE VP30
 Entwickler  Developer
 Augenschraube M16 x 150 mm  Eye bolt M 16 x 150 mm
7
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
Nr. 1 Schlaghülse für Radialwellendichtringe No. 2 Montagehilfe für Kugellager und

No. 1 Sleeve for radial oil seals Radialwellen-dichtringe
No. 2 Fit-up aid for ball bearings and radial oil seals
Ø D2
Ø143m
m Ø D1
Ø136mm
10mm
60mm
30mm
100mm
D1 / mm D2 / mm Montagehilfe für Pos.

Montagehilfe für Radialwellendichtringe Pos. 330 Fit-up aid for item
Fit-up aid for radial oil seals item 330
95 100 290
No. 3 Montagehilfe für Kugellager Nr. 4 Demontagevorrichtung für Lagerträger

Nr. 3 Fit-up aid for ball bearings No. 4 Disassembly device for bearing carrier
Ø D4
E 460mm
360mm
D1 / mm D2 / mm E/mm Demontagehilfe
Montagehilfe für Pos.
für Pos.
Fit-up aid for item.
Fit-up aid for
280,260,300,270,390,
item
460 360 300 50
8
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
Nr.5 Zweiarmabzieher 88010 size 3;4 Nr. 6 Augenschraube M16 x 150 mm

No.5 Two-armed extractor 88010 Größe 3;4 No. 6 Eye bolt M 16 x 150 mm
220mm
13mm
340mm
Two-armed extractor for bearing item Augenschraube zum Anheben von Profilhohlwellen und
280,260,300,270,390,350, 340, 360 Baugruppen.
Eye bolt for lifting profile hollow shafts and assembly
Claw width 35 mm groups.
Claw height 13 mm
Width 340 mm
Depth 220 mm
Nr. 7 Hydraulischer-
DreiarmabzieherZweiarmabzieher
No. 7 Hydraulic-three-armed extractor
Hydraulischer Dreiarmabzieher, für die Demontage von

Stirnrädern und Kugellager.
Hydraulic three-armed extractor for disassembly of spur
gears and ball bearings.
9
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
Montageanleitung allgemein – General assembly instructions
ACHTUNG ! ATTENTION !
Unsachgemäße Handhabung beim Inappropriate handling when opening,
Öffnen, Zerlegen und Zusammenbauen dismantling and assembling can lead to
kann zur Gefährdung von Personen, der the endangerment of persons, the system
Anlage und des Produktes führen. and the product.
Derartige Arbeiten darf deshalb nur Therefore only technical personnel may
Fachpersonal durchführen, das von dem execute such work, who was authorized
Hersteller ermächtigt und besonders by manufacturer and particularly
ausgebildet wurde. trained.Of course, also the manufacturer
is at your disposal.
Selbstverständlich steht Ihnen auch der
Hersteller zur Verfügung. For damage, regardless of which type,
which results from neglect of this
Für Schäden, gleich welcher Art, die durch
regulation, the manufacturer does not take
Nichtbeachtung dieser Vorschrift
over liability.
entstehen, übernimmt der Hersteller keine
Haftung.
10
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
Montageanleitung – General Aassembly instructions Type 4343.03 – 4343.07
Montageanleitung – Assembly instructions Type 4343.03 Alte Version / Old Version

Die Positionen 5-9 dieser Anleitung beziehen sich auf die Zeichnung auf Seite 14.
Item 5-9 of this instruction refer to the drawing on page 14.
1. Lageraußenschale des unteren

Kegelrollenlagers (gepaart) Pos. 300 in
Lagerträger Pos. 030 treiben.
Drive the external leaf of the lower tapered roller
bearing (paired), item 300, in the bearing carrier,
item 030.
Distanzring des gepaarten
Kegelrollenlagers Pos. 300 auf die
Lageraußenschale legen.
Lay down the spacing ring of the paired tapered
roller bearing, item 300, on the external leaf of the
bearing.
2. Beide Kegelrollenlager (gepaart) Pos. 300

auf ca. 100 °C erwärmen und auf die
Antriebswelle Pos. 140 aufschrumpfen.
Heat both tapered roller bearings (paired), item 300,
to approx. 100°C and then shrink them on the drive
shaft, item 140.
Zweite Lageraußenschale auf das
Kegelrollenlager legen.
Lay down the second external leaf of the bearing on
the tapered roller bearing.
Distanzring Pos. 170 auf die
Lageraußenschale legen. Sicherungsblech
Pos. 530 aufziehen.
Lay down the spacing ring, item 170, on the
external leaf of the bearing. Shrink on the safety
plate.
Nutmutter Pos. 540 bis Anschlag anziehen.
+ ¼ Umdrehung.
Screw down the groove nut, item 540, as far as it
will go.
+ ¼ rotation
Laufring Pos. 185 auf ca. 85 °C erwärmen.
Heat the ball race, item 185, to approx. 85°C.
Laufringfläche mit Kleber Loctite 270
einstreichen.
Lubricate the ball race surface with adhesive Loctite
270.
Laufring auf Antriebswelle aufschrumpfen.
Shrink the ball race on the drive shaft.
Distanzring Pos. 230 aufziehen.
Shrink on the spacing ring, item 230.
11
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
3. Lagerträger Pos. 30 mit Kantholz

unterbauen, so dass Antriebswelle Pos.
140 eingesteckt werden kann.
Underpin the bearing carrier, item 030, with a
squared timber so that the drive shaft, item 140, can
be inserted.
Maßdifferenz zwischen Zentrierung-Deckel
Pos. 020 und Lagerschale-Lagerträger Pos.
30 ermitteln.
Differenz mit Passscheibe ausgleichen.
Determine the gauge difference between the
centring and the cap, item 020, as well as between
the bearing cup and the bearing carrier, item 030
and shim it.
Dichtringdeckel Pos. 020 mit
Befestigungsschrauben Pos. 510 am
Lagerträger Pos. 30 befestigen.
Auf Ölschmiernut achten!
Fix the sealing ring cap, item 020, with fixing bolts,
item 510, at the bearing carrier, item 030.
Pay attention to the oil groove!
4. Lagerträger Pos. 30 wenden.

Turn the bearing carrier, item 030.
Passfedern Pos. 470 in Antriebswelle Pos.
140 treiben.
Drive the keys, item 470, in the drive shaft, item
140.
Zahnrad Pos. 100 auf ca. 120 °C erwärmen
und auf die Antriebswelle aufschrumpfen.
Heat the spur gear, item 100, to approx. 120°C and
then shrink it on the drive shaft.
Zahnrad Pos. 100 mit Sicherungsring Pos.
430 sichern.
Secure the spur gear, item 100, with circlip, item
430.
Verlängerung Pos. 605 anbringen. Mit
Loctite 270 sichern.
Attach the lengthening piece, item 605. Secure it
with Loctite 270.
12
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
Montageanleitung – Assembly instructions Type 4343.04-07 Neue Version / New Versio n

Die Positionen 5-9 dieser Anleitung beziehen sich auf die Zeichnung auf Seite 15.
Item 5-9 of this instruction refer to the drawing on page 15.
1. Zahnwelle Pos. 140 einölen (z.B. SAE 90)

Lubricate the splined shaft, item 140, with oil. (e.g.
SAE 90).
Innenring des Pendelrollenlagers Pos. 300 mittels
Wärmeofen auf ca. 100°C erwärmen und auf die
Zahnwelle aufschrumpfen.
Heat the inner ring of the ball joint bearing, item
300, with the heating furnace to approx. 100°C.
Then shrink it on the splined shaft.
Scheibe Pos. 465 einlegen und das
Pendelrollenlager Pos. 300 mittels Sicherungsring
Pos. 435 sichern.
Insert disc, item 465. Then secure the ball joint
bearing, item 300 with the circlip, item 435.
Bohrung des Lagerträgers mit Öl einstreichen.
Lubricate the boring of the bearing carrier with oil.
Zahnwelle mittels Augenschraube und S-Haken in
den Lagerträger bis zum Anschlag eintreiben.
Drive the splined shaft with the help of the eye bolt
as well as of the s-hook in the bearing carrier as far
as it will go.
2. Laufring Pos. 185 mittels Wärmeofen auf ca. 60 °C

erwärmen.
Heat the ball race, item 185, with the heating
furnace to approx. 60°C.
Innenseite des Laufrings mit Kleber (z.B. Loctite
270) gleichmäßig bestreichen und auf die
Zahnwelle Pos. 140 aufschrumpfen.
Evenly lubricate the inner surface of the ball race
with adhesive (e.g. Loctite 270). Then shrink it on
the splined shaft, item 140.
Distanzring Pos. 230 mittels Wärmeofen auf ca. 60
°C erwärmen.
Heat the spacing ring, item 230, with the heating
furnace to approx. 60°C.
Innenseite des Laufrings mit Kleber (z.B. Loctite
270) gleichmäßig bestreichen und auf die
Zahnwelle Pos. 140 aufschrumpfen.
Evenly lubricate the inner surface of the ball race
with adhesive (e.g. Loctite 270). Then shrink it on
the splined shaft, item 140.
Kleberrückstände entfernen!
Remove adhesive residues!
13
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
3. Radialwellendichtring Pos. 425 in den

Dichtringdeckel Pos. 020 mittels Einpressplatte
eintreiben.
Drive the radial oil seal, item 425 in the sealing ring
cap, item 020, by using the press-in plate.
Dichtflächen des Dichtringdeckels sowie des
Lagerträgers mit Reiniger (Noba) entfetten und mit
anaerober Dichtmasse (Loctite 0573) eindichten.
Degrease the sealing surfaces of the sealing ring
cap as well as of the bearing carrier with detergent
(Noba). Afterwards, seal it with anaerobic sealant
(Loctite 0573).
Dichtringdeckel auf den Lagerträger aufsetzen und
mit Pos. 510 verschrauben (210 Nm).
Attach the sealing ring cap to the bearing carrier
and screw it together with item 510 (210 Nm).
Achtung! der Radialwellendichtring darf nicht
beschädigt werden!
Attention! The sealing ring cap must not be
damaged!
4. Baugruppe Lagerträger drehen.

Turn the bearing carrier assembly.
Passfeder Pos. 470 mittels Kupferhammer in die
Zahnwelle Pos. 140 eintreiben. Zahnwelle einölen
(z.B. SAE 90).
Drive the keys, item 470, with the copper hammer in
the splined shaft, item 140. Lubricate the splined
shaft (e.g. SAE 90).
Stirnrad Pos. 100 mit einem Heizofen oder
Induktionswärmer auf ca. 120°C erwärmen und auf
die Ritzelwelle eintreiben.
Heat the spur gear, item 100, with the heating
furnace or the induction heater to approx. 120°C.
Then drive it into the pinion shaft.
Stirnrad Pos. 100 mit Sicherungsring Pos. 430
sichern.
Secure the spur gear, item 100, with the circlip, item
430.
14
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
Alte Version / Old Version
Achtung! Attention!
Die Lagerinnenringe müssen immer stirnseitig an der Antriebswelle anliegen; ggf. mit Fühlerlehre prüfen!
Das Loslager hat ca. 2 mm Axialspiel im Gehäuse.
The bearing inner rings must always be frontal to the input shaft; if necessary, check by means
of a feeler gauge! The movable bearing has approx. 2 mm axial play within the housing.
Dieser Distanzring wird mit dem gepaarten Kegelrollenlager mitgeliefert.

This spacer is supplied with the paired taper roller bearing.
Pos. 230 ist ein Laufring, welcher mit Loctite 270 auf der Welle aufgeklebt werden muss.
Item 230 is a sleeve that is to be fixed on the shaft with Loctite 270.
Die Sechskantschrauben Pos. 490 müssen im Gehäuse eingeschraubt und mit Loctite 270 gesichert werden.
Item 490 fittings have to be screwed into the housing and secured with Loctite 270.
Das Axialspiel der Antriebswelle muss zwischen 0,05 und 0,08 mm in eingebautem Zustand liegen.
The axial play of the input shaft has to be between 0.05 and 0.08 mm in built-in condition.
Die Montage der Antriebswelleneinheit erfolgt gemäß Service Manual für Getriebe Typ 4343.
The assembly of the input shaft unit is to be made according to the service manual of gearbox type 4343.
15
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
Neue Version / New Version
Achtung! Attention!
Die Lagerinnenringe müssen immer stirnseitig an der Antriebswelle anliegen; ggf. mit Fühlerlehre prüfen!
Das Loslager hat ca. 2 mm Axialspiel im Gehäuse.
The bearing inner rings must always be frontal to the input shaft; if necessary, check by means of a feeler
gauge! The movable bearing has approx. 2 mm axial play within the housing.
16
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
5. Passfedern Pos. 470 in die Zahnwellen

Pos. 150/160 eintreiben.
Drive the keys, item 470, into the splined shaft, item
150/160.
Zahnräder Pos. 110, 120, 130 auf ca. 120
°C erwärmen und auf die entsprechende
Zahnwelle Pos. 150/160 aufschrumpfen.
Heat the spur gears, item 110, 120, 130 to approx.
120°C. Then shrink them on the corresponding
splined shaft, item 150/160.
Zahnräder mit Sicherungsringen Pos. 430
sichern.
Secure the spur gears with the circlips, item 430.
6. Rillenkugellager Pos. 260 auf ca. 100 °C

erwärmen und auf die Zahnwellen Pos.
150/160 aufschrumpfen (Profilseite).
Heat the grooved ball bearing, item 260, to approx.
100°C and shrink it on the splined shafts, item
150/160.
7. Gehäuse Pos. 10 pumpenseitig ablegen, so

dass es seine Lage nicht verändern kann.
Lay down the housing, item 10, on the pump side so
that it cannot be moved.
Trennfläche des Lagerträgers Pos. 30 oder
des Gehäuses Pos. 10 mit anaerober
Dichtmasse Loctite 573 einstreichen.
Lubricate the separation planes of the bearing
carrier, item 30, or of the housing, item 10 with
anaerobic sealant Loctite 573.
Vormontierten Lagerträger mittels Kran in
das Gehäuse Pos. 10 ablassen und
eintreiben.
Lower the pre-assembled bearing carrier with the
crane, insert it into the housing, item 10, and then
drive it in.
Achtung! Schmierölbohrung muss in
Richtung oben zeigen.
Attention! The lubricant boring has to face upwards.
17
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
8. Lagerträger Pos. 30 mit Schrauben Pos.

510 am Gehäuse Pos. 10 befestigen.
Fix the bearing carrier, item 30, with bolts, item 510,
at the housing, item 10.
Verschlussschraube Pos. 580 mit Cu-Ring
Pos. 630 am Gehäuse befestigen.
Fix the locking screw, item 580, with the Cu-ring,
item 630, at the housing.
Gehäuse wenden.
Turn the housing.
9. Hydraulikschlauch Pos. 648 am Lagerträger

befestigen.
Fix the hydraulic hose, item 648, at the housing.
Hydraulikschlauch Pos. 648 mit Schraube
Pos. 495 und Rohrschelle Pos. 608 sichern.
Secure the hydraulic hose, item 648, with screw,
item 495 and pipe clip, item 608.
10. Rillenkugellager Pos. 270 und

Pendelrollenlager Pos. 280 in das Gehäuse
treiben.
Drive the grooved ball bearing, item 270, and the
ball joint bearing, item 280, in the housing.
Die Innenringe der Lager auf ca. 100 °C
erwärmen und die vormontierten,
abgekühlten Profilhohlwelleneinheiten
einschrumpfen.
Heat the inner rings of the bearing to approx.
100°C. Then shrink them on the pre-assembled,
chilled profile hollow shaft unit.
Pendelrollenlager Pos. 290 auf ca. 100 °C
erwärmen und auf die Antriebswelleneinheit
aufschrumpfen.
Heat the ball joint bearing, item 290, to approx.
100°C and then shrink it on the drive shaft unit.
18
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
11. Deckel Pos. 90/93 mit anaerober

Dichtmasse Loctite 573 einstreichen und
am Gehäuse Pos. 10 mit Schrauben Pos.
500 befestigen.
Lubricate the cap, item90/93, with anaerobic sealant
Loctite 573 and fix it with screws, item 500, at the
housing, item 10.
Ölmessstäbe Pos. 25 einstecken.
Insert the oil dipsticks, item 25.
Verschlussschrauben Pos. 580/590 mit
Cu-Ring Pos. 630 anbringen.
Attach the locking screws, item 580/590 with the
Cu-ring, item 630.
12. Pumpenanbauflansche vormontieren:

Entlüftungsventile Pos. 595 mit Cu-Ring
Pos. 610 anbringen.
Pre-assemble the pump flange:
Attach the vent valve, item 595, with the Cu-ring,
item 610.
Verschlussschrauben Pos. 560 mit Cu-Ring
Pos. 610 anbringen.
Install the locking screws, item 560, with the Cu-
ring, item 610.
Abdeckbleche Pos. 245 mit Kerbnägeln
Pos. 545 an Anbauflanschen anbringen.
Attach the cover plates, item 245, with groove pins,
item 545, to the mounting flange.
O-Ringe Pos. 390/400/410 anbringen.
Attach the o-rings, item 390/400/410.
13. Trennflächen der Pumpenanbauflansche

oder des Gehäuses (zusätzlich) mit
anaerober Dichtmasse Loctite 573
einstreichen.
Lubricate the separation planes of the pump flanges
or (additionally) of the housing with anaerobic
sealant Loctite 573.
Pumpenanbauflansche Pos. 40/50/60/70 an
die entsprechende Anbaustelle des
Gehäuses Pos. 20 montieren.
Mount the pump flanges, item 40/50/60/70 on the
corresponding part of the housing, item 20.
Achtung! Schmieröltaschen müssen immer
nach oben zeigen!
Attention! The oil pockets have to face upwards.
19
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
14. Pumpenanbauflansche Pos. 40/50/60/70

mit Sechskantschrauben Pos. 520
befestigen.
Fix the pump flanges, item 40/50/60/70 with
hexagon bolts, item 520.
Durch leichte Schläge mit einem
Kunststoffhammer auf die Flansche und
mittels einer Hülse auf die Lagerinnenringe
werden Verspannungen gelöst.
Tensions can be loosened by slight beats with the
soft hammer onto the flanges or by slight beats onto
the inner rings of the bearings with a sleeve.
Radialwellendichtringe Pos. 330/340
einfetten und an den entsprechenden
Stellen montieren.
Degrease the radial oil seals,item 330/340 and
mount them on the corresponding part.
15. Zwischenplatte vormontieren.

Pre-assemble the intermediate plate.
Seckskantschrauben Pos. 180 mit Loctite
270 in Zwischenplatte Pos. 095 einsetzen.
Insert the hexagon bolts, item 180 with Loctite 270
in the intermediate plate, item 095.
Abdeckblech Pos. 187 mit
Sechskantschraube Pos. 495 (gesichert mit
Loctite 270) befestigen.
Fix the cover plate, item 187, with hexagon bolts,
item 495 (secure it with Loctite 270).
Schneidringverschraubung des
Hydraulikschlauchs Pos. 648 an
Zwischenplatte Pos. 095 befestigen
(gesichert mit Loctite 270).
Fix the mechanical joint of the hydraulic hose, item
648 at the intermediate plate, item 095 (secure it
with Loctite 270).
16. Getriebe senkrecht stellen und sichern, so

dass es seine Lage nicht verändern kann.
Place the gearbox vertically and secure it so that it
cannot be moved.
Dichtfläche (Trennfläche) stirnseitig am
Gehäuse Pos. 10 mit anaerober
Dichtmasse Loctite 573 eindichten.
Seal the sealing surface (separation plane) on the
face side of the housing, item 10, with anaerobic
sealant Loctite 573.
Vormontierte Zwischenplatte mittels Kran
knapp über das Gehäuse Pos. 10 hängen.
Position the pre-assembled intermediate plate
closely above the housing, item 10, with the help of
a crane.
20
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
17. Hydraulikschlauch Pos. 648 über die

Schneidringverschraubung an der
Zwischenplatte Pos. 095 befestigen.
Fix the hydraulic hose, item 648, at the itnermediate
plate, item 095, above the mechanical joint.
18. Deckel Pos. 80 mit anaerober Dichtmasse

eindichten und zusammen mit der
Zwischenplatte Pos. 095 und
Sechskantschrauben Pos. 520 am
Gehäuse Pos. 10 befestigen.
Seal the cover, item 80, with anaerobic sealant
Entlüftungsfilter anbringen.
Lochscheibe Pos. 220 mit
Sechskantschraube Pos. 490 an der
Abtriebswelle befestigen.
Fix the breaker plate, item 220, with the hexagon
bolt, item 40 at the drive shaft.
Überschüssige Dichtmasse entfernen.
Remove excessive sealant
Getriebe anhand der Anbauzeichnung
überprüfen.
Check the gearbox as per the mounting drawing.
Freigabe.
Release.
19. Getriebe pumpenseitig ablegen.

Lay the gearbox down on the pump side.
Antriebswelle Pos. 140 mit einem
rückschlagfreien Hammer
(Kunststoffhammer) nachschlagen.
Restrike the drive shaft, item 140, with a blow-back
proofed hammer (soft hammer).
Augenschraube in die Antriebswelle
einschrauben.
Screw the eye bolt in the drive shaft.
Messuhr stirnseitig auf die Antriebswelle
ausrichten.
Adjust the test gauge so that it is on the face side
towards the drive shaft.
Getriebe mittels Kran anheben.
Lift the gearbox with a crane.
Das Axialspiel ablesen (Axialspiel: 0,05 mm
-0,08 mm).
Read the axial play (axial play: 0,05 mm – 0,08 mm)
Differenz mit Passscheiben ausgleichen.
Shim the difference.
21
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
20. Dichtringdeckel Pos. 20 abschrauben.

Unscrew the sealing ring cap, item 20.
Radialwellendichtring Pos. 425 in
Dichtringdeckel einpressen.
Press the radial oil seal, item 425, in the sealing ring
cap.
Dichtlippe mit Fett einstreichen.
Lubricate the sealing lip with grease.
O-Ring Pos. 370 anbringen.
Attach o-ring, item 370.
Dichtringdeckel Pos. 20 mit anaerober
Dichtmasse Loctite 573 eindichten und mit
Befestigungsschrauben Pos. 510 am
Lagerträger Pos. 30 befestigen.
Seal the sealing ring cap, item 20, with anaerobic
sealant Loctite 573. Then fix it at the bearing carrier,
item 30, with fixing screws, item 510.
Auf Ölschmiernutstellung achten!
Pay attention to the position of the oil groove!
22
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
Demontageanleitung allgemein – General disassembly instructions
Für die Demontage des Getriebes sind For the disassembly of the gearbox the
folgende Vorarbeiten erforderlich: following preliminary work is necessary:
 Getriebe nur in ausgebautem Zustand  Dismantle gearbox only in removed
demontieren. condition.
 Alle nicht zum Getriebe gehörenden Teile  All parts not belonging to the gearbox must
müssen abgebaut werden. be removed.
 Getriebeöl ablassen. Lösen Sie dafür  Drain gear oil. For that purpose loosen plug
Verschlussschraube Pos. 580/630. item 580/630
Verwenden Sie dabei geeignete Use suitable collection receptacles oil
Auffanggefäße Ölinhalt ca. 60l. content approx. 60 l.
 Pumpenleitungen abbauen.  Remove pump pipes.
 Öl aus den Pumpenanschlusskammern  Drain oil out of the pump connection
ablassen. chambers.
 Pumpen vom Getriebe abbauen.  Remove pumps from the gearbox.
 Achten Sie beim Transport auf eine  Pay attention in the case of transport to a
ausreichende Tragkraft des Kranes. sufficient carrying capacity of the crane.
Getriebegewicht ohne Pumpen ca. 1300 Gearbox weight without pumps approx.
kg. 1300 kg.
 Zur Demontage/Montage legen Sie das  For disassembly/re-assembly place the
Getriebe auf den SAE-Flansch bzw. auf der gearbox onto the SAE flange or onto the
Pumpenseite ab. pump side.
 Stellen Sie sicher, dass das abgesetzte  Guarantee that the put down gearbox
Getriebe seine Lage nicht ändern kann. cannot change its position.
 Beachten Sie die Hinweise auf der  Observe the information on the spare part
Ersatzteilzeichnung E4343 und auf der drawing E4343 and on the assembly
Anbauzeichnung A4343. drawing A4343.
23
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
Demontageanleitung - Disassembly instructions Type 4343

21. Getriebe antriebsseitig ablegen, so dass es
seine Lage nicht ändern kann.
Lay down the gearbox on the drive side so that it
cannot be moved.
Alle Sechskantschrauben Pos. 520 lösen.
Loosen all hexagon head screws, item 520.
22. Alle Pumpenflansche mittels

Abdruckschrauben und Kran vom Getriebe
abdrücken.
Remove all pump flanges with the ejector screws
and the crane from the gearbox.
23. Sollte sich die Profilhohlwelleneinheit beim

Abdrücken der Flansche nicht lösen, so
sollte der Spezialabzieher zum Einsatz
kommen.
Shouldn’t the profile hollow shaft unit become
unscrewed on removing the flanges make use of
the special extractor.
24
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
24. Profilhohlwelleneinheiten mittels Abzieher

herausziehen.
Remove the profile hollow shaft unit with the
extractor.
Support the extraction with hammer strokes (soft

hammer) onto the housing.
Loosen ball bearings that remained in the housing
with the mounting lever.
25. Befestigungsschrauben Pos. 520 des

Deckels Pos. 80 und der Zwischenplatte
Pos. 095 lösen und Deckel und
Zwischenplatte mittels Abdrückschrauben
abdrücken, so dass auch der
Hydraulikschlauch Pos. 648 gelöst werden
kann.
Loosen the fixing screws, item 520, of the cap, item
80, as well as of the intermediate plate, item 095.
Lift off the cap as well as the intermediate plate with
the help of the ejector screws so that you are able
to loosen the hydraulic hose, item 648.
Demontierten Deckel und Zwischenplatte
reinigen und überprüfen.
Clean and check the disassembled cover and the
intermediate plate.
26. Gehäuse wenden (pumpenseitig ablegen).

Turn the housing (lay it down on the pump side).
Befestigungsschrauben Pos. 520 des
Lagerträgers Pos. 030 lösen.
Loosen the fixing screws, item 520, of the bearing
carrier, item 030.
Lagerträger komplett mittels
Abdrückschrauben und Kran aus dem
Gehäuse Pos. 10 herausziehen.
Completely extract the bearing carrier from the
housing, item 10. Use the ejector screws as well a
crane.
25
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
27. Kleinmaterial wie z. B. Abdeckblech,

Verschlussschrauben,
Radialwellendichtringe und
Entlüftungsventile von den
Pumpenflanschen lösen.
Loosen the incidentals, such as cover plate, locking
screws, radial oil seals and vent valves from the
pump flanges.
Pumpenanbauflansche reinigen und prüfen.
Clean and check the pump mounting flanges.
Demontiertes Gehäuse reinigen und prüfen.
Clean and check the disassembled housing.
28. Die ausgebauten Profilhohlwelleneinheiten

demontieren:
Disassemble the dismantled profile hollow shaft
units.
Rillenkugellager / Pendelrollenlager mittels
Zweiarmabzieher (Werkzeug Nr. 5) abziehen.
Take off the grooved ball bearings / ball joint
bearings with the two-armed extractor.
Sicherungsringe Pos. 430 lösen.
Loosen the circlips, item 430.
Zahnräder auf / mit einer hydraulischen
Presse abpressen.
Press out the spur gears with the help of a hydraulic
press.
Passfedern Pos. 470 entfernen.
Remove the keys, item 470.
Alle Einzelteile reinigen und überprüfen.
Clean and check all component parts.
26
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
29. Hydraulikschlauch Pos. 648 demontieren.

Disassemble the hydraulic hose, item 648.
Pendelrollenlager Pos. 290 mittels
Lucas (Werkzeug Nr.7) abziehen.
Take off the ball joint bearing, item 290, with the
two-armed extractor.
Sicherungsring Pos. 430 lösen.
Loosen circlip, item 430.
Zahnrad Pos. 100 mittels Lucas (Werkzeug Nr.7)
abziehen.
Take off the spur gear, item 100, with the two-
armed extractor.
Passfedern Pos. 470 entfernen.
Remove the keys, item 470.
Befestigungsschrauben Pos. 520 des
Deckels Pos. 20 lösen und Deckel
entfernen.
Loosen the locking screws, item 520, at the cap,
item 20. Then remove the cap.
Lagerträger Pos. 030 Mittels Vorrichtung (Werkzeug
Nr. 4) unterlegen und die
Antriebswelle auf einer hydraulischen
Presse auspressen.
Shim the bearing carrier, item 030. Then press out
the drive shaft with the help of a hydraulic press.
Das im Lagerträger verbliebene, gepaarte
Kegelrollenlager aus dem Lagerträger
drücken.
Press the remaining paired tapered roller bearing
out of the bearing carrier.
Alle demontierten Einzelteile reinigen und
überprüfen.
Clean and check all remaining component partsl
27
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
Problemanalyse – Troubleshooting
Ölstandskontrolle – Ölwechsel Oil level control – Oil change

Ölstandskontrollen und Ölwechsel sind der Oil level checks and oil changes are to be learnt from
Betriebsanleitung zu entnehmen. the operating instructions.
Undichtigkeit Leakage
Undichtigkeiten lokalisieren. Locate leakage.
Falls die Radialwellendichtringe Pos. 425 undicht If the radial seals item 425 are leaky the complete
sind, muss die komplette Baugruppe assembly unit "drive shaft" must be exchanged. The
"Antriebswelle" ausgetauscht werden. Baugruppe assembly unit "drive shaft" can only be dismantled
"Antriebswelle" kann nur bei ausgebautem with dismounted gearbox, as described in the
Getriebe, wie in der Demontageanleitung disassembly instructions.
beschrieben, ausgebaut werden.
With damaged radial seals item 330 this must be
Bei beschädigten Radialwellendichtringen Pos. exchanged. When changing the radial seals it is to be
330, muss dieser getauscht werden. Beim made certain that the seal seats at the profile hollow
Wechseln der Radialwellendichtringe ist darauf shafts and the ball races are not damaged. When
zu achten, dass die Dichtringsitze an den damaged also these have to be exchanged.
Profilhohlwellen und an den Laufringen nicht
With leakage between pump flange and housing it is
beschädigt sind. Bei Beschädigungen sind auch
to be examined whether the O-ring is still alright.
diese zu wechseln.
Exchange of the O-ring is described in the
Bei Undichtigkeiten zwischen disassembly instructions.
Pumpenanbauflansch und Gehäuse ist zu prüfen,
Operational noise
ob der O-Ring noch i. O. ist. Austausch des O-
Rings in der Demontageanleitung beschrieben. The operational noise should be smooth and regular.
If indefinable strong (high) operational noise comes
Laufgeräusche
up you have to try to locate it. With damage at the
Das Laufgeräusch soll weich und gleichmäßig gear wheels or ball bearings the gearbox must be
sein. Falls undefinierbare starke (hohe) dismantled and the defective unit must be exchanged
Laufgeräusche auftreten, muß versucht werden, in accordance with the disassembly insructions.
diese zu lokalisieren. Bei Beschädigungen an
Wear determination
Zahnrädern oder Kugellagern muß das Getriebe
demontiert und die defekte Einheit nach der After having removed the shaft sets all components
Demontageanleitung ausgetauscht werden. have to be cleaned carefully. Check the oil deposits
for impurities and solid particles. Control all
Verschleißermittlung
components regarding cracks by means of a suitable
Nach Ausbau der Wellensätze alle Bauteile procedure. Control all components regarding wear.
sorgfältig reinigen. Ölablagerungen auf
Verunreinigungen und Feststoffpartikel prüfen.
Alle Bauteile mit geeigneten Verfahren auf Risse
kontrollieren. Alle Bauteile auf Verschleiß
kontrollieren.
28
4343.03-4343.07 (RH 170)
Bucyrus SN: 2707787 / 3686883 / 3736801 / 3736802 / 3736803
Anlagen – Enclosures
 Zeichnungen – Drawings
 Ersatzteillisten – Parts lists
29
08.2018
8. Hydraulic system
6040

CONTENTS
8. HYDRAULIC SYSTEM
8.1 Introduction ...................................................................................... 8.1 - 1
8.1.1 Foreword ................................................................................ 8.1 - 1
8.1.2 Safety..................................................................................... 8.1 - 1
8.1.3 General .................................................................................. 8.1 - 5
8.2 Depressurizing, bleeding, flushing ................................................. 8.2 - 1
8.2.1 Depressurizing of the hydraulic system ................................. 8.2 - 1
8.2.2 Bleeding of the hydraulic system ........................................... 8.2 - 3
8.2.3 Flushing of the hydraulic system ............................................ 8.2 - 5
8.3 Hydraulic circuit diagram ................................................................ 8.3 - 1
8.3.1 Technical data ....................................................................... 8.3 - 1
8.3.2 Components of the hydraulic schematic ................................ 8.3 - 1
8.3.3 Components of the hydraulic system .................................... 8.3 – 5
8.3.4 Hydraulic circuit diagram...................................................... 8.3 - 13
8.4 Main hydraulic components ............................................................ 8.4 - 1
8.4.1 Main pumps ........................................................................... 8.4 - 1
8.4.2 Swing pump ........................................................................... 8.4 - 2
8.4.3 Rotor ...................................................................................... 8.4 - 3
8.4.4 Valve blocks ........................................................................... 8.4 - 8
8.5 Description of hydraulic circuits ..................................................... 8.5 - 1
8.5.1 Load limiting system ........................................................... 8.5.1 - 1
8.5.2 Pressure cut off system ...................................................... 8.5.2 - 1
8.5.3 Servo system ...................................................................... 8.5.3 - 1
3720208en – (00) Page 8 - 1

CONTENTS
8.5.4 Working functions ............................................................... 8.5.4 - 1
8.5.5 Travel system ..................................................................... 8.5.5 - 1
8.5.6 Swing system ...................................................................... 8.5.6 - 1
8.5.7 Track tensioning system ..................................................... 8.5.7 - 1
8.5.8 Cooling system for hydraulic oil .......................................... 8.5.8 - 1
8.5.9 Cooling system for engines ................................................. 8.5.9 - 1
8.5.10 Cooling system for pump gearbox .................................... 8.5.10 - 1
8.6 Pressure checking and setting........................................................ 8.6 - 1
8.6.1 Introduction ............................................................................ 8.6 - 1
8.6.2 Pressure settings ................................................................... 8.6 - 4
8.6.3 Tools ...................................................................................... 8.6 - 5
8.6.4 Hydraulic systems .................................................................. 8.6 - 6
8.7 Installation of hydraulic pumps....................................................... 8.7 - 1
8.8 Hydraulic cylinders (Faceshovel)..................................................... 8.8 -1
8.8.1 Boom cylinder ..................................................................... 8.8.1 - 1
8.8.1.1 Introduction ......................................................... 8.8.1 -1
8.8.1.2 Safety ................................................................. 8.8.1 - 2
8.8.1.3 Design configuration ......................................... 8.8.1 - 3
8.8.1.4 Assembly ........................................................... 8.8.1 - 5
8.8.1.5 Tightening torques ........................................... 8.8.1 - 12
8.8.2 Arm cylinder ....................................................................... 8.8.1 - 1
8.8.2.1 Introduction ......................................................... 8.8.2 -1
8.8.2.2 Safety ................................................................. 8.8.2 - 2
8.8.2.3 Design configuration .......................................... 8.8.2 - 3
Page 8 - 2 3720208en – (00)

CONTENTS
8.8.2.4 Assembly ........................................................... 8.8.2 - 5
8.8.3 Bucket crowd cylinder ......................................................... 8.8.3 - 1
8.8.3.1 Introduction ......................................................... 8.8.3 -1
8.8.3.2 Safety ................................................................. 8.8.3 - 2
8.8.3.4 Assembly ........................................................... 8.8.3 - 5
8.8.4 Clam cylinder ...................................................................... 8.8.4 - 1
8.8.4.1 Introduction ......................................................... 8.8.4 -1
8.8.4.2 Safety ................................................................. 8.8.4 - 2
8.8.4.4 Assembly ........................................................... 8.8.4 - 5
3720208en – (00) Page 8 - 3

CONTENTS
Page 8 - 4 3720208en – (00)

8.1 HYDRAULIC SYSTEM
8.1 Introduction
8.1.1 Foreword 8.1.2 Safety Instructions
The Service Manual contains important infor- Danger in case of non-observance of safety
mation for personnel servicing the machine. Ma- instructions
chine technical data listed in other machine docu-
ments are not always repeated in this book.
This CAT hydraulic excavator has
The documentation of a CAT mining machine in- been built in accordance with
cludes: state-of-the-art standards and the
recognized safety rules.
 Operation and Maintenance Manual However, operating the machine if
 Spare Parts Catalog curred, or carrying out repair work
 inexpertly
 Service Manual
 endangers the lives of people in
contact with it
The service manual does not contain technical
data on auxiliary units for the operation of specific  damages the machine and other
or optional equipment or data of individual devices. property.
The refilling quantities specified for consumables Stop the hydraulic excavator im-
are approximate quantities which are intended as a mediately if you suspect or notice
help for planning consumable requirements. any damage to ensure the safety of
the operator, other people or mate-
Each component is equipped with suitable check- rial property at the application area
ing devices, e.g. a dipstick or checking plugs, per- of the excavator.
mitting the operator to check exactly the filling of All components of CAT machines
the components. are perfectly tuned to each other.
Trouble-free operation and a long
service life can only be achieved
with original CAT spare parts.
2440575en – (03) Page 8.1 - 1

Personnel Personnel
Therefore secure and lock it. Wear a safety helmet, safety foot-
wear and safety gloves.
Follow the accident prevention
Only specially trained and qualified
Loose, wide garments can catch
personnel with the appropriate
on machine parts and result in
injury.
If you lack such knowledge, expe-
rienced personnel, e.g. from Cater-
harness which is equipped with fall
pillar Global Mining HMS, are to
arrestors and safety lines.
give you detailed instructions.
The personnel must have read and
understood the Operation and
define the responsibilities of each
Maintenance Manual and in partic-
assistant beforehand. The individ-
ular the chapter
ual responsibilities are to be care-
Page 8.1 - 2 2440575en – (03)


safe state.
forms and handrails provided for Before carrying out assembly
this purpose. work, the machine and the equip-
ment must be secured against in-
Always keep ladders, steps and advertent movement, e.g. by plac-
platforms in a non-slip state. Re- ing the working equipment on the
move any oil, grease, earth, clay, ground.
immediately.
Hydraulic and lubricating sys-
tem:
Securing the working equip-
ment Always observe the safety regula-
tions applicable to the product
Secure the machine and the work- when handling oils, greases and
ing equipment against inadvertent other chemical substances.
and unauthorized start. Position
working equipment on the ground Close open unused bores, pipe
in such a way that it cannot move and hose connections so that they
when mechanical or hydraulic are impermeable to pressure.
connections become detached. Refill the hydraulic system with
Use hoists or other appropriate collected drain hydraulic oil only
support devices when you install, through the return flow filters. Dis-
remove or displace any equipment pose of waste oil without polluting
or component. Thus you prevent the environment.
them from inadvertent movements, Observe the correct working se-
slip or fall. quence when fitting or replacing
2440575en – (03) Page 8.1 - 3


erpillar Global Mining HMS. Do not
remove the lead seals from pres-
Always replace defective, mechan- sure relief valves and hydraulic
ically prestressed components. accumulators.
Never open them! The Service
Manual contains no information on
such work.
Re-commissioning
machine is high and the consuma-
bles have at least the same tem-
perature. Therefore take care to Before re-commissioning:
Be careful when handling acids,
e.g. battery acid. Acid splashes  Check all oil levels and correct
may injure the eyes and the skin. them if necessary.
If the acid is splashed onto your
repaired components.
care immediately.  Check all functions of the exca-
If the acid is splashed in your eyes, vator including brakes during a
rinse thoroughly with running wa- test run. Release the hydraulic
ter and seek medical care immedi- excavator for re-commissioning
ately. only if all its functions operate
properly.
mable liquids.
easily.
Page 8.1 - 4 2440575en – (03)

8.1.3 General
This Service Manual contains information in addi- The Service Manual covers the information you
tion to the Operation and Maintenance Manual need when handling your excavator. However,
and the Spare Parts Catalog, to familiarize the Caterpillar Global Mining HMS will be pleased to
personnel with the designated use, maintenance answer any questions you have on its products.
and repair of the CAT excavator. Please contact your local CAT dealer or your Cat-
erpillar subsidiary.
The information in the Service Manual corre-


2440575en – (03) Page 8.1 - 5

Page 8.1 - 6 2440575en – (03)

Dieses Kapitel ist in Bearbeitung.
This chapter is in work.
Se está trabajando en el grupo constructivo.
Ce sous-ensemble est en cours.
Данный раздел в процессе подготовки.
Este capítulo está em elaboração
Энэ дэд бүлэг боловсруулалтын шатанд байгаа.
Tato část se připravuje.
本部分正在准备中。
Gruppo in phase de realizzazione.
Ovaj odeljak je u pripremi.
Tätä osaa valmistellaan.
Αυτό το τμήμα είναι υπό προετοιμασία.
Dette kapittelet er under utarbeiding
Detta avsnitt förbereds.




8.5 DESCRIPTION OF HYDRAULIC CIRCUITS
8.5.2 Pressure cut-off

On each main pump a pressure cut-off valve is
installed. The pressure cut-off is activated as soon
as the system pressure reaches its max. level of
300 bar for the cylinder functions and 350 bar for
the travel function.
The pressure cut-off valve is mounted on the regu-
lator of the main pump. It is opened under system
pressure and the pump then de-strokes to such a
reduced flow that only the pressure in the system
is maintained.
3746439en - (00) Page 8.5.2 - 1

8.5 DESCRIPTION OF HYDRAULIC CIRCUITS
Page 8.5.2 - 2 3746439en - (00)



8.5 HYDRAULIC CIRCUITS – TRAVEL SYSTEM
8.5.5 Travel system 2-speed function
Remark: When the solenoid valve (-2Y22) on the solenoid

valve bank (26) is not activated the control lines for
The position numbers in the pictures of this
the 2-speed function are connected to the hydrau-
section refer to the hydraulic circuit diagram
lic tank. The travel motors stay in “low speed
and the components listed in chapter 8.3 - ‘De-
mode” - maximum displacement.
scription of the hydraulic system’.
When the solenoid valve (-2Y22) on the solenoid
valve bank (26) is activated, a pressure of 50 bar is
If the electric system receives the information that
applied to the travel motors and they change to
both engines are running, the solenoid valve (46,
“high speed mode” - minimum displacement (fig.
fig. 4) is inactive and the ports C and D of the logic
14 - 17).
valves (47, fig. 5) are supplied with high pressure.
The connection between the logic valves (47) and
Leakage oil from the control blocks flows back to
travel valve blocks (92 & 93) are blocked. The
the tank.
main pumps P2 & P3 are used for travel (fig. 2 to
6).
Anti-cavitation valves flanged onto the travel con-
trol blocks prevent cavitation in the travel motors.
When the function ‘Travel’ is not activated the oil
flows via the travel valve blocks (92 & 93) to the 4-
spool control valves of attachment.
Travel boost
As long as the function ‘Travel’ is activated with the
The solenoid valve (-2Y24) on the solenoid valve
foot pedals, servo oil flows to the travel valve
bank (26) operates the pressure cut-off valves of
blocks (92 & 93, fig. 1).
the main pumps so that the travel pressure is in-
creased to 350 bar (fig. 18 - 21).
The travel valve blocks (92 & 93) shift so that the
ports to the 4-spool control valves are blocked. Oil
flows to the travel motors either through (B) - „for-
Travel retarder valves
ward“, or (A) - „backwards“.
Travel motors (121) and travel valve blocks are
The travel retarder valves are in the travel motors.
connected via the rotor (91, fig. 11 - 13).
They prevent the excavator from „running away“
when travelling downhill, and ensure positive travel
The secondary relief valves for each direction of
drive down the slope.
travel are in the travel motors. The valves are set
to 400 bar. When this pressure is reached relief oil
The travel retarder valves are in the circuits in such
is fed via the relief valve to the low-pressure side of
a way that oil flowing from the travel motors must
the motors.
flow through them in order to get to the tank.
Oil returning from the travel motors flows through
The control piston determines the amount of oil
the rotor (91) and the return lines to the tank (fig.
which can flow through the valve. When system
11 to 13).
pressure drops (e.g. excavator travelling downhill),
pressure spring pushes the control piston back.
Leakage oil from the travel motors is returned to
the tank (fig. 11 - 13).
When the excavator is travelling, the control piston
of the retarder valve adopts a so-called „float posi-
Travel parking brake
tion“ which is determined by the resistance to ex-
cavator travel and the pump oil pressure resulting
Onto each travel motor a travel parking brake is
from it.
installed. When a travel function is activated the
travel brake is released by the working pressure of
the travel motor. When the machine is stopped the
Service lift and access ladder
travel brakes are automatically applied by spring
force.
If the service lift or the access ladder are lowered
the functions for swing and travel are disabled.
3746442en - (00) Page 8.5.5 - 1

Remark:
The following colour code refers only to hydraulic
lines and not to components!
Colour Code Designation

P2 Main pump P2
P3 Main pump P3
P High pressure circuit
R Return oil circuit
L Leak oil circuit
S Servo circuit
(35 bar)
H Auxiliary circuit
(50 bar)

3 4 Main pump
25 1 Proportional valve block
26 1 Solenoid valve bank
32 1 Block with relief valves and high Primary relief valve for P3 and P4
pressure filters
pressure filters
39 4 Check valves
43 4 Check valves
46 1 Solenoid valve Operation of logic valves -2Y21
47 2 Logic valve
60 1 Hydraulic tank
64 4 Tank line pressurizing valve
90 1 Travel block Assembly consisting of item 91, 92 & 93
91 1 Rotor
92 1 Travel valve block RH
93 1 Travel valve block LH
121 4 Travel motor
-#B## Pressure sensors Main pump pressure
TP Test point
Table 1
Page 8.5.5 - 2 3746442en - (00)

Fig. 1 Servo lines for travel– 3843654b-03
Fig. 2 Pressure supply for Solenoid valve – 3843688a-01
3746442en - (00) Page 8.5.5 - 3

Fig. 3 Pressure supply for Solenoid valve – 3843659e-01
Fig. 4 Control lines for logic valves – 3843659d-01
Page 8.5.5 - 4 3746442en - (00)

Fig. 5 Control lines for logic valves – 3843654c-04
Fig. 6 Main pump lines for travel – 3843689a-01
3746442en - (00) Page 8.5.5 - 5

Fig. 7 Main pump lines for travel – 3843689b-02
Fig. 8 Main pump lines for travel – 3843653c-02
Page 8.5.5 - 6 3746442en - (00)

Fig. 10 Return lines to tank – 3843653a-02
3746442en - (00) Page 8.5.5 - 7

Fig. 11 Travel system in undercarriage – 3726818a-04
Fig. 12 Travel system in undercarriage (LH) – 3726818b-04
Page 8.5.5 - 8 3746442en - (00)

Fig. 13 Travel system in undercarriage (RH) – 3726818c-05
Fig. 14 2-speed function for travel – 3843654b-02
3746442en - (00) Page 8.5.5 - 9

Fig. 15 2-speed function for travel – 3726818a-03
Fig. 16 2-speed function for travel – 3726818b-03
Page 8.5.5 - 10 3746442en - (00)

Fig. 17 2-speed function for travel – 3726818c-06
Fig. 18 Travel boost for main pumps – 3843654c-03
3746442en - (00) Page 8.5.5 - 11

Fig. 19 Travel boost for main pumps – 3843688b-02
Fig. 20 Travel boost for main pumps 3843659_001b-03
Page 8.5.5 - 12 3746442en - (00)

Fig. 21 Travel boost for main pumps 3843688c-02
3746442en - (00) Page 8.5.5 - 13

Operation with the LH engine only to 400 bar. When this pressure is reached relief oil
is fed via the relief valve to the low-pressure side of
When only the LH engine is running the oil of the the motors.
main pump P1 (3/1) flows through the LH high
pressure filter (37) and via the RH logic valve Oil returning from the travel motors flows through
(47/2) to the RH travel control valve (92) (fig. 27 to the rotor (91) and the return lines to the tank (fig.
30). 32 to 34).
The oil of the main pump P2 (3/2) flows through
the LH high pressure filter (37) to the LH travel Leakage oil from the travel motors is returned to
control valve (93) (fig. 27 to 30). the tank (fig. 32 to 34).

only the LH engine is running, the solenoid valve Remark:
(46) is operated and the ports A and B of the logic
The connection between the RH logic valve (47/2)
and the RH travel valve block (92) is opened and
the main pumps P1 & P2 are used for travelling Colour Code Designation
(fig. 23 to 30).
P1 Main pump P1
flows via the travel valve blocks (92 & 93) to the 4- P2 Main pump P2
As long as the function ‘Travel’ is activated with the P High pressure circuit
blocks (92 & 93, fig. 22). R Return oil circuit
L Leak oil circuit
ward“, or (A) - „backwards“. S Servo circuit
(35 bar)
connected via the rotor (91) (fig. 32 to 34).


3 4 Main pump
pressure filters
pressure filters
39 4 Check valves
43 4 Check valves
47 2 Logic valve
60 1 Hydraulic tank
Page 8.5.5 - 14 3746442en - (00)


91 1 Rotor
121 4 Travel motor
TP Test point
Table 2
Fig. 22 Servo lines for travel– 3843654b-03
3746442en - (00) Page 8.5.5 - 15

Page 8.5.5 - 16 3746442en - (00)

3746442en - (00) Page 8.5.5 - 17

Page 8.5.5 - 18 3746442en - (00)

3746442en - (00) Page 8.5.5 - 19

Page 8.5.5 - 20 3746442en - (00)

3746442en - (00) Page 8.5.5 - 21

Operation with the RH engine only is fed via the relief valve to the low-pressure side of
the motors.
When only the RH engine is running the oil of the
main pump P4 (3/4) flows through the RH high Oil returning from the travel motors flows through
pressure filter (32) to the LH logic valve (47/1) (fig. the rotor (91) and the return lines to the tank (fig.
40 to 43). 45 to 47).
The oil of the main pump P3 (3/3) flows through
the RH high pressure filter (32) to the RH travel Leakage oil from the travel motors is returned to
control valve (92) (fig. 40 to 43). the tank (fig. 45 to 47).

only the RH engine is running, the solenoid valve Remark:
(46) is operated and the ports A and B of the logic
The connection between the RH logic valve (47/2)
and the RH travel valve block (93) is opened and
the main pumps P3 & P4 are used for travelling Colour Code Designation
(fig. 36 to 43).
P3 Main pump P3
flows via the travel valve blocks (92 & 93) to the 4- P4 Main pump P4
As long as the function ‘Travel’ is activated with the P High pressure circuit
blocks (92 & 93, fig. 35). R Return oil circuit
L Leak oil circuit
ward“, or (A) - „backwards“. S Servo circuit
(35 bar)
connected via the rotor (91) (fig. 45 to 47).

to 400 bar. When this pressure is reached relief oil

3 4 Main pump
pressure filters
pressure filters
39 4 Check valves
43 4 Check valves
47 2 Logic valve
60 1 Hydraulic tank
Page 8.5.5 - 22 3746442en - (00)


91 1 Rotor
121 4 Travel motor
TP Test point
Table 3
Fig. 35 Servo lines for travel – 3843654b-03
3746442en - (00) Page 8.5.5 - 23

Page 8.5.5 - 24 3746442en - (00)

3746442en - (00) Page 8.5.5 - 25

Page 8.5.5 - 26 3746442en - (00)

3746442en - (00) Page 8.5.5 - 27

Page 8.5.5 - 28 3746442en - (00)

3746442en - (00) Page 8.5.5 - 29

Page 8.5.5 - 30 3746442en - (00)


8.5 HYDRAULIC CIRCUITS - TRACK TENSIONING SYSTEM
8.5.7 Track tensioning system

Depending on the operating status of the ma-
Remark: chine there are 3 working conditions of the
track tensioning system:
section refer to the hydraulic circuit diagram
and the components listed in chapter 8.3 - ‘De-
1. The excavator was travelling for more than 15
scription of the hydraulic system’.
seconds with one or both tracks:
Details of the components are described in
chapter 8.4.
5 seconds after completion of the travel op-
eration the solenoid valve (-2Y20, fig. 8) is ac-
tivated for 5 seconds. This is controlled by the
Tensioning the tracks
Servo Control System (SCS).
See directions in Operating Instructions.
When the solenoid valve (-2Y20) is energised
the pressure relief valve (1.11, fig. 8) is by-
Each crawler track is kept tensioned automatically
passed and the auxiliary pressure is in-
and constantly by a hydraulic track tensioning sys-
creased to 80 bar by the pressure relief valve
tem.
(1.10, fig. 8). This pressure is directly charged
into the track tensioning system.
This pressure of 80 bar is operating the
Prior to start of operation and after change-over valve (133b, fig. 6). The pilot
repair work on the track tensioning controlled check valves (133a, fig. 6) are
system make sure that the stop opened and a higher pressure which might
cocks (132, fig. 6) are opened to have built up during travelling is reduced to 70
make the system functional. bar.
When the operating pressure for the change-

After starting one or both engines the track ten- over valve (133b) has reached 70 bar the pilot
sioning system is pressurised via the rotor (91, fig. controlled check valves (133a) are closed and
5) by the auxiliary pressure of 60 bar. This pres- the track tensioning pressure stays at 70 bar.
sure is limited by the pressure relief valve in the
valve block (25, fig. 4). When the track tensioning After 5 sec. (set energising time for the sole-
cylinders (130, fig. 6) and the accumulators (131, noid valve -2Y20) the pressure relief valve
fig. 6) are filled the tracks are tensioned. (1.11) is again in function and the auxiliary
pressure is reduced to 60 bar.
Function
2. The excavator was travelling for less than 15
The pumps (6, fig. 1 & 2) draw the oil from the seconds with one or both tracks:
suction manifolds at the hydraulic tank via check
valves (44, fig. 3) and filter (36, fig. 3). The pumps The solenoid valve (-2Y20) is not activated
are protected by a pressure relief valve in valve and the pressure in the track tensioning sys-
block (25, fig. 4) which is set at 60 bar. tem remains unchanged.
The oil flows via the rotor (91, fig. 5 & 6) and the
track tensioning block (133, fig. 6) in the undercar- 3. The excavator is digging and the travel func-
riage to the tensioning cylinders (130, fig. 6) and tion is not operated:
diaphragm accumulators (131, fig. 6).
A track tensioning pressure of 70 bar is via pi-
The diaphragm accumulators (131) are shock ab- lot controlled check valves (133a, fig. 6) avail-
sorbers that dampen the horizontal movement of able at the diaphragm accumulators (131, fig.
the idlers in case of external forces. If the shock 6) and the track tensioning cylinders (130, fig.
forces are excessive, oil is cracked off to the tank 6). The pilot controlled check valves (133a)
through safety valves (134, fig. 6) in the distributor are in closed position.
assembly (fig. 7). These safety valves are set at The change-over valve (133b, fig. 6) is not ac-
330 bar. Such oil losses are automatically replen- tive.
ished from the system when the required track
tensioning pressure is going below 60 bar.
3746444en - (00) Page 8.5.7 - 1

Remark: Remark:
When the track tensioning pressure has been re-
leased (e.g. for repair reasons) the tensioning is
done again with a pressure of 60 bar, which is
controlled by the pressure relief valve (1.11, fig. 8). Colour Code Designation
After the first operation of the travel system for Auxiliary circuit
more than 15 seconds the tracks are tensioned P (60 / 80 bar)
with 70 bar as described above.
P Track tensioning circuit
Ref.-no. Quantity Designation further remarks

-2Y20 1 Solenoid valve
-5B5 1 Contamination Filter Servo
1.10 1 Pressure relief valve pressure setting 80 bar
1.11 1 Pressure relief valve pressure setting 60 bar
6 2 Double gear pump
25 1 Servo control block
36 1 Filter
44 2 Check valve
91 1 Rotor
130 2 Track tensioning cylinder
131 2 Diaphragm accumulator
132 2 Lever operated ball valve
133 1 Track tensioning block contains 133A & 133B
133A 2 Pilot controlled check valve
133B 1 Change over valve operating pressure: 70 bar
134 2 Pressure relief valve secondary relief valve (330 bar)
TP n/a Test point
Table 1
Page 8.5.7 - 2 3746444en - (00)

Fig. 1 Track tensioning system in superstructure – 3843657_001c-02
Fig. 2 Track tensioning system in superstructure – 3843657_001d-02
3746444en - (00) Page 8.5.7 - 3

Fig. 3 Track tensioning system in superstructure – 3843659-001c-01
Fig. 4 Track tensioning system in superstructure – 3843654c-01
Page 8.5.7 - 4 3746444en - (00)

Fig. 5 Track tensioning system in superstructure – 3726938b-01
Fig. 6 Track tensioning system in undercarriage – 38433382-01
3746444en - (00) Page 8.5.7 - 5

Fig. 7 Track tensioning system in undercarriage – 3843382-02
Fig. 8 Solenoid valve and pressure relief valves within servo control block – 3843673c-03
Page 8.5.7 - 6 3746444en - (00)

8.5 HYDRAULIC SYSTEMS – COOLING SYSTEM FOR HYDR. OIL
8.5.8 Cooling system for hydraulic oil This fail-save system ensures that in case of an
electric problem (e.g. a broken cable to the propor-
Remark: tional valve) the fan pump stays at maximum flow
so that maximum cooling for the hydraulic oil is
The position numbers in the pictures of this achieved.
section are referring to the hydraulic circuit
diagram and the components listed in chapter The return oil of the fan motors (81, fig. 4) is direct-
8.3 - ‘Description of the hydraulic system’. ly flowing to the separate filter compartment at the
oil cooler module.
The 2 fan pumps (8/1 & 8/2, fig. 1 & 2) are axial The 2 cooling charge pumps with pressure relief
piston swash plate pumps with variable displace- valves (12/1 & 12/2, fig. 1 & 2) are charging the
ment. hydraulic oil coolers (80, fig. 6). The pressure relief
valves are set to 16 bar.
The flow of the axial piston fan pumps are elec-
tronically controlled and regulated with proportional
valves mounted onto the fan pumps. Remark:
The electric system regulate the pump flow and
thus the fan speed to minimum at an oil tempera-
ture below + 40° C and to maximum at an oil tem-
perature above + 52° C.
With low oil temperature the electric system is
supplying maximum current (580 mA) to the pro- P Fan oil circuit
portional valves of the cooling pumps and the
pumps are at minimum flow. C Cooling oil circuit
With increasing oil temperature the electric system
is reducing the current for the proportional valves R Return oil circuit
to 150 mA and the cooling pumps are increasing
the flow to the fan motors.

2 2 Pump gearbox
8 2 Fan pump Axial piston pump
12 2 Cooling charge pump Gear pump
80 2 Hydraulic oil cooler
81 2 Fan motor Gear motor
Table 1
3746445en - (00) Page 8.5.8 - 1

Fig. 1 Pumps for hydraulic oil cooling (RH) – 3843751-01
Fig. 2 Pumps for hydraulic oil cooling (LH) – 3843752-01
Page 8.5.8 - 2 3746445en - (00)

Fig. 3 Fan pumps – 3843639b-01
Fig. 4 Fan motors – 3726792-01
3746445en - (00) Page 8.5.8 - 3

Fig. 5 Cooling oil pumps – 3843639a-01
Fig. 6 Hydraulic oil coolers – 3726793a-01
Page 8.5.8 - 4 3746445en - (00)

8.5 HYDRAULIC CIRCUITS – COOLING SYSTEM FOR ENGINES
8.5.9 Cooling system for engines With rising temperature in the cooling system the
flow of the radiator fan pump and consequently the
Remark: speed of the fan is increasing.
At temperatures above + 99° C the maximum flow
section are referring to the hydraulic circuit
is passing through the fan motor and it is turning
diagram and the components listed in chapter
with maximum speed.
8.3 - ‘Description of the hydraulic system’.
With low engine temperature the electronic system
is supplying maximum current (650 mA) to the
The 2 double pumps for cooling (8/1 & 8/2, fig. 1 &
proportional valve of the radiator fan pump and the
2) are axial piston pumps with variable displace-
pump is at minimum flow.
ment.
On each drive unit one double pump is flanged
With increasing engine temperature the electronic
directly onto the pump gearbox (2/1 & 2/2, fig. 1).
system is reducing the current for the proportional
One pump is driving the fan motor (140, fig. 4) for
valve to 50 mA and the radiator fan pump is in-
the engine radiator. The second pump is driving
creasing the flow to the fan motor.
the fan motor for the hydraulic oil cooling system
(see chapter 8.5.8).
This fail-save system ensures that in case of an
electric problem (e.g. a broken cable to the propor-
Each radiator fan pump is driving a gear motor
tional valve) the fan pump stays at maximum flow
(140). The motors are driving the fans for the radia-
so that maximum cooling for the engine is
tors of the engines.
achieved.
The flow of the radiator fan pump is regulated with
Remark:
help of a proportional valve which is directly
flanged onto the pump regulator (fig. 5). The following colour code refers only to hydraulic
Depending on the actual temperature in the engine lines and not to components!
cooling system the electronic system of the ma-
chine is regulating the volume flow of the radiator
fan pump and thus the speed of the fan. The tem- Colour Code Designation
perature range for the regulation is + 89° C to + C Fan pump circuit
99° C.
At coolant temperatures below + 89° C in the en-
gine cooling system the fan pump is regulated to
minimum flow so that the fan is turning very slowly
and the warm-up period of the engine is shortened.

2 2 Pump gearbox
8 2 Radiator fan pump Axial piston pump
140 2 Fan motor Gear motor
Table 1
3746446en – (00) Page 8.5.9 - 1

Fig. 1 Fan pumps – 2441395c-09
Fig. 2 Fan pumps – 3843684a-01
Page 8.5.9 - 2 3746446en – (00)

Fig. 3 Feed and return lines cooling system engines - 3843684b-01
Fig. 4 Fan motors - 3843674_002-01
3746446en – (00) Page 8.5.9 - 3

Fig. 5 Fan pump with electronic regulator - 630920
Page 8.5.9 - 4 3746446en – (00)

8.5 HYDRAULIC CIRCUITS - COOLING FOR PUMP GEARBOX
8.5.10 Cooling system for gear oil temperature. The data is displayed on the
pump gearbox BCS. Depending on the gearbox version the com-
ponents are either installed in a block at the gear
Remark: pump or in the gearbox housing.
To avoid, that the gear oil is pumped out of the
The position numbers in the pictures of this system (e.g. because of leaks) the system is pre-
section refer to the hydraulic circuit diagram loaded to 1,0 bar by a throttle check valve (194)
and the components are listed in chapter 8.3 - and a pressure switch (D) is indicating loss of
‘Description of the hydraulic system’. pressure in the whole system.
Remark:
The pump gearbox (2) is equipped with a cooling
system for the gear oil. A gear pump (6) is pump- The following colour code refers only to hydraulic
ing the gear oil through a filter (191) to the gear oil lines and not to components!
cooler (193) and back into the pump gearbox (2)
(fig. 1 to 3).
For each gearbox an oil cooler is installed in the P Pressure oil circuit
hydraulic oil cooler module. The hydraulic oil cool-
ing fan is also sucking air through the gear oil
cooler. A check valve (192) with an opening pres- R Return oil circuit
sure of 6,0 bar protects the oil cooler against pres-
sure peaks especially when the engine is started
under cold weather conditions.
A chip indicator is monitoring the condition of the
gear box. A temperature sensor is monitoring the
The quantities in table 1 refer to 1 drive unit

2 1 Pump gear box
6B 1 Gear pump
191 1 Filter for gear oil
192 1 Check valve Opening pressure: 6,0 bar
193 1 Gear oil cooler section
194 1 Throttle check valve Opening pressure: 1,0 bar
D 1 Pressure switch -3B16 (LH) & -4B16 (RH) Setting: 0,5 bar
Table 1
3746447en - (00) Page 8.5.10 - 1

Fig. 1 System for gear oil cooling of pump gearbox (LH) – 3843687a-01
Fig. 2 System for gear oil cooling of pump gearbox (RH) – 3843687b-01
Page 8.5.10 - 2 3746447en - (00)

Fig. 3 Gear oil coolers in hydraulic oil cooler module – 3843859-01
Fig. 4 Check valve (194) – 3688099-01
3746447en - (00) Page 8.5.10 - 3

Fig. 5 Pressure switch (D) and check valves – 643375
Page 8.5.10 - 4 3746447en - (00)


8.7 INSTALLATION OF HYDRAULIC PUMPS
8.7 Installation of hydraulic

pumps
8.7.1 General
When removing or installing hydraulic pumps all Always observe the safety regulations applicable to
relevant safety regulations have to be observed. the product when handling oils, greases and other
chemical substances.
8.7.2 Components
Table for Fig. 1

[kg]
1 4 Main pump 353
2 2 Swing pump (double pump) 180
3 2 Fan pump (double pump) 76
4 2 Charge pump for hydr. oil cooler 62
5 2 Charge pump for swing system 24,5
6 2 Pump for servo system
33
7 2 Lubrication pump for pump gearbox
Table 1
3746449en - (00) Page 8.7 - 1

12, 14, 15
17, 19, 20
Fig. 1 Installation of hydraulic pumps - 643372
8.7.3 Removal and installation of the Installation of a pump

hydraulic pumps
1. Apply lubricating paste (Part-no. 244 905) to
splines of pump shaft, adapter and gearbox
Removal of a pump shaft.
1. Disconnect electric cables. 2. Install new O-ring with grease.
2. Close gate valves between hydraulic tank and 3. Attach lifting device to the pump and lower into
suction line of the pump. place. Insert and tighten mounting bolts with
required torque (see table).
3. Open hydraulic lines of the pump cautiously.
Collect hydraulic oil in suitable container. 4. Connect all hydraulic lines as market.
4. Remove hydraulic lines and mark them to avoid Open gate valves of the hydraulic tank!
mix up. Close all open hoses, lines, bores and
housings carefully to prevent dirt from penetrat-
ing. All axial piston pumps have to be
filled with hydraulic oil before start
5. Attach lifting device to the pump; disassemble up to avoid damage of the pump
mounting bolts and remove the pump. when running dry.
Page 8.7 - 2 3746449en - (00)

Bleed pumps! 6. Connect electric cables again.
5. Filling and bleeding the pumps has to be done

through the ports for the leak oil lines (Fig. 2).
Fig. 2 Filling and bleeding of the pumps - 643373
3746449en - (00) Page 8.7 - 3

Page 8.7 - 4 3746449en - (00)

Technical Handbook
Hydraulic Cylinder
Part Number: 3695766
eng
8. Hydraulic Cylinders
Contents
8 Hydraulic Cylinders ...........................................................................................................2

8.1 Preface ................................................................................................................................ 2
8.2 Product Description...........................................................................................................3
8.2.1 Cylinder ................................................................................................................................ 3
8.2.2 Technical Data ..................................................................................................................... 3
8.2.3 Cylinder Design.................................................................................................................... 3
8.3 Safety Instructions............................................................................................................. 4
8.4 Description of Cylinder Type and Components ............................................................. 5
8.4.1 Cylinder Type ....................................................................................................................... 5
8.4.2 Cylinder Components ..........................................................................................................6
8.4.3 Piston Rod Components ...................................................................................................... 7
8.4.4 Rod-end Eye Components .................................................................................................. 7
8.4.5 Cylinder Head Components ................................................................................................. 8
8.5 Storage, Start-up and Maintenance ................................................................................. 9
8.6 Hydraulic Cylinder Spare Parts ...................................................................................... 11
8.6.1 Cylinder D320/210; Ref. No.: 3695766 .............................................................................. 11
8.6.2 Spare Parts Drawing of Rod-end Eye................................................................................ 12
8.6.3 Cylinder Components ........................................................................................................ 13
8.6.4 Piston Rod Components .................................................................................................... 14
8.6.5 Rod-end Eye Components ................................................................................................ 14
8.6.6 Cylinder Head Components ............................................................................................... 15
8.7 List of Required Tools ..................................................................................................... 15
8.8 Dismantling Instructions ................................................................................................. 16
8.8.1 Removing the Piston Rod from the Cylinder Tube ............................................................ 16
8.8.2 Dismantling the Components on the Piston End ............................................................... 17
8.9 Assembly Instructions .................................................................................................... 18
8.9.1 Installation of Seals and Guide Strips on Cylinder Head ................................................... 18
8.9.2 Attach the Cylinder Head to the Piston Rod ...................................................................... 20
8.9.3 Mounting of Components, External Seals and Guide Strips on the Piston Rod ............... 21
8.9.4 Mounting the Bearing Bushes on the Cylinder Bottom and Rod-end Eye......................... 24
8.9.5 Mounting of the Rod-end Eye ............................................................................................ 25
8.9.6 Mounting the Piston into the Cylinder Tube ....................................................................... 28
8.9.7 Attaching the SAE Closure Flange to the Cylinder ............................................................ 30
8.9.8 Miscellaneous .................................................................................................................... 31
Ref. No.: 3695766 Page 1

Issued on 26.01.2010
8 Hydraulic Cylinders
8.1 Preface
This chapter describes the work necessary to maintain and service hydraulic cylinders.
The figures, descriptions and illustrations included reflect the current design status. There may be
some representations that differ from the equipment operated by your company. However, this has
no effect on the overall equipment function.
In case of doubt, get in touch with Bucyrus Service Division.
Forthcoming technical innovations or modifications applied on a series production basis will be in-
cluded in later issues of the Technical Manual.
Special tools recommended for the respective assembly work are shown in Chapter 8.7 'List of Re-
quired Tools’.
All components of a hydraulic cylinder have been appropriately matched to each other. Only if origi-
nal Bucyrus spare parts are used may a troublefree operation and long service life be achieved.
The wear parts and spares needed for hydraulic cylinder maintenance can be seen from the spare
parts list pertaining to the respective equipment.
This chapter is not intended to provide information on how to refurbish damaged components of a
hydraulic cylinder. Only specialized workshops are in a position to say whether a damaged compo-
nent can be refurbished and what work is involved to do so. Work carried out inhouse should be li-
mited to the installation of new Bucyrus wear parts and spares. All the work required in this con-
nection must be performed with great care and in a clean environment. Carelessness in this respect
may result in serious consequential damage affecting the entire hydraulic system.
After completion of repair/maintenance work the hydraulic cylinder must be vented before it is taken
into service. Entrapped air may combust under certain operating conditions due to auto-ignition (di-
esel effect) and cause damage to the cylinders after short operating periods.
Flushing out the entire hydraulic system is a must if contamination or even metal chips are found in a
defective cylinder, on the bar magnet or in the filters.
Page 2 Ref. No.: 3695766

8.2 Product Description
8.2.1 Cylinder
This section is applicable to cylinders of ref. No. 3695766.
8.2.2 Technical Data

• Piston dia. = 320 mm
• Rod dia. = 210 mm
• Stroke = 2450 mm
• Operating pressure = 320 bar
• Test pressure = 420 bar
• Hydraulic fluid = Mineral oil
• Working temperature = -20°C to + 80°C
• Piston rod coating = chrome-plated
• Cylinder function = Push and pull action
8.2.3 Cylinder Design

• Single-stage cylinder with rod cushioning and head-end cushioning
• Retraction and extension connections as per SAE 2", 6000 PSI
• Venting at cap and rod end via G¼ connection
• Eye on rod end and clevis on cap end with bronze bushings
• Cylinder head of flanged and cylinder bottom of welded construction
• Seal arrangement on rod end: 1 wipers and 2 U-cups
• Seal arrangement on cap end: 1 mechanical seal set
• Guiding system of the rod end by means of 4 guide rings made of fabric-reinforced laminate
• Guiding system of the cap end by 2 guide rings of fabric-reinforced laminate and 2 guide ring of
RG7
Ref. No.: 3695766 Page 3

8.3 Safety Instructions
Make sure to observe accident prevention rules.
Before work commences every person entrusted with commissioning, opera-

tion, inspection and maintenance as well as repair of the hydraulic excavator
must have read and understood the operating manual and in particular this
chapter on SAFETY issues.
The operating staff must have the experience and technical knowledge neces-
sary. Tools, lifting equipment, attachment means, jack stands, working plat-
forms and other auxiliary devices must be in good and operationally safe work-
ing condition.
Make sure to first depressurize in a suitable manner all line systems on which
work is to be carried out.
Park the excavator on horizontal ground and safeguard it to prevent inadvertent

rolling. Carefully set down the working attachment on the ground, switch off the
motors and secure them to prevent inadvertent starting.
Do not disconnect pipe couplings and hydraulic hoses before the hydraulic sys-
tem has been carefully checked if in pressureless state. Beware of hot hydraulic
fluid.
Fully retract the piston rods of hydraulic cylinders intended to be removed. Se-
cure the piston rod in that position on the cylinder to make sure it cannot be
extended inadvertently; now proceed by disconnecting the hydraulic lines or
tubing.
Collect hydraulic fluid spillage in suitable containers.
Remove and mount the piston rod and rod bush by means of hoisting equip-
ment.
Carefully close off any hose and tube connections, open boreholes and casings
exposed during removal of a component to prevent the ingress of dirt.
If feasible, carry out assembly work on hydraulic cylinders, especially the re-
moval and mounting of piston rods, with the cylinder being in vertical position.
Lower cylinders of great length into assembly pits.
Cleanliness at the workplace has utmost priority. Do not use cotton waste but
instead use lint-free cleaning rags.
Use the cylinder tools recommended.
For the removal of sealing and wear parts use suitable auxiliary tools, e.g.
rounded-off screwdrivers. Sealing faces must never be damaged.
Page 4 Ref. No.: 3695766

8.4 Description of Cylinder Type and Components
8.4.1 Cylinder Type
Ref. No.: 3695766 Page 5

8.4.2 Cylinder Components
Item Quantity Unit Order No. Designation Weight
1 1 Cylinder tube, compl. 1485
2 1 Piston rod, compl. 923
3 1 Rod-end eye, compl. 416
4 1 Cylinder head, compl. 203
5 2 Bush 9,4
6 1 Nameplate 0,003
7 2 Grooved pin, round head 0,001
8 15 Hexagon-head bolt 1,981
9 15 Supporting washer 0,07
10 2 SAE closure flange 2
20 3 Protective element 0,002
36 1 Blanking end 0,186
37 2 Plug cover 0,01
38 1 Sealing compound
Inspection/mounting instruc-
39 0
tions
40 0 Painting directives
Page 6 Ref. No.: 3695766

8.4.3 Piston Rod Components
2.1 1 Piston rod 918
2.2 1 Bolt 3,5
2.3 1 Cushioning bush 1,7
2.4 2 Plug 0,056
2.5 18 Ball 0,004
2.6 2 Set screw 0,032
2.7 2 Guide ring 0,073
2.9 1 Mechanical seal set 0,2
8.4.4 Rod-end Eye Components
3.1 1 Rod-end eye 340
3.2 1 Flange 76
3.3 10 Hexagon-head bolt 1,1
3.4 2 Bush 15,7
3.5 1 Cylindrical dowel pin 0,185
3.7 2 Seal cap 0,01
Ref. No.: 3695766 Page 7

8.4.5 Cylinder Head Components
4.1 1 Cylinder head 202
4.2 1 Wiper 0,18
4.3 1 U-ring 0,39
4.4 1 U-ring 0,32
4.6 1 Back ring 0,029
4.7 1 O-Ring 0,054
4.8 1 Blanking end 0,186
Page 8 Ref. No.: 3695766

8.5 Storage, Start-up and Maintenance

Corrosion Protection
Factory-applied Preservation
Hydraulic cylinders are preserved through the test fluid on which they operated and are therefore ca-
pable of being stored for up to half a year. If longer storage periods are desired this must be stated in
the purchase order. For storage periods of up to one year the cylinders will be tested with anti-
corrosion oil of brand ARAL Konit W10 (alternatively Resilan M 46) or ESSO Rustban 335 and sub-
sequently emptied. In case storage periods of more than one year are required the tests will be per-
formed with the above mentioned anti-corrosion oil and the unit delivered with oil filled in. The sto-
rage instructions described under Pt. 3 must be carefully followed if this storage period is used. In
the event of storage periods exceeding two years the manufacturer must be consulted. If hydraulic
cylinders with uncoated piston rods are concerned, the manufacturer must in any case be contacted
to discuss preservation requirements.
Sealing
The corrosion protection can only be effective if all connections are closed off so as to be air-tight:
Flanges are blanked off with plugs of soft plastic material backed-up by a metal plate. Tube and
threaded connections will be closed off with threaded plastic covers or plugs of plastic material. Cy-
linders which cannot be emptied completely and cylinders filled with oil will be closed off so as to be
tight to oil. For this purpose plug screws with seal ring and in the case of tube connections plug fit-
tings with cap nuts will be used.
Surface Protection
External surfaces such as flange faces, bearings, spot facings, centerings, supporting surfaces, non-
primed cylinder tubes and, in the case of non-corrosion-protected piston rods, the portion projecting
out of the cylinder will be treated with ARAL Resilan WA or ESSO Rustban 397. In case of plunger
cylinders a film of anti-corrosion oil will be applied to plunger, guide and the inner surface of the cy-
linder tube. Unless there is a customer-issued painting specification the hydraulic cylinders are nor-
mally delivered with a proven universal priming coat applied.
Transportation
For transportation and handling purposes hydraulic cylinders must be prepared and treated with
care, i.e. suitable packing procedures and auxiliary packing material must be employed to prevent
damage that may be caused by drops, impacts or striking against each other.
The piston rods must be safeguarded to prevent them from being extended inadvertently. All connec-
tions must be closed off.
In case of piston rods projecting from cylinders, the free piston rod end must be protected against
damage by means of suitable packing material. Handling of or contact with substances that may
have a corrosive impact on the chrome plating of the piston rod must by all means be avoided.
Ref. No.: 3695766 Page 9

Storage
Upon receipt of the goods the customer shall convince itself that the hydraulic cylinders have not suf-
fered damage in transit and that all plug screws are in good condition. Any damaged items used to
close off the goods must be renewed immediately. Damage to the external paint coat must be
touched up. The hydraulic cylinders must exclusively be stored in dry rooms, free from dust and
fumes, with temperatures kept constant in a range between 10°C and 20°C. When the first year of
storage has elapsed the cylinders shall be turned over at least once a year to displace entrapped air
bubbles that may have developed and in this manner also provide the respective surfaces with oil
again.
Mounting
As regards hydraulic cylinders stored for more than two years the manufacturer should first be con-
sulted because prior to installation a replacement of seals and gaskets may be necessary depending
on the relevant type and design of the cylinder. Usually, the mounting position of the hydraulic cy-
linder is optional. Care must be exercised to ensure the hydraulic cylinders are mounted without
stresses and transverse forces acting on them since, otherwise, premature wear or malfunctions
may occur. Before the cylinder is hooked up to the hydraulic system pipes and tubing must be
flushed clean with a suitable oil to be on the safe side and eliminate any residual contamination from
the tubing system. External preservation agents must be removed using cleaner’s solvent or petro-
leum.
Startup
Minor amounts of the corrosion protection oil remaining inside the cylinder need not be removed
from the cylinder since this oil is compatible with most of the customary hydraulic fluids on mineral oil
basis. Cylinders filled with corrosion protection oil must be emptied and filled with the working fluid
prior to startup. To enable proper functioning and in the interest of maximum operational safety and
service life of the hydraulic cylinders the hydraulic fluid must be filtered (recommendable is 10 µm
nominal). Only proven proprietary brands on mineral oil basis acc. to DIN 51524 and DIN 51525
should be used as working fluid. If other hydraulic fluid brands are to be used the manufacturer must
be consulted. The piston rod should be free from paint remnants and other traces of external dirt or
contamination. If this is not the case, the rod must be cleaned thoroughly. Some cylinder types re-
quire the rod-end eye mounts to be secured on site. Prior to startup the hydraulic cylinder must be
repeatedly vented in both end positions until the working fluid exits without air bubbles having
formed. Normally, the cylinders are suited for an operating temperature between -20°C and +80°C. It
is mandatory that the manufacturer be consulted if this temperature range is either exceeded or fal-
len below.
Maintenance
The standard chrome-plating of the piston rod has not been designed to withstand aggressive envi-
ronmental influences on a permanent basis so that particularly effective maintenance steps must be
taken in this case, especially if the piston rod remains in extended position. Repeatedly checking the
oil filters during the run-in period of the equipment is recommended. On account of their design and
material selection the hydraulic cylinders as a rule do not require maintenance during the operating
period. However, prerequisite in this context is that the above instructions regarding transportation,
storage, installation and startup are carefully followed and observed.
Page 10 Ref. No.: 3695766

8.6 Hydraulic Cylinder Spare Parts

8.6.1 Cylinder D320/210; Ref. No.: 3695766
Ref. No.: 3695766 Page 11

8.6.2 Spare Parts Drawing of Rod-end Eye
Page 12 Ref. No.: 3695766

3 1 Rod-end eye, compl. 416
5 2 Bush 9,4
6 1 Nameplate 0,003
7 2 Grooved pin, round head 0,001
9 15 Supporting washer 0,07
10 2 SAE closure flange 2
20 3 Protective element 0,002
37 2 Plug cover 0,01
38 1 Sealing compound
Inspection/mounting instruc-
39 0
tions
40 0 Painting directives
Ref. No.: 3695766 Page 13

2.1 1 Piston rod 918
2.2 1 Bolt 3,5
2.3 1 Cushioning bush 1,7
2.4 2 Plug 0,056
2.5 18 Ball 0,004
2.6 2 Set screw 0,032
8.6.5 Rod-end Eye Components
3.1 1 Rod-end eye 340
3.2 1 Flange 76
3.3 10 Hexagon-head bolt 1,1
3.4 2 Bush 15,7
3.5 1 Cylindrical dowel pin 0,185
3.7 2 Seal cap 0,01
Page 14 Ref. No.: 3695766

4.2 1 Wiper 0,18
4.3 1 U-ring 0,39
4.4 1 U-ring 0,32
4.6 1 Back ring 0,029
4.7 1 O-Ring 0,054
4.8 1 Blanking end 0,186
8.7 List of Required Tools

• Compressed air impact wrench
• Compressed air gun
• Face pin spanner wrench
• Torque wrench (3000Nm)
• Hexagon wrench
• Loctite mounting compound (lubricant)
• Spirit level
• Copper grease or similar
• Hex screwdriver
• Star wrench
• Chisel
• Vernier caliper
• Hammer
• Center punch
• Hydraulic press
• Workbench
Ref. No.: 3695766 Page 15

8.8 Dismantling Instructions

Disassembly of elements on the cylinder:
• Remove all SAE flanges and drain the hydraulic fluid from the cylinder.
• Collect spent oil in suitable containers and dispose of the oil in line with the respective regula-
tions.
8.8.1 Removing the Piston Rod from the Cylinder Tube

Disassembly of elements on the cylinder tube
Piston rod
Support piston rod, item 2, at the rod eye mount (e.g. by
suspension from a crane hook) and pull it out of the cy-
linder, item 1, by approx. 500 mm.
Fillister-Head Screws
Remove fillister-head screws, item 8.
Pull piston rod, item 2, out of cylinder tube, item 1, to stop

position (up to cylinder head, item 4).
Cylinder tube
When piston rod, item 2, has been retracted up to stop
position (on cylinder head, item 4) the cylinder head can
be moved out of the centering guide with a quick, sharp
pull.
Alternatively, cylinder head, item 4, can be pushed out of

the cylinder centering guide via M12 thread.
Page 16 Ref. No.: 3695766

8.8.2 Dismantling the Components on the Piston End

Removing the elements from the piston rod
Hexagon-head bolts
Remove hexagon head bolts, item 3.3, of the rod-end
eye bill of material.
Rod-end eye
Pull the rod-end eye, item 3.1, off the flange, item 3.2, of
the rod-end eye bill of material.
Flange
Unscrew flange, item 3.2, of the rod-end eye bill of ma-
terial and remove from piston rod, item 2.
Cylinder head
Carefully pull cylinder head, item 4, off piston rod, item 2,
without causing damage to the thread.
Ref. No.: 3695766 Page 17

8.9 Assembly Instructions

Prior to mounting make sure to observe the following:
• Check to make sure all components are in perfect condition.
• Deburr all sharp edges and remedy damage that may have been caused during dismantling.
• Do not use sharp-edged or unsuited tools.
• Carefully eliminate dirt, chips or other foreign particles.
• Apply a thin film of oil or grease to all components including sealing elements.
• Make sure to replace all wear parts (scraper, U-cups etc.).
• Otherwise, the installation is done analogously to what has been said for dismantling but in re-
verse order.
• Pre-tighten all bolts at the required torque as indicated on the drawing.
8.9.1 Installation of Seals and Guide Strips on Cylinder Head

Assembly of elements on the cylinder head:
U-cup
Press U-cup, items 4.3 and 4.4 of the cylinder head bill of
material, together into a kidney-shape and place it into
the groove.
Mount the split supporting ring.
Guide ring
Mount split guide rings, item 4.5 of the cylinder head bill
of material.
Scraper
Press scraper, item 4.2 of the cylinder head bill of ma-
terial, together into a kidney shape and place it into the
groove.
Page 18 Ref. No.: 3695766

Supporting ring
Mount supporting ring, item 4.6 of the cylinder head bill of
material.
Make sure the supporting ring is arranged correctly at the

O-ring side not subjected to pressure.
O-ring
Mount O-ring, item 4.7 of the cylinder head bill of materi-
al.
Complete sealing and guiding system

Apply a thin film of oil to the inner guide of the cylinder
head, item 4, (preferably use the hydraulic fluid).
Ref. No.: 3695766 Page 19

8.9.2 Attach the Cylinder Head to the Piston Rod

Mounting the elements onto the piston rod
Piston rod
Protect piston-rod thread against damage and apply oil
film to piston rod (preferably use the hydraulic fluid).
Cylinder head
Carefully slide the cylinder head, item 4, onto the piston
rod, item 2, without causing damage to the thread and
seals.
Cylinder head
Push cylinder head, item 4, forward to such an extent
that additional components such as flange and rod-end
eye can be mounted.
Page 20 Ref. No.: 3695766

8.9.3 Mounting of Components, External Seals and Guide Strips on the Piston Rod
Piston rod
Apply a thin film of oil to the areas of guides and seals of
the piston rod, item 2, (preferably use the hydraulic fluid).
Guide ring
Mount split guide rings, item 2.8 of the piston rod bill of
material.
Rotating seal ring

Mount mechanical seal set, item 2.9 of the piston rod bill
of material.
Cushioning unit
Screw pin, item 2.2, with cushioning bush, item 2.3, of
the piston rod bill of material into the piston rod, item 2,
up to the stop position.
Ref. No.: 3695766 Page 21

Balls
To secure the cushioning unit insert the 18 balls, item
2.5, of the piston rod bill of material.
Plug
Insert the plugs, item 2.4, of the piston rod bill of material
into the bore.
Setscrew
Tighten the setscrews, item 2.6, of the piston rod bill of
material to secure the cushioning unit.
Securing the setscrews by dotting mark

Safely secure the setscrews by fixing them with a dotting
mark.
Place the center punch about 2-3 mm away from the
edge of the tapped hole and drive the material inward
with a hammer blow.
Page 22 Ref. No.: 3695766


Guide rings
Mount split guide rings, item 2.7 of the piston rod bill of
material.
The joints of the guide rings, item 2.7 and item 2.8 of the
piston rod bill of material, must be staggered by 180°.
Piston safeguard
Cover the piston-side components on the piston rod, item
2, with a protective film to prevent them from being dam-
aged and dirt from coming into contact with the guide
elements.
Ref. No.: 3695766 Page 23

8.9.4 Mounting the Bearing Bushes on the Cylinder Bottom and Rod-end Eye
Mounting of elements on the clevis and rod-end eye
Bush
Cool bushes using liquid nitrogen.
Bush
Place the bushes, item 3.4, of the rod-end eye bill of ma-
terial on the bore.
Bush
Carefully and slowly press bushes, item 3.4, of the rod-
end eye bill of material into the rod-end eye until the stop
position is reached and without exerting canting forces.
Succeed with second bush as described above.
Bush
Carefully and slowly press bushes, item 5, of the cylinder
bottom into the clevis until the stop position is reached
and without exerting canting forces.
Page 24 Ref. No.: 3695766

8.9.5 Mounting of the Rod-end Eye

Piston rod
Grind the thread flanks of the piston rod, item 2, so as to
be smooth removing any burrs etc.
Clean the attachment face „A“ (on piston rod and rod-end
eye).
Piston rod
Apply Anti Seize 8155, Loctite, to the thread of the piston
rod. Take care not to coat the attachment face „A“ of the
piston rod.
Flange
Apply Anti Seize 8155, Loctite, to the thread of the
flange, item 3.2, of the rod-end eye bill of material and
mount flange onto the piston rod, item 2.

Insert cylindrical dowel pin, item 3.5, of the rod-end eye
bill of material in the rod-end eye, item 3.
Ref. No.: 3695766 Page 25

Hexagon-head bolts
Prior to mounting apply antifriction bearing grease to the
hexagon head bolts, item 3.3 of the rod-end eye bill of
material. Do not use Molykote!
Rod end eye

Pre-assemble the rod end eye, to the piston rod, item 2.
The rod end eye must make full contact with surface „A“.
Flange
Attach flange, item 3.2, to rod end eye, to such an extent
that a gap „a“ of width 1.5 mm to 3 mm is left.
Piston rod
Seal the joint between flange and piston rod by applying
a silicone layer.
Hexagon-head bolts
Mount the hexagon-head bolts, item 3.3 of the rod-end eye

bill of material.
Page 26 Ref. No.: 3695766

Hexagon-head bolts
Tighten hexagon-head screws, item 3.3, of the rod-end
eye bill of material uniformly by hand (cross-torquing until
finger-tight). Subsequently, check gap width „a“ = 1.5 mm
to 3 mm. Opposite locations to show the same dimen-
sion.
Hexagon-head bolts
Use cross-torquing to tighten the hexagon-head screws
in three steps as shown in table 01. Step 1 tightening
may take place by means of impact wrench. For step 2
and 3 tightening a torque wrench must be used. Seal
exposed threads of the hexagon-head screws, item 3.3,
using Anti Seize 8155.
Table 01
Ma = Nm Ma = Nm Ma = Nm
Size Width A/F – 6-pt.
Step 1 Step 2 Step 3
M30x2 36 850 1350 1700
Material 10.9
Flange
Seal the joint between flange and rod end eye by apply-
ing a silicone layer.
Ref. No.: 3695766 Page 27

8.9.6 Mounting the Piston into the Cylinder Tube

Assembly of elements on the cylinder tube:
Cylinder tube
To facilitate mounting of the piston rod assembly apply a
film of suitable grease to the cylinder tube, item 1, in the
front area of the fit.
Piston rod
Suspend the piston rod via the erection hoisting means
(e.g. by hanging it into the crane hook).
Piston rod
Apply a film of oil to the sealing and guide components
on the piston rod (preferably use the hydraulic fluid).
Piston rod
Align the piston rod assembly horizontally with the cy-
linder tube and insert it carefully.
Page 28 Ref. No.: 3695766

Piston rod
Insert the piston rod assembly into the cylinder tube until
stop position always verifying the correct alignment.
Apply a coat of suitable grease (e.g. copper grease or
similar) to the fillister-head screws, item 8.
Insert hexagon-head bolts, item 8 with disc item 9 and
tighten them (cross-torquing, finger-tight).
Ref. No.: 3695766 Page 29

Tighten bolts item 8 in crossover procedure with 3000 Nm.
8.9.7 Attaching the SAE Closure Flange to the Cylinder

Assembly of elements on the cylinder:
Closure flange
Mount the closure flanges, item 10, on the rod end and
cap end to rule out that dirt or contamination may enter
the cylinder.
Blanking end
Insert the blanking end, item 36, on the rod end and item
4.8 on the cap end.
Insert the sealing caps, item 37, on the cap end and seal-
ing item 20 on the cylinder head.
Insert the sealing caps, items 3.7, of the rod-end eye bill
of material on the rod-end eye.
Page 30 Ref. No.: 3695766

8.9.8 Miscellaneous
Prior to startup fill in oil and vent the cylinder carefully (refer to chapter 8.5).
Ref. No.: 3695766 Page 31

Technical Handbook
Hydraulic Cylinder
eng
Contents

8.1 Preface ................................................................................................................................ 2
8.2.1 Cylinder ................................................................................................................................ 3
8.2.2 Technical Data ..................................................................................................................... 3
8.2.3 Cylinder Design.................................................................................................................... 3
8.4.1 Cylinder Type ....................................................................................................................... 5
8.4.4 Clevis Components .............................................................................................................. 7
8.6.1 Cylinder D250/180; Ref. No.: 4525832 .............................................................................. 11
8.6.3 List of Spares for Cylinder, Ref. No.: 4525832 .................................................................. 13
8.6.4 List of Spares for Piston Rod ............................................................................................. 14
8.6.5 List of Clevis Spares .......................................................................................................... 14
8.6.6 List of Cylinder Head Spares ............................................................................................. 15
8.9.3 Installation of Seals on the Piston Rod .............................................................................. 21
8.9.4 Mounting the Bearing Bushes on Cylinder Bottom and Clevis .......................................... 22
8.9.5 Mounting the Flange ..........................................................................................................23
8.9.6 Preparation of the Bush ..................................................................................................... 24
8.9.7 Mounting the Clevis ...........................................................................................................25
8.9.10 Miscellaneous .................................................................................................................... 31
Ref. No.: 4525832 Page 1

8.1 Preface
quired Tools’.
into service.
Entrapped air may combust under certain operating conditions due to auto-ignition (diesel effect) and
cause damage to the cylinders after short operating periods.
Page 2 Ref. No.: 4525832

8.2.1 Cylinder


• Retraction and extension connections as per SAE 1 1/2", 6000 PSI
• Venting at cap and rod end via Retraction and extension connections
• Clevis on rod end and on the cap end with bronze bushings
• Guiding system of the rod end by means of 1 guide ring made of fabric-reinforced laminate
bronze
Ref. No.: 4525832 Page 3


ing condition.

tem has been carefully checked if in pressureless state.
Beware of hot hydraulic fluid.
tubing.
ment.
Page 4 Ref. No.: 4525832

8.4.1 Cylinder Type
Ref. No.: 4525832 Page 5

3 1 Clevis, compl. 330
5 2 Bush 9,566
6 1 Bush 1
7 2 Back ring 0,007
8 2 O-ring 0,003
9 1 Nameplate 0,003
10 3 SAE closure flange 1,8
12 2 Protective plug 0,002
14 15 Disk 0,032
15 1 Ring 0,8
17 1 Wiper 0,037
18 1 Ring 0,2
21 1 Test-/assembling rule
Page 6 Ref. No.: 4525832

2.1 1 Piston rod 606,8
8.4.4 Clevis Components
3.1 1 Clevis 271
3.2 2 Bush 9,566
3.3 1 Flange 45
3.4 10 Twelve-point screw 0,6
3.5 1 O-ring 0,035
Ref. No.: 4525832 Page 7

4.2 1 Scraper 0,037
4.3 1 U-cup 0,227
4.4 1 U-cup 0,181
4.6 1 Supporting ring 0,022
4.7 1 O-ring 0,043
Page 8 Ref. No.: 4525832


the purchase order.
For storage periods of up to one year the cylinders will be tested with anti-corrosion oil of brand AR-
AL Konit W10 (alternatively Resilan M 46) or ESSO Rustban 335 and subsequently emptied.
In case storage periods of more than one year are required the tests will be performed with the
above mentioned anti-corrosion oil and the unit delivered with oil filled in. The storage instructions
described under Pt. 3 must be carefully followed if this storage period is used.
In the event of storage periods exceeding two years the manufacturer must be consulted.
If hydraulic cylinders with uncoated piston rods are concerned, the manufacturer must in any case be
contacted to discuss preservation requirements.
Sealing
threaded connections will be closed off with threaded plastic covers or plugs of plastic material.
Cylinders which cannot be emptied completely and cylinders filled with oil will be closed off so as to
be tight to oil.
For this purpose plug screws with seal ring and in the case of tube connections plug fittings with cap
nuts will be used.
Surface Protection
out of the cylinder will be treated with ARAL Resilan WA or ESSO Rustban 397.
In case of plunger cylinders a film of anti-corrosion oil will be applied to plunger, guide and the inner
surface of the cylinder tube.
Unless there is a customer-issued painting specification the hydraulic cylinders are normally deli-
vered with a proven universal priming coat applied.
Transportation
The piston rods must be safeguarded to prevent them from being extended inadvertently.
All connections must be closed off.
Ref. No.: 4525832 Page 9

Storage
fumes, with temperatures kept constant in a range between 10°C and 20°C.
When the first year of storage has elapsed the cylinders shall be turned over at least once a year to
displace entrapped air bubbles that may have developed and in this manner also provide the respec-
tive surfaces with oil again.
Mounting
on the relevant type and design of the cylinder.
Usually, the mounting position of the hydraulic cylinder is optional.
Care must be exercised to ensure the hydraulic cylinders are mounted without stresses and trans-
verse forces acting on them since, otherwise, premature wear or malfunctions may occur.
Before the cylinder is hooked up to the hydraulic system pipes and tubing must be flushed clean with
a suitable oil to be on the safe side and eliminate any residual contamination from the tubing system.
External preservation agents must be removed using cleaner’s solvent or petroleum.
Startup
nominal).
Only proven proprietary brands on mineral oil basis acc. to DIN 51524 and DIN 51525 should be
used as working fluid. If other hydraulic fluid brands are to be used the manufacturer must be con-
sulted.
The piston rod should be free from paint remnants and other traces of external dirt or contamination.
If this is not the case, the rod must be cleaned thoroughly.
Some cylinder types require the rod-end eye mounts to be secured on site.
Prior to startup the hydraulic cylinder must be repeatedly vented in both end positions until the work-
ing fluid exits without air bubbles having formed.
Normally, the cylinders are suited for an operating temperature between -20°C and +80°C. It is man-
datory that the manufacturer be consulted if this temperature range is either exceeded or fallen be-
low.
Maintenance
taken in this case, especially if the piston rod remains in extended position.
Repeatedly checking the oil filters during the run-in period of the equipment is recommended. On ac-
count of their design and material selection the hydraulic cylinders as a rule do not require mainten-
ance during the operating period. However, prerequisite in this context is that the above instructions
regarding transportation, storage, installation and startup are carefully followed and observed.
Page 10 Ref. No.: 4525832


8.6.1 Cylinder D250/180; Ref. No.: 4525832
Ref. No.: 4525832 Page 11

Page 12 Ref. No.: 4525832

8.6.3 List of Spares for Cylinder, Ref. No.: 4525832
5 2 Bush 9,566
6 1 Bush 1
7 2 Back ring 0,007
8 2 O-ring 0,003
9 1 Nameplate 0,003
14 15 Disk 0,032
15 1 Ring 0,8
17 1 Wiper 0,037
18 1 Ring 0,2
Ref. No.: 4525832 Page 13

8.6.4 List of Spares for Piston Rod
8.6.5 List of Clevis Spares
3.1 1 Clevis 271
3.2 2 Bush 9,566
3.3 1 Flange 45
3.5 1 O-ring 0,035
Page 14 Ref. No.: 4525832

8.6.6 List of Cylinder Head Spares
4.2 1 Scraper 0,037
4.3 1 U-cup 0,227
4.4 1 U-cup 0,181
4.7 1 O-ring 0,043

• Hexagon wrench
• Spirit level
• Hex screwdriver
• Star wrench
• Open-end wrench
• Chisel
• Vernier caliper
• Hammer
• Center punch
• Workbench
Ref. No.: 4525832 Page 15


tions.

Piston rod
Support piston rod, item 2, at the clevis mount (e.g. by
Hexagon-head bolts
Remove hexagon head bolts, item 13.

Cylinder tube
pull.

Page 16 Ref. No.: 4525832


Flange
Remove twelve-point screws, item 3.4 of the fork eye bill
of material.
Clevis
Pull clevis, off the flange, item 3.3 of the fork eye bill of
material.
Flange
Remove flange, item 3.3, of the fork eye bill of material
from the piston rod, item 2.
Cylinder head
Ref. No.: 4525832 Page 17


verse order.

Guide ring
Mount split guide ring, item 4.5 of the cylinder head bill of
material.
U-cup
Press U-cups, items 4.3 and 4.4, of the cylinder head bill
of material together into a kidney-shape and place it into
the groove.
Scraper
groove.
Page 18 Ref. No.: 4525832

Supporting ring
material.

O-ring
al.
Scraper and ring

Insert hexagon-head screws, item 16, and manually tigh-
ten (finger-tight) ring, item 18, and scraper, item 17, with
ring, item 15, on the cylinder head, item 4.

head, item 4 (preferably use the hydraulic fluid).
Ref. No.: 4525832 Page 19


Piston rod
Cylinder head
seals.
Cylinder head
Push cylinder head, item 4, forward to such an extent that

additional components such as flange and clevis can be
mounted.
Page 20 Ref. No.: 4525832

8.9.3 Installation of Seals on the Piston Rod

Piston rod
Seals and gaskets

Insert split guide rings, items 2.4, 2.2 and mechanical
seal set, item 2.3 of the piston rod bill of material.
The joints of the guide rings and guide strips, items 2.2
and 2.4 of the piston rod bill of material, must be stag-
gered by 180°.
Piston rod
elements.
Ref. No.: 4525832 Page 21

8.9.4 Mounting the Bearing Bushes on Cylinder Bottom and Clevis

Mounting the elements on cap-end eye and clevis
Bush
Cool bushes item 5 and bushes item 3.2 of the fork eye
bill of material using liquid nitrogen.
Bush
Place the bushes item 5 and bushes item 3.2 of the fork
eye bill of material on the bore.
Bush
Carefully and slowly press bush, item 5 and bushes item
3.2 of the fork eye bill of material of the cylinder bottom
into the clevis without exerting canting forces.
Note: bush plane with inner edge (measure 129 mm).
Page 22 Ref. No.: 4525832

8.9.5 Mounting the Flange

Piston rod
Clean the attachment face „A“ (on piston rod and clevis).
O-ring
piston rod.
O-ring
Place the O-ring, item 3.5, of the fork eye bill of material
onto the piston rod.
Flange
flange, item 3.3 of the fork eye bill of material.
Ref. No.: 4525832 Page 23

Flange
Mount the flange, item 3.3, of the fork eye bill of material
onto the piston rod, item 2.
8.9.6 Preparation of the Bush

Mounting the elements onto bush
Bush
Mount supporting rings, item 7, and O-rings, item 8, onto
the bush, item 6.
Bush
Bush
To facilitate the installation of the bush, item 6, apply a
coat of suitable grease to the outside diameter.
Page 24 Ref. No.: 4525832

8.9.7 Mounting the Clevis

Bush
Insert the bush, item 6, into the piston rod, item 2.
Twelve-point screws
twelve-point screws, item 3.4 of the fork eye bill of ma-
terial. Do not use Molykote!
Rod end eye

Pre-assemble the fork eye, to the piston rod, item 2.
The fork eye must make full contact with surface „A“.
Flange
Attach flange, item 3.3, to fork eye, to such an extent that
a gap „a“ of width 1.5 mm to 3 mm is left.
Ref. No.: 4525832 Page 25

Piston rod
a silicone layer.
Twelve-point screws
Mount the twelve-point screws, item 3.4 of the fork eye
bill of material
O-ring
Pull rod end eye, away from attachment face „A“ to such
an extent that the O-ring, item 3.5 of the fork eye bill of
material, can be inserted.
Twelve-point screws
Tighten twelve-point screws, item 3.4 of the fork eye bill
of material, uniformly by hand (cross-torquing until finger-
tight).
Subsequently, check gap width „a“ = 1.5 mm to 3 mm.
Opposite locations to show the same dimension.
Page 26 Ref. No.: 4525832

Twelve-point screws
Use cross-torquing to tighten the twelve-point screws in
three steps as shown in table 01.
Step 1 tightening may take place by means of impact
wrench. For step 2 and 3 tightening a torque wrench
must be used.
Seal exposed threads of the twelve-point screws, item
3.4, of the fork eye bill of material using Anti Seize 8155.
Table 01
M27x2 32 570 890 1135
Material 10.9
Ref. No.: 4525832 Page 27


Cylinder tube
Piston rod
Piston rod
Piston rod
Page 28 Ref. No.: 4525832

Piston rod
Hexagon-head bolts
Prior to mounting apply a coat of suitable grease (e.g.
copper grease or similar) to the hexagon-head bolts, item
13.
Hexagon-head bolts
Insert hexagon-head screws, item 13, and tighten (cross-
torquing, finger-tight).
Hexagon-head bolts
Tighten hexagon-head screws, item 13, by cross-
torquing.
Tightening torque: 850 Nm.
Ref. No.: 4525832 Page 29


Closure flanges
the cylinder.
Venting screws
ing caps, item 3.6 of the fork eye bill of material, of the
fork eye.
Page 30 Ref. No.: 4525832

8.9.10 Miscellaneous
Ref. No.: 4525832 Page 31

Technical Handbook
Hydraulic Cylinder
eng
Contents

8.1 Preface ................................................................................................................................ 2
8.2.1 Cylinder ................................................................................................................................ 3
8.2.2 Technical Data ..................................................................................................................... 3
8.2.3 Cylinder Design.................................................................................................................... 3
8.4.1 Cylinder Type ....................................................................................................................... 5
8.4.4 Clevis Components .............................................................................................................. 7
8.6.1 Cylinder D250/180; Ref. No.: 4525832 .............................................................................. 11
8.6.4 List of Spares for Piston Rod ............................................................................................. 14
8.6.5 List of Clevis Spares .......................................................................................................... 14
8.6.6 List of Cylinder Head Spares ............................................................................................. 15
8.9.4 Mounting the Bearing Bushes on Cylinder Bottom and Clevis .......................................... 22
8.9.6 Preparation of the Bush ..................................................................................................... 24
8.9.10 Miscellaneous .................................................................................................................... 31
Ref. No.: 4525832 Page 1

8.1 Preface
quired Tools’.
into service.
Page 2 Ref. No.: 4525832

8.2.1 Cylinder


• Clevis on rod end and on the cap end with bronze bushings
• Guiding system of the rod end by means of 1 guide ring made of fabric-reinforced laminate
bronze
Ref. No.: 4525832 Page 3


ing condition.

tubing.
ment.
Page 4 Ref. No.: 4525832

8.4.1 Cylinder Type
Ref. No.: 4525832 Page 5

5 2 Bush 9,566
6 1 Bush 1
7 2 Back ring 0,007
8 2 O-ring 0,003
9 1 Nameplate 0,003
14 15 Disk 0,032
15 1 Ring 0,8
17 1 Wiper 0,037
18 1 Ring 0,2
Page 6 Ref. No.: 4525832

8.4.4 Clevis Components
3.1 1 Clevis 271
3.2 2 Bush 9,566
3.3 1 Flange 45
3.5 1 O-ring 0,035
Ref. No.: 4525832 Page 7

4.2 1 Scraper 0,037
4.3 1 U-cup 0,227
4.4 1 U-cup 0,181
4.7 1 O-ring 0,043
Page 8 Ref. No.: 4525832


the purchase order.
Sealing
be tight to oil.
nuts will be used.
Surface Protection
Transportation
Ref. No.: 4525832 Page 9

Storage
Mounting
Startup
nominal).
sulted.
low.
Maintenance
Page 10 Ref. No.: 4525832


8.6.1 Cylinder D250/180; Ref. No.: 4525832
Ref. No.: 4525832 Page 11

Page 12 Ref. No.: 4525832

5 2 Bush 9,566
6 1 Bush 1
7 2 Back ring 0,007
8 2 O-ring 0,003
9 1 Nameplate 0,003
14 15 Disk 0,032
15 1 Ring 0,8
17 1 Wiper 0,037
18 1 Ring 0,2
Ref. No.: 4525832 Page 13

8.6.4 List of Spares for Piston Rod
8.6.5 List of Clevis Spares
3.1 1 Clevis 271
3.2 2 Bush 9,566
3.3 1 Flange 45
3.5 1 O-ring 0,035
Page 14 Ref. No.: 4525832

8.6.6 List of Cylinder Head Spares
4.2 1 Scraper 0,037
4.3 1 U-cup 0,227
4.4 1 U-cup 0,181
4.7 1 O-ring 0,043

• Hexagon wrench
• Spirit level
• Hex screwdriver
• Star wrench
• Open-end wrench
• Chisel
• Vernier caliper
• Hammer
• Center punch
• Workbench
Ref. No.: 4525832 Page 15


tions.

Piston rod
Hexagon-head bolts

Cylinder tube
pull.

Page 16 Ref. No.: 4525832


Flange
Remove twelve-point screws, item 3.4 of the fork eye bill
of material.
Clevis
Pull clevis, off the flange, item 3.3 of the fork eye bill of
material.
Flange
Remove flange, item 3.3, of the fork eye bill of material
from the piston rod, item 2.
Cylinder head
Ref. No.: 4525832 Page 17


verse order.

Guide ring
Mount split guide ring, item 4.5 of the cylinder head bill of
material.
U-cup
Press U-cups, items 4.3 and 4.4, of the cylinder head bill
of material together into a kidney-shape and place it into
the groove.
Scraper
groove.
Page 18 Ref. No.: 4525832

Supporting ring
material.

O-ring
al.
Scraper and ring

Insert hexagon-head screws, item 16, and manually tigh-
ten (finger-tight) ring, item 18, and scraper, item 17, with
ring, item 15, on the cylinder head, item 4.

head, item 4 (preferably use the hydraulic fluid).
Ref. No.: 4525832 Page 19


Piston rod
Cylinder head
seals.
Cylinder head
Push cylinder head, item 4, forward to such an extent that

additional components such as flange and clevis can be
mounted.
Page 20 Ref. No.: 4525832


Piston rod
Seals and gaskets

Insert split guide rings, items 2.4, 2.2 and mechanical
seal set, item 2.3 of the piston rod bill of material.
The joints of the guide rings and guide strips, items 2.2
and 2.4 of the piston rod bill of material, must be stag-
gered by 180°.
Piston rod
elements.
Ref. No.: 4525832 Page 21

8.9.4 Mounting the Bearing Bushes on Cylinder Bottom and Clevis

Mounting the elements on cap-end eye and clevis
Bush
Cool bushes item 5 and bushes item 3.2 of the fork eye
bill of material using liquid nitrogen.
Bush
Place the bushes item 5 and bushes item 3.2 of the fork
eye bill of material on the bore.
Bush
Carefully and slowly press bush, item 5 and bushes item
3.2 of the fork eye bill of material of the cylinder bottom
into the clevis without exerting canting forces.
Note: bush plane with inner edge (measure 129 mm).
Page 22 Ref. No.: 4525832


Piston rod
O-ring
piston rod.
O-ring
Place the O-ring, item 3.5, of the fork eye bill of material
onto the piston rod.
Flange
flange, item 3.3 of the fork eye bill of material.
Ref. No.: 4525832 Page 23

Flange
Mount the flange, item 3.3, of the fork eye bill of material
onto the piston rod, item 2.
8.9.6 Preparation of the Bush

Mounting the elements onto bush
Bush
Mount supporting rings, item 7, and O-rings, item 8, onto
the bush, item 6.
Bush
Bush
To facilitate the installation of the bush, item 6, apply a
coat of suitable grease to the outside diameter.
Page 24 Ref. No.: 4525832


Bush
Insert the bush, item 6, into the piston rod, item 2.
Twelve-point screws
twelve-point screws, item 3.4 of the fork eye bill of ma-
terial. Do not use Molykote!
Rod end eye

Pre-assemble the fork eye, to the piston rod, item 2.
The fork eye must make full contact with surface „A“.
Flange
Attach flange, item 3.3, to fork eye, to such an extent that
a gap „a“ of width 1.5 mm to 3 mm is left.
Ref. No.: 4525832 Page 25

Piston rod
a silicone layer.
Twelve-point screws
Mount the twelve-point screws, item 3.4 of the fork eye
bill of material
O-ring
an extent that the O-ring, item 3.5 of the fork eye bill of
material, can be inserted.
Twelve-point screws
Tighten twelve-point screws, item 3.4 of the fork eye bill
of material, uniformly by hand (cross-torquing until finger-
tight).
Page 26 Ref. No.: 4525832

Twelve-point screws
must be used.
3.4, of the fork eye bill of material using Anti Seize 8155.
Table 01
M27x2 32 570 890 1135
Material 10.9
Ref. No.: 4525832 Page 27


Cylinder tube
Piston rod
Piston rod
Piston rod
Page 28 Ref. No.: 4525832

Piston rod
Hexagon-head bolts
13.
Hexagon-head bolts
Insert hexagon-head screws, item 13, and tighten (cross-
torquing, finger-tight).
Hexagon-head bolts
torquing.
Ref. No.: 4525832 Page 29


Closure flanges
the cylinder.
Venting screws
ing caps, item 3.6 of the fork eye bill of material, of the
fork eye.
Page 30 Ref. No.: 4525832

Ref. No.: 4525832 Page 31

Technical Handbook
Hydraulic Cylinder
eng
Contents

8.1 Preface ................................................................................................................................ 2
8.2.1 Cylinder ................................................................................................................................ 3
8.2.2 Technical Data ..................................................................................................................... 3
8.2.3 Cylinder Design.................................................................................................................... 3
8.4.1 Cylinder Type ....................................................................................................................... 5
8.4.3 Piston rod Components ....................................................................................................... 6
8.4.4 Fork eye Components ......................................................................................................... 7
8.4.5 Cylinder head Components ................................................................................................. 7
8.6.1 Cylinder D200/110; Ref. No.: 4525841 .............................................................................. 10
8.6.4 List of Spares for Piston rod .............................................................................................. 12
8.6.5 List of Spares for Fork eye ................................................................................................. 13
8.6.6 List of Spares for Cylinder head ........................................................................................ 13
8.9.1 Installation of Seals and Guide Rings on Cylinder Head ................................................... 17
8.9.4 Mounting the Bearing Bushes on Clevis ............................................................................ 21
8.9.5 Mounting the Articulated Bearing on the Cylinder Bottom ................................................. 22
8.9.10 Miscellaneous .................................................................................................................... 31
Ref. No.: 4525841 Page 1

8.1 Preface
quired Tools’.
into service.
Page 2 Ref. No.: 4525841

8.2.1 Cylinder

• Stroke = 715 mm

• Single-stage cylinder with head-end cushioning
• Clevis on rod end and eye on cap end with articulated bearing
• Seal arrangement on cap end: 1 Slipring seal kit
• Guiding system of the rod end by means of 2 guide rings made of fabric-reinforced laminate
• Guiding system of the cap end by 1 guide rings of fabric-reinforced laminate, 1 guide rings of
GG- 25 and 2 guide strips of PTFE - bronze
Ref. No.: 4525841 Page 3


ing condition.

tubing.
ment.
Page 4 Ref. No.: 4525841

8.4.1 Cylinder Type
Ref. No.: 4525841 Page 5

2 1 Piston rod 105
3 1 Fork eye 152
6 1 Cylinder head 36,1
8 1 Data plate 0,003
10 2 SAE lock plug 1,7
11 11 Hexagonal bolt 0,351
12 11 Disk 0,22
13 1 Spherical bearing 15
14 1 Circlip 0,162
25 1 Sealing caps 0,002
29 2 Grooved pin 0,001
8.4.3 Piston rod Components
2.2 2 Wearing 0,071
2.4 1 Slipring seal kit 0,07
Page 6 Ref. No.: 4525841

8.4.4 Fork eye Components
3.1 1 Fork eye 130
3.2 1 Flange 15,2
3.3 2 Bush 5,775
3.4 10 12-pointed bolt 0,6
3.5 1 Cylindrical pin 0,035
3.6 1 O-ring 0,024
3.7 2 Sealing caps 0,002
8.4.5 Cylinder head Components
6.2 1 Wiper 0,006
6.3 1 Wiper 0,032
6.5 2 U-ring 0,071
6.7 1 Back ring 0,015
6.8 1 O-ring 0,033
Ref. No.: 4525841 Page 7


the purchase order.
Sealing
be tight to oil.
nuts will be used.
Surface Protection
Transportation
Page 8 Ref. No.: 4525841

Storage
Mounting
Startup
nominal).
sulted.
low.
Maintenance
Ref. No.: 4525841 Page 9


8.6.1 Cylinder D200/110; Ref. No.: 4525841
Page 10 Ref. No.: 4525841

Ref. No.: 4525841 Page 11

2 1 Piston rod 105
3 1 Fork eye 152
6 1 Cylinder head 36,1
8 1 Data plate 0,003
10 2 SAE lock plug 1,7
11 11 Hexagonal bolt 0,351
12 11 Disk 0,22
13 1 Spherical bearing 15
14 1 Circlip 0,162
25 1 Sealing caps 0,002
29 2 Grooved pin 0,001
8.6.4 List of Spares for Piston rod
2.2 2 Wearing 0,071
2.4 1 Slipring seal kit 0,07
Page 12 Ref. No.: 4525841

8.6.5 List of Spares for Fork eye
3.1 1 Fork eye 130
3.2 1 Flange 15,2
3.3 2 Bush 5,775
3.4 10 12-pointed bolt 0,6
3.5 1 Cylindrical pin 0,035
3.6 1 O-ring 0,024
3.7 2 Sealing caps 0,002
8.6.6 List of Spares for Cylinder head
6.2 1 Wiper 0,006
6.3 1 Wiper 0,032
6.5 2 U-ring 0,071
6.7 1 Back ring 0,015
6.8 1 O-ring 0,033
Ref. No.: 4525841 Page 13


• Torque wrench (1200 Nm)
• Hexagon wrench
• Spirit level
• Hex screwdriver
• Star wrench
• Chisel
• Vernier caliper
• Hammer
• Center punch
• Mounting pliers for Seeger rings
• Hydraulic press
• Workbench
Page 14 Ref. No.: 4525841


tions.

Piston rod
Hexagon-head bolts

Cylinder tube
pull.

Ref. No.: 4525841 Page 15


Flange
Remove twelve-point screws, item 3.4 of the rod end eye
bill of material.
Clevis
Pull the clevis, off the flange, item 3.2, of the rod-end eye
bill of material.
Flange
Unscrew flange, item 3.2, of the rod-end eye bill of ma-
terial and remove from piston rod, item 2.
Cylinder head
Page 16 Ref. No.: 4525841


verse order.
8.9.1 Installation of Seals and Guide Rings on Cylinder Head

Guide rings
Mount split guide rings, item 6.6 and item 6.4 of the cy-
linder head bill of material.
U-cups
Press U-cups, items 6.5, of the cylinder head bill of ma-
terial together into a kidney-shape and place it into the
groove.
Scraper
groove.
Ref. No.: 4525841 Page 17

Scraper
Place scraper, item 6.2 of the cylinder head bill of materi-
al, into the groove.
Supporting ring
material.

O-ring
al.
Complete sealing and guiding system

head, item 6, (preferably use the hydraulic fluid).
Page 18 Ref. No.: 4525841


Piston rod
Cylinder head
seals.
Cylinder head
Push cylinder head, item 6, forward to such an extent
that additional components such as flange and rod-end
eye can be mounted.
Ref. No.: 4525841 Page 19


Piston rod
Guide rings
Mount split guide rings, item 2.3 and item 2.5 of the pis-
ton rod bill of material.
Rotating seal ring

Mount mechanical seal set, item 2.4 of the piston rod bill
of material.
Guide strips
Mount split guide strips, item 2.2 of the piston rod bill of
material.
The joints of the guide rings and guide strips, items 2.2,
2.3 and 2.5 of the piston rod bill of material, must be
staggered by 180°.
Page 20 Ref. No.: 4525841

Piston rod
elements.
8.9.4 Mounting the Bearing Bushes on Clevis

Mounting the elements on clevis
Bush
Cool bushes item 3.3 of the fork eye bill of material using
liquid nitrogen.
Bush
Place the bushes item 3.3 on the bore, carefully and
slowly press bushes item 3.3 of the fork eye bill of ma-
terial of the cylinder bottom into the clevis without exert-
ing canting forces.
Ref. No.: 4525841 Page 21

8.9.5 Mounting the Articulated Bearing on the Cylinder Bottom

Assembly of elements on the clevis:
Articulated bearing
Place articulated bearing, item 13, in position on the cy-
linder bottom so that it can be mounted by means of
pressing tools.
For larger bearings (steel/steel paired sliding action) use

special mounting equipment.
Articulated bearing
Place the pressing tool onto the outer race (end face) of
the articulated bearing, item 13.
Articulated bearing
Use the pressing tool to press home the articulated bear-
ing, item 13.
Circlip
Using mounting pliers for Seeger rings insert the circlip,
item 14, into the cylinder bottom.
Page 22 Ref. No.: 4525841

Articulated bearing
In case of radial articulated bearings with separated or
split outer race arrange cutting line offset by 90° in rela-
tion to the main load application direction.

Piston rod
O-ring
piston rod.
O-ring
Place the O-ring, item 3.6, of the rod-end eye bill of ma-
terial onto the piston rod.
Ref. No.: 4525841 Page 23

Flange
Apply Anti Seize 8155, Loctite, to the flange item 3.2, of
the rod-end eye bill of material.
Flange
Mount the flange, item 3.2, of the rod-end eye bill of ma-
terial onto the piston rod, item 2.


Insert the cylindrical dowel pin, item 3.5, of the rod-end
eye bill of material into the rod end eye.
Piston rod
Cover the piston rod, item 2, with suitable material to
prevent it from being damaged.
Page 24 Ref. No.: 4525841

Twelve-point screws
twelve-point screws, item 3.4 of the rod-end eye bill of
material. Do not use Molykote!
Rod end eye

Pre-assemble the rod end eye, to the piston rod, item 2.
The rod end eye must make full contact with surface „A“.
Flange
Attach flange, item 3.2, to rod end eye, to such an extent
that a gap „a“ of width 1.5 mm to 3 mm is left.
Piston rod
a silicone layer.
Ref. No.: 4525841 Page 25

Twelve-point screws
Mount the twelve-point screws, item 3.4 of the rod-end
eye bill of material.
O-ring
an extent that the O-ring, item 3.6 of the rod-end eye bill
of material, can be inserted.
Twelve-point screws
Tighten twelve-point screws, item 3.4 of the rod-end eye
bill of material, uniformly by hand (cross-torquing until
finger-tight).
Page 26 Ref. No.: 4525841

Twelve-point screws
must be used.
3.4, of the rod-end eye bill of material using Anti Seize
8155.
Table 01
Size SW – 12-point
M27x2 32 570 890 1135
Material 10.9
Ref. No.: 4525841 Page 27


Cylinder tube
Piston rod
Piston rod
Piston rod
Page 28 Ref. No.: 4525841

Piston rod
Hexagon-head bolts
11.
Hexagon-head bolts
Insert hexagon-head bolts, item 11 with disc item 12 and
tighten them (cross-torquing, finger-tight).
Hexagon-head bolts
torquing.
Ref. No.: 4525841 Page 29


Closure flanges
the cylinder.
Insert the sealing caps item 25, on the cap end and item
3.7 of the fork eye.
Page 30 Ref. No.: 4525841

Ref. No.: 4525841 Page 31

08.2018
9. Electric system
6040

CONTENTS
9. ELECTRIC, ELECTRONIC
9.1 Introduction............................................................................................... 1
9.1.1 Foreword ................................................................................... 1
9.1.2 Safety instructions ..................................................................... 2
9.1.3 General ...................................................................................... 4
9.2 Electric System ......................................................................................... 1
9.2.1 Overview of switch cabinets ...................................................... 1
9.2.2 Electrical documentation............................................................ 1
9.2.3 List of electrical components ..................................................... 4
9.2.4 Circuit diagram .......................................................................... 6
9.2.5 Connection tables – terminal strips ............................................ 8
9.2.6 Connection tables – plug connections ..................................... 11
9.2.7 Schematic symbols .................................................................. 12
9.3 Control And Monitoring Platform (CAMP) .............................................. 1
9.3.1 Introduction to CAMP................................................................. 1
9.3.2 Overview of the individual control system .................................. 1
9.3.3 Location of the main components .............................................. 1
9.3.4 Servo Control System (SCS) ..................................................... 3
9.3.5 Auxiliary System (AS) ................................................................ 7
9.3.6 Drive Controller Left Hand (DCLH) ............................................ 9
9.3.7 Drive Controller Right Hand (DCRH) ....................................... 11
9.3.8 Board Control System (BCS) ................................................... 13
3721499en – (00) Page 9 - 1

CONTENTS
9.4 Communication and control loops within CAMP ................................... 1
9.4.1 Controller Area Network (CAN) ................................................. 1
9.4.2 Electronic Hydraulic Servo Control (EHSC) ............................... 3
9.4.3 Hand Levers and Pedals ........................................................... 5
9.4.4 Pump flow regulation ................................................................. 6
9.4.5 Lubrication system ..................................................................... 8
9.4.6 Lights ......................................................................................... 9
9.5 Electric Components................................................................................ 1
9.5.1 Location of components............................................................. 1
9.5.2 List of components..................................................................... 4
9.6 BCS Software ............................................................................................ 1
9.6.1 Overview of the menus .............................................................. 1
9.6.2 Start screen ............................................................................... 6
9.6.3 Service menus ......................................................................... 11
9.6.4 Fault storage menus ................................................................ 32
9.6.5 Setup menus ............................................................................. 1
9.7 Troubleshooting ....................................................................................... 1
9.7.1 Safety instructions ..................................................................... 1
9.7.2 General troubleshooting ............................................................ 2
9.7.3 Specific troubleshooting per error ID ......................................... 1
Page 9 - 2 3721499en – (00)

9.1 ELECTRIC, ELECTRONIC
For these reasons, Caterpillar, like the automobile

9.1 Introduction industry, decided some years ago to adopt another
form of electrical diagram: the detailed circuit dia-
9.1.1 Foreword gram.
The present chapter describes how to use these

Electrical systems in earth-moving machinery have new, CAD-based circuit diagrams and their ac-
spread far beyond the original fields of application companying documents.
such as starting and lighting equipment. New appli-
cations are essentially monitoring and control func- This Service Manual applies to automotive elec-
tions. This development has necessarily increased trical systems in earth-moving machinery. In any
the number of electrical circuits to such an extent case, the relevant accident prevention regulations
that the whole field of electrical applications has and the respective requirements for different oper-
become evermore complicated and confusing to ating voltages must be observed. The regulations
the non-electrician. are not part of this manual.
The schematic diagrams used in the past have

reinforced this impression.
3721500en - (00) Page 9.1 - 1

9.1.2 Safety instructions
Prior to working on electrical Handling of batteries

systems Batteries give off explosive gases.
The personnel carrying out repairs Do not use fire and unshielded
must have know-how and experi- light sources in the vicinity of bat-
ence in the repair of the electrical teries and do not smoke.
systems installed in this machine
or of electrical systems of similar Battery acid is toxic and caustic.
machines. Avoid any contact with the mouth,
If such know-how is lacking, me- skin, eyes and clothing. Do not
ticulous instruction must be given spill battery acid and do not inhale
by experienced personnel, e.g. the vapours.
from Caterpillar. Wear gloves, firm working clothing
Before carrying out any mainte- and goggles when handling batte-
nance and repair work, the ma- ries.
chine must be secured as follows: If the skin is splashed with acid,
• Park the machine on level and rinse with plenty of water and con-
stable ground. sult a doctor.
• Stand the working equipment on If the eyes are splashed with acid,
the ground. rinse thoroughly with running wa-
• Shut off the engine.
ter and consult a doctor immedi-
ately.
• Withdraw the key from the key-
Do not set down tools on the bat-
operated switch of the electrical
tery. They may induce a short-
system.
circuit, causing irreparable damage
• Secure the machine against inad- to the battery and injuring persons.
vertent movements by placing
chocks under the tracks or Do not wear metal necklaces,
wheels. bracelets or watch-straps when
working on the battery. The metal
• Before carrying out work on the parts may induce a short-circuit,
electrical system or before weld- resulting in burns.
ing set the battery main switch to
'OFF'. Dispose of used batteries separate-
ly from other waste in the interests
of environmental protection.
After completion of the work:
Set the battery main switch to 'ON.
Page 9.1 - 2 3721500en - (00)

Alternator, Personnel qualifications

General notes Working on the electrical system of
Do not disconnect electric cables the machine requires basic electri-
from the alternator and the regula- cal and mechanical knowledge, as
tor when the engine is running. well as knowledge of the appropri-
This would damage the alternator ate technical terms. Working on the
and the regulator. electrical system includes all tasks
described in this chapter including
Carry out voltage and continuity troubleshooting and replacing
checks with measuring instru- hardware components.
ments only.
To ensure safe use, the specified
Do not use test lamps since the activities may only be carried out
currents in the circuit under test by qualified technical personnel or
may be very strong. an instructed person under the
Do not "tap against ground". This direction and supervision of quali-
causes a short-circuit with conse- fied personnel. In other words, only
quent damage to the alternator and appropriately trained and qualified
regulator. personnel are permitted to work
with or near the excavator.
Qualified personnel fulfils all of the
Batteries following requirements:
When connecting the batteries do • Is able to recognize possi-
not interchange the cables (pay ble hazards and institute the ap-
attention to polarity). propriate safety measures due to
their professional training,
knowledge, and experience as well
Fuses as their understanding of the rele-
vant conditions pertaining to the
Risk of short-circuits and sparking work to be done.
Remove fuses only after the corre- • Observes the rules relevant
sponding circuit has been de- to the subject area.
energized:
• Is familiar with all warnings
Shut off the engine, set the key- and precautions according to this
operated switch of the electrical documentation and the documen-
system to "0" and withdraw the tation of the respective component
key. and understand their content.
Set the battery main switch to • Has appropriate safety
'OFF'. equipment and has been trained in
Replace defective fuses only by first aid.
fuses of the same current rating. Persons who work on the electrical
system must not consume any
alcohol, drugs, or pharmaceuticals
that may affect their ability to re-
spond.
3721500en - (00) Page 9.1 - 3

9.1.3 General
It must be ensured that all persons performing

work on the machine have read the relevant chap-
ters of the operating instructions before starting any
work.
The user of the machine is responsible for ensuring

that all relevant national and international laws and
regulations will be complied with.
Page 9.1 - 4 3721500en - (00)

9.2 ELECTRIC SYSTEM - 24 VOLT
9.2 Electric System - 24 Volt Signal Terminal Circuit Notes

available no. breaker
For organizational reasons, the documentation for 12V 1
the electric system - 24 volt is attached to the spare Direct battery 2 -1F22
parts list. max. 6A
This way the diagrams match to the individual ma- 12V 3 -1F23
chine. Direct battery 4 -1F24
max. 6A
24V 5 -1F25
9.2.1 Overview of switch cabinets Key switch 6 -1F26 Before
max. 15A battery
main
The machine includes the following switch cabi-
switch.
nets:
• X1 cabinet, underneath the operator’s cabinet
Power supply for the 2way Radio is supplied in the
• X10 cabinet, behind the hydraulic tank
Operator‘s Console. 2pin plug direct Battery +.
• X30 LH drive controller cabinet
• X40 RH drive controller cabinet
• X3 Terminal box hydraulic tank 9.2.2 Electrical documentation
• X24 Terminal box servo valve block
This section introduces the scope and content of
the electrical documentation and how to use it in
daily operation.
The electrical documentation includes 5 sections:
• Circuit diagram (current flow diagram)
• Layout drawing
• Connection tables - terminal strips
• Connection tables - plug connections
• Electrical components and extras

(bill of material)
• Wiring harness
Fig. 1 Switch cabinets - 642888
Customer connection points Always refer to the documentation,

which is relevant to the specific ma-
Customer connections are available on the X2 chine-serial-number.
terminal in the X1 cabinet to install customer
equipment such as 2 way radio, fire fighting sys-
tem.
3721501en - (01) Page 9.2 - 1

9.2.2.1 Naming of electrical components Based on these groups, the electrical components
are coded in the electrical documentation and in
The components of the machine are grouped as the spare parts list. This code consists of:
follows:
• Group number 1: Parts not connected to any • Group number
controller. These are parts like the key switch,
battery, main switches and working lights. • Letter according to DIN 40 719
• Group number 2: Components connected to • Identifying number

the Servo controller / ICN-V.
Example: -2K1
• Group number 3: Components connected to
the drive controller LH. 2: Component connected to the Servo control-
ler / ICN-V
• Group number 4: Components connected to K: Relays, cabinets
the drive controller RH. 1: Identifier
The following table shows an excerpt of the DIN

• Group number 5: Components connected to
40 719 standard.
the auxiliary controller.
• Group number 6: Parts related to the BCS

tower. These are parts like the BCS screen
and the FM Radio.
Page 9.2 - 2 3721501en - (01)

Letter Designation Examples

A Assembly group, parts of groups Amplifiers, magnetic amplifiers, combinations of
devices
B Transformation from non-electrical into Metering transformers, thermo sensors, thermo
electrical magnitudes (and vice versa) cells, photo-electric cells, dynamometers, quartz
crystals, magnetic field sensors, inclinometers
C Capacitors ----
D Time-lags, accumulators, binary elements Coupling links, bi-stable elements,
monostable elements
E Miscellaneous Lights, heaters
F Safety devices Fuses, overload guards, interlocks, circuit break-
ers, safety relays, releases
G Generators, electrical supplies Rotary generators, rotary frequency converters,
batteries, power supplies, oscillators
H Monitors Optical and acoustic monitors
I ---- ----
K Relays, contactors Power contactors, auxiliary contactors,
auxiliary relays, blinker relays, time-lag
relays
L Inductive devices Throttle coils
M Motors ----
P Meters, testers Indicating, recording and metering instruments,
impulse initiators, clocks
Q High-voltage switch relays Circuit breakers, main switches, isolators,
motor isolators (thermistors), automatic
cut-outs, fused circuit breakers
R Resistance Adjustable resistances, potentiometers,
shunts
S Switches, selectors Buttons, limit switches, control switches,
signal emitters
T Transformers Transformers, converters
U Modulators, converters Frequency converters, converters, inverters,
transverters, demodulators, reversing
converters
V Diodes Cancelling diodes for solenoid valves
W Conductive paths, hollow conductors Switch lines, cables, busbars
X Terminals, plugs, sockets Isolating plugs/sockets, test sockets, terminal
strips, solder strips
Y Electrically actuated mechanical devices Brakes, couplings, valves
Z End points, compensating devices, filters, Cable duplications
limiters, Y-terminals
Table 1
3721501en - (01) Page 9.2 - 3

9.2.2.2 Layout drawing The key includes the columns:

1: Device designation
The layout drawing is a detailed illustration in either 2: Amount
3D or schematic form. It shows the location of the 3: Function / Description
most important electrical components. The compo- 4: Description
nents are indicated by schematic symbols accord- 5: Schematics
ing to DIN standard, see section “Naming electrical 6: Location
components”. Their unique identifier is their re- 7: Group
spective part codes. 8: S/N Nr.
The line highlighted in yellow indicates the infor-

mation on relay -2K1, one of the examples for en-
tries in the list of electrical components that is ex-
plained below.
1 Device designation
The unique identifier of the electrical component

that is the schematic symbols according to DIN
standard, see section “Naming electrical compo-
nents”.
Fig. 2 Layout drawing - 642889
Example
9.2.3 List of electrical components
Relay -2K1, see the line highlighted in yellow in
the figure.
The key to electrical components in the circuit dia-
gram is a systematically arranged list accomplish-
ing the circuit diagram. Its purpose is to locate
components both in the circuit diagrams and on the 2 Amount
machine itself. It also contains the components’
part numbers (Part No.). The number of particular component parts on the
machine.
Example
-2K1 is included once in the machine.
3 Function / description
Function of the component.
Example
• -2K1: “RELAY”
• -2B10: “SENSOR – HYD. OIL MIN.”
Fig. 3 Layout drawing - 642631
Page 9.2 - 4 3721501en - (01)

4 Description 8 S/Nr. or Part-No.
Additional information on the component. This is the Part-No. for ordering spare parts. If no
Part No. is given, the part in question is associated
with the electrical system but is part of another
Example
assembly group.
The Part No. must then be determined using the
• “RELAY” for the relay relevant spare parts sheets. For example the part
• “FLOAT SWITCH” and “PLUG” for the sen- numbers for solenoid valves are to be found in the
sor “HYD. OIL MIN.” hydraulic systems.
5 Schematics
Example:
Current path number that appears at the bottom
-2Y1 PROPORTIONAL VALVE
edge of each circuit diagram sheet, see section
“Circuit diagram”. The current path number helps to
locate electrical components in the circuit dia-
grams.
Example
-2K1 is located on sheet 50, column 5 in the cir-

cuit diagram matching to the list of electrical
components shown in the figure above.
6 Location
The location is the approximate position on the

machine in which the electrical component is in-
stalled. Fig. 4 Figure spare parts list - 642898
Example:
The relay -2K1 is located in the switch cabinet.
Fig. 5 Data spare parts list - 642899

7 Group
The group number of the component might be

used as cross reference to the spare parts list if the
part in question is associated with the electrical
system but is part of another assembly group.
Example:
For the valve -2Y1, the group number is 23.217

in the figure below.
3721501en - (01) Page 9.2 - 5

IMPORTANT: The arrow indicates a reference to a

9.2.4 Circuit diagram different page of the circuit diagram. Physically on
the machine, the shown connection of the refer-
The circuit diagram (current flow diagram) is a ence might be a cable of 5 cm length.
representation of the electrical circuits of the ma-
chine in all their details.
The diagram shows for all electrical supplies and
components:
• The function
• The way they are connected
The circuit diagram comprises several DIN A4

sheets arranged in function groups.
All components are shown in the de-energized
state (i.e. no current flowing) and without any actu-
ating elements acting.
The electrical supplies and components are identi-

fied by the spare parts number and indicated by
symbols according to the DIN standards 40 700, 40
703, 40 708 and 40 711 to 40 716. Fig. 7 References - 642645
Each page is divided into 0 – 9 columns or current The information included in the reference is:
paths with a description below each current path
(2).
Each page has a page number or “Blatt Sheet”

located in the bottom right corner (3). On the bot-
tom left corner is the machine model to which the
electrical drawing applies (1).
Fig. 8 Reference information - 642646
Fig. 6 Circuit diagram - 642652
If electric connections are separated on two differ-

ent pages references will be used.
The reference is indicated by the arrow in the fig-
ure.
Page 9.2 - 6 3721501en - (01)

Current path
The current paths run from positive to negative.

The numbers given at the right-hand side, along-
side the main horizontal paths, stand for:
Fig. 11 Relays in the circuit diagram - 642892
The location of the contact is stated below the coil

at the bottom of the page.
Fig. 9 Current path - 642653
1 30: Positive (unswitched)

2 15: Positive (key switched)
3 VIQ: Positive (deenergized by use of
Emergency stop) Fig. 12 Location of the contact - 642650
4 31: Negative (unswitched)
The location of the coil is indicated directly below
the relay contact.
Relays
Basically, the two relay types (1) and (2) are used.
Fig. 13 Location of the coil - 642649
Numbers on the contact points of relays or switch

contacts are exactly as to be found on the actual
component.
Fig. 10 Relay types - 642651
Relays that have closer, opener or changer con-
tacts in other current paths have an indication (un-
In general, the coil and the contact of the relay are der the current path for the energizing coil) as to
placed on different pages of the circuit diagram. the current path in which the contacts are to be
found.
3721501en - (01) Page 9.2 - 7

9.2.5 Connection tables - terminal

Collector terminal points strips
Collector terminal points (open circles) are coded
with the identification of the relevant terminal strip The "Connection tables - terminal strips" show the
or plug connection. See section "Connection table connections between electrical components. They
terminal strips" and section "Connection table - are exact illustrations of the terminal strips as fitted
plug connections". in the machine. The key to the circuit diagram
gives the exact location of the various terminal
strips.
The connection tables make it possible to locate
Example: the cable connections of a particular component
without checking the continuity.
The line has a discon-
necting point on termi- The following figures show
nal strip -X1, terminal • a part of the X1 terminal strip in the X1 switch
No.6 cabinet
• the related excerpt of the X1 switch cabinet
layout
Cable cross section • the related connection table
Figures alongside current paths indicate the cable

cross section.
Example:
Cable cross section =

10 mm²
Cable colour coding Fig. 14 X1 terminal strip - 642882
Combinations of letters alongside the current path

indicate the cable colour coding according to DIN
or ISO.
Example:
bl or BL = blue
br or BN = brown
ge or YE = yellow
gn or GN = green
gr or GY = grey
rt or RD = red sw
sw or BK = black
vi or VT = violet
ws or WH = white
Page 9.2 - 8 3721501en - (01)

The table includes the following items:
• End points (targets)
• Bridges (jumpers)
• Terminal No.
• Type of terminal
• Cable cross section
• Potential
• End points (targets)
End point
The end point numbers serve in the location of the

contact point of a specific terminal. They state the
receiver and actual connection point.
End point 1 is always located at the bottom side or
where the locking bracket is (see arrow).
Fig. 15 X1 layout - 642883
Fig. 17 End point numbers - 642900
Example:
In the connection table shown in the figure, end

point number 3 of terminal No. 61 indicates that
this line from terminal No. 61 is related to the cou-
pling relay -4K4.
The cables have tagged sleeves with the appropri-

ate end point number.
Fig. 16 X1 connection table - 643140
3721501en - (01) Page 9.2 - 9

Bridges
If terminal points need to be extended, the relevant

terminals are interconnected with bridges (jump-
ers). Bridges are indicated by a yellow jumper bar.
Fig. 18 Tagged sleeves - 642884
This makes re-connection easy (and accurate) if

several cables have been disconnected at the
same time (e.g. during trouble-shooting).
Two types of terminal strips with red indicator LED Fig. 21 Bridges - 642887
are used.
• Type 1: The LED is lighting if the signal is Terminal No.

+24V.
All terminals on a particular strip are listed here.
The numbers are also to be found on the strip (in
switch box).
Type of terminal
This column contains the terminal coding as used

by the manufacturer.
Cable cross section
This column indicates the cross section of the in-

Fig. 19 High in Signal = +24 V - 642885
coming/outgoing cable.
Type 2: The LED is lighting if the signal is 0V.

Potential
This column indicates the voltage potential of the

relevant terminal point. No entry means that the
potential is 24 Volt.
Fig. 20 High in Signal = +0 V - 642886
Page 9.2 - 10 3721501en - (01)

Cross section of cable (mm²)

9.2.6 Connection tables – plug con- Here the cross section of the incoming /outgoing
nections cable is indicated in mm².
The "Connection table - plug connections" gives

the pin and sleeve connections of multi-pole plug No.
connections.
This number is that of the relevant pin or sleeve
The table includes the following items: connection. The numbers are stamped into the
plug housing.
• End point - sleeve connections
• Cross section of cable (mm²) End point
• No. of pin or sleeve End point No. of the plug (pin connections).
• End point - pin connections
• Code
Fig. 22 Plug connections - 642893
End point (target)
This is the number of the end point of the sockets

(sleeve connections).
Code
The code indicates the specific position in the plug

connection.
3721501en - (01) Page 9.2 - 11

9.2.7 Schematic symbols
Fig. 23 Schematic symbols 1 - 642894
Page 9.2 - 12 3721501en - (01)

3721501en - (01) Page 9.2 - 13

Page 9.2 - 14 3721501en - (01)

9.3 CONTROL AND MONITORING PLATFORM (CAMP)
9.3 Control And Monitoring Plat- 1 Hand Levers and Pedals

form (CAMP) 2 Can Bus 2
3 Board Control System (BCS)
4 Can Bus 1
9.3.1 Introduction to CAMP 5 Drive Controller Left Hand (DCLH)
6 SAE J1939 Left Hand
The electronic CAMP system ensures the control 7 Left Engine ECM
and monitoring of most of the electrical and hy- 8 Auxiliary System (AS)
draulic functions of the excavator. 9 Right Engine ECM
10 SAE J1939 Right Hand
11 Drive Controller Right Hand (DCRH)
9.3.2 Overview of the individual 12 ICN-V
control systems 13 Can Bus 3
14 Servo Controller (SC)
Overall, the CAMP system comprises the CAMP-
related control systems and main components as
well as the 24 Volt electric system. 9.3.3 Location of the main
components
Basically, the CAMP system consists of the follow-
ing four control systems:
 Servo Control System (SCS), sub-divided into The following figure shows the location of the main
the Servo Controller (SC) and the ICN-V components of the CAMP system. Dotted lines
 Auxiliary System (AS) indicate that the components are located beneath
 Drive Controller Left Hand (DCLH) the driver’s cabin.
 Drive Controller Right Hand (DCRH)
Further main components of the CAMP system

are:
 Board Control System (BCS)
 Hand Levers
 Pedals
The control systems and the further main compo-

nents of the CAMP system are interconnected via
a controller area network (CAN) bus system.
The following figure illustrates the controller setup.
Fig. 1 CAMP main components - 642639
3721490en - (01) Page 9.3 - 1

Fig. 2 Location of the main components - 642656
1 Servo Control System (SCS)

2 Auxiliary System (AS)
3 Drive Controller Left Hand (DCLH)
6 Hand Levers
7 Pedals
Page 9.3 - 2 3721490en - (01)

9.3.4 Servo Control System (SCS)
The desired working movements are detected by

microcontrollers. These microcontrollers perma-
nently observe the position of the hand levers and
pedals. As soon as the microprocessors detect
movement of the hand levers and pedals, the cor-
responding signals are transmitted to the electronic
units. These units activate the drive control in order
to provide the hydraulic energy needed for work-
ing. Only then do they activate the electrohydraulic
valves which control the execution of the working
movements.
The SCS is responsible for:
 Coordinating the machine controls Fig. 4 ICN-V - 642897
 Controlling the parking brakes
 Controlling the track tensioning system -2A2 Devise designation servo controller
 Controlling the logic valve -X202 Connector of the ICN-V
9.3.4.1 Introduction with basic functions The ICN-V is the subunit for the SC. It is a rugged,
compact CAN-node-module which is, among oth-
The SCS is located in the X1 Electrical Cabinet ers, used to control hydraulic components. The
(Switch Cabinet) in the excavator’s cab module. ICN-V thus allows usage in decentralized control
The SCS consists of the Servo Controller (SC) concepts.
itself and the so-called ICN-V.
The SCS can be considered as the central control
node in the CAMP system. It coordinates the ma-
chine controls. Furthermore, the SCS is responsi-
ble for controlling the parking brakes, the track
tensioning system, and the logic valve. The joy-
sticks and pedals are connected to the SCS.
9.3.4.2 Technical data
Each CPU module of the SC provides

 12 digital inputs
 8 analogue inputs (0 – 10 V or 0 – 20 mA)
 8 outputs (digital signal or pulse-width-
Fig. 3 Servo controller - 642660
modulated, PWM, signal)
 1 analogue output (0 – 20 mA).
CPU1 First CPU module  Degree of protection: IP66K IP-class acc. to

CPU2 Second CPU module DIN 40050
-2A1 Devise designation servo controller  Operating ambient temperature:
-X200 Connector of CPU1 -40 °C to +80 °C (-40 °F to +176 °F)
-X201 Connector of CPU2 (load-dependent)
 Power supply
The SC consists of two individual CPU modules.
 12 V/24 V nominal voltage
Both modules are equipped with a 16-bit microcon-
troller and a CAN-controller. The modules are con-  8 V–32 V DC on-board voltage
nected via an internal serial interface.  supply failure detection
Due to its architecture, the SC is not interchange-  load-dump-protection
able with the Drive Controllers or the Auxiliary  separate battery connection for back-up
Controller. supply of the clock
3721490en - (01) Page 9.3 - 3

The ICN-V provides

 8 outputs (PWM signal)
 Operating voltage: 8…32V

 Operating temperature:
-40°C…+85°C (-40 °F to +185 °F)
 Environmental protection according to IP66k
9.3.4.3 Terminal plan (connectors)
Electric components that are connected to the

SCS belong to group number 2 in the circuit dia-
gram. Examples would be -2K1, -2Y1, -2S4, or -
2H1.
 Open the clamp on the upper side of the CPU

module (1).
 Remove the connector by moving it up and
turning it right (2).
 Remove the connector on the lower side of the
Fig. 5 Connector controller- 642904a controller in the same way.
A Position of the connector clamp

B Position of the connector cable (when
connected)
9.3.4.5 Installation and removal
Servo controller:
Preparing the installation:

 Switch off the engines.
 Switch off the ignition.
 Switch off the battery main switch and secure it Fig. 7 Screw on the lower side - 642901
with a padlock against unintended restart.
 Loosen the screws on the lower side of the
Removing the controller: controller. Use a Phillips screwdriver (PH2) and
a wrench (8).
 Carefully hold the controller while removing the
screws on the upper side of the controller.
 Remove the controller by lifting it up and out.
Installing the controller:

 Hold the controller so that the label faces to you
and rotate it such that connector –X201 is on
the upper side.
 Slide the controller into mounting position and
install it in reverse order of the de-installation.
Page 9.3 - 4 3721490en - (01)

Completing the installation:

 Restart the machine.
 Open the “Servo Controller” menu in the “Ser-
vice” menu. Make sure that the serial number of
the new controller is displayed correctly in tab
“History”.
ICN-V controller:

 Switch off the battery main switch and secure it
against unintended restart.
Removing the controller:
Fig. 9 Screws on the upper side - 642642

Fig. 8 ICN-V controller - 642643
 Open the clamp on the lower side of the con-

troller (1).
turning it right (2).
controller. Use a Phillips screwdriver (PH2) and
a wrench (8). Fig. 10 Open the controller - 642902
 Open the controller by removing the six screws

on the side of connector –X202. Use a torx
wrench (TTX20).
3721490en - (01) Page 9.3 - 5

After having exchanged a defective controller, the

BCS compares the factory-set parameter values
(default values) of the new controller with the pa-
rameter values that were last saved for the old
defective controller. In the event of a mismatch, a
notification is displayed at the BCS screen.
You are then asked to confirm if either the last-
saved values or the default values are to be used.
 Carefully slide the board out of device.

 Set the dip switch as follows:
Up: 2, 8, 9
Down: 1, 3, 4, 5, 6, 7, 10
 Close the controller in reverse order of the
opening.
the lower side.

the new controller is displayed correctly in tab
“History”.
During the general commissioning of the unit, the

factory settings (parameters) will be saved.
If a controller or the CPU1/2 gets exchanged and
internal parameters of the new controller or
CPU1/2 do not match with the factory/old controller
or CPU1/2 settings, a fault message is triggered.
9.3.4.6 Settings and adjustments
Via the BCS menu Servo Controller, you can

read out the current settings for the SCS. Further-
more, you can adjust the parameters for the SC
and the ICN-V according to the actual require-
ments.
Via the BCS menu Controller Config (menu tabs
“Servo Contr. {1…3}”), you have extended possibil-
ities to configure both the SC and the ICN-V ac-
cording to the actual requirements.
You can – and are supposed to – save any change
in the controller configuration.
Page 9.3 - 6 3721490en - (01)

9.3.5 Auxiliary System (AS)  Degree of protection: IP66K IP-class acc. to

DIN 40050
 Operating ambient temperature:
9.3.5.1 Introduction with basic functions
-40 °C to +80 °C (-40 °F to +176 °F)
(load-dependent)
The AS is located in the X1 Electrical Cabinet
(Switch Cabinet) in the excavator’s cab module.  Power supply
The AS consists of the Auxiliary Controller (AC).  12 V/24 V nominal voltage
 8 V–32 V DC on-board voltage
 supply failure detection
 load-dump-protection
 separate battery connection for back-up
supply of the clock
Electric components that are connected to the AS

belong to group number 5 in the circuit diagram.
Examples would be -5B2, -5H23, -5B4, or -5K4.
Fig. 12 Auxiliary controller - 642657
CPU CPU module

I/O I/O module
-5A1 Devise designation auxiliary controller
-X500 Connector of CPU module Fig. 13 Connector controller- 642904a
-X501 Connector of I/O module
The AC consists of a CPU module and an I/O A Position of the connector clamp
module. Both modules are equipped with a 16-bit B Position of the connector cable (when
microcontroller and a CAN-controller. The modules connected)
are connected via an internal serial interface.
Due to its architecture, the AC is fully interchange-
able with the drive controllers (DC). The hardware
setup is identical, but the software would have to
be changed.
The AS controls the boarding and maintenance

lights as well as the lubrication system.
The CPU module of the AC provides

The I/O module of the AC provides

 8 outputs (digital)
 4 analogue outputs (0 – 20 mA)
3721490en - (01) Page 9.3 - 7

9.3.5.4 Installation and removal 9.3.5.5 Settings and adjustments
Preparing the installation: Via the BCS menu Auxiliary Controller, you can
 Switch off the engines. read out the current settings for the AC. Further-
 Switch off the ignition. more, you can adjust the parameters for the AC
according to the actual requirements.
against unintended restart. Via the BCS menu Controller Config (menu tab
“Aux. Contr.”), you have extended possibilities to
Removing the controller: configure the AC according to the actual require-
ments.

Fig. 14 Auxiliary controller - 642641
 Open the clamp on the upper side of the con-

troller.
turning it left.
 Remove the connector on the lower side of the
controller in the same way.
controller. Use a Phillips screwdriver (PH2) and
a wrench (8).

the upper side.

 Open the “Auxiliary Controller” menu in the
“Service” menu. Make sure that the serial num-
ber of the new controller is displayed correctly
in tab “History”.
Page 9.3 - 8 3721490en - (01)


9.3.6 Drive Controller Left Hand
(DCLH) The CPU module of the DCLH provides
The DCLH is mounted close to the pumps of the
left engine.
The I/O module of the DCLH provides
 4 outputs (analogue, 0 – 20 mA)
 Degree of protection: IP66K IP-class acc. to

DIN 40050
-40 °C to +80 °C (-40 °F to +176 °F)
(load-dependent)
 Power supply
Fig. 15 Drive controller left hand controller - 642658  8 V–32 V DC on-board voltage
CPU CPU module  load-dump-protection
I/O I/O module  separate battery connection for back-up
-3A1 Devise designation servo controller supply of the clock
-X300 Connector of CPU module
-X301 Connector of I/O module
The DCLH consists of a CPU module and an I/O
module. Both modules are equipped with a 16-bit Electric components that are connected to the
microcontroller and a CAN-controller. The modules DCLH belong to group number 3 in the circuit dia-
are connected via an internal serial interface. gram. Examples would be -3K1, -3B9, -3Y3, or
The DCLH is fully interchangeable with the Drive -3F9.
Controller Right Hand (DCRH) because both
hardware and software are identical.
Furthermore, due to its architecture, DCLH is fully
interchangeable with the AC. In this case, how-
ever, the hardware setup is identical, but the soft-
ware would have to be changed.
The DCLH is the independent controller for the left-

engine power train. It controls the left engine’s start
Fig. 16 Connector controller- 642904a
and stop functions, the flow of the main pumps,
and the hydraulic oil cooling. Furthermore, the
DCLH controls the automatic reduction of the left A Position of the connector clamp
engine’s speed (so-called “rev reduction”). B Position of the connector cable (when
The DCLH’s modules collect all machine values connected)
(pressures, contaminations, temperatures, etc.). If
any threshold value is exceeded, the DCLH will
send corresponding error messages, which are 9.3.6.4 Data exchange
then displayed at the BCS screen.
The engine is connected to the drive controller via
a SAE J1939 BUS. This interface is used to read
data generated by the sensors of the engines.
3721490en - (01) Page 9.3 - 9

Data sent by the sensors are evaluated by the  Slide the controller into mounting position and
CAMP system and displayed on the BCS screen. install it in reverse order of the de-installation.
9.3.6.5 Installation and removal Completing the installation:

Preparing the installation:  Open the “Servo Controller” menu in the “Ser-
 Switch off the engines. vice” menu. Make sure that the serial number of
 Switch off the ignition. the new controller is displayed correctly in tab
 Switch off the battery main switch and secure it “History”.
Via the BCS menu LH Engine Controller, you can
read out the current settings for the DCLH. Fur-
thermore, you can adjust the parameters for the
DCLH according to the actual requirements.
Via the BCS menu Controller Config (menu tab
“Eng. Cont. LH”), you have extended possibilities
to configure the DCLH according to the actual re-
quirements.

Fig. 17 Removing the controller - 642913
 Open the clamp on the left side of the control-

ler.
turning it left.
 Remove the connector on the right side of the
controller accordingly.
 Loosen the screws on the left side of the con-
troller. Use a Phillips screwdriver (PH2).
screws on the right side of the controller.
 Remove the controller by sliding it to the right
and lifting it out.

the left side.
Page 9.3 - 10 3721490en - (01)

9.3.7 Drive Controller Right Hand The I/O module of the DCRH provides
(DCRH)  14 digital inputs
 4 outputs (analogue, 0 – 20 mA)
The DCRH is mounted close by the pumps of the
 Degree of protection: IP66K IP-class acc. to
right engine.
DIN 40050
-40 °C to +80 °C (-40 °F to +176 °F) (load-
dependent)
 Power supply
 8 V–32 V DC on-board voltage
 load-dump-protection
 separate battery connection for back-up
supply of the clock

Fig. 18 Drive controller RH - 642659
Electric components that are connected to the
DCRH belong to group number 4 in the circuit dia-
The DCRH consists of a CPU module and an I/O gram. Examples would be -4K3, -4B9, -4Y3, or
module. Both modules are equipped with a 16-bit -4F3.
microcontroller and a CAN-controller. The modules
are connected via an internal serial interface.
The DCRH is fully interchangeable with the DCLH
because both hardware and software are identical.
Furthermore, due to its architecture, DCRH is fully
interchangeable with the AC. In this case, how-
ever, the hardware setup is identical, but the soft-
ware would have to be changed.
Fig. 19 Connector controller- 642904a
The DCRH is the independent controller for the
right-engine power train. It controls the right en-
gine’s start and stop functions, the flow of the main A Position of the connector clamp
pumps, and the hydraulic oil cooling. Furthermore, B Position of the connector cable (when
the DCRH controls the automatic reduction of the connected)
right engine’s speed (so-called “rev reduction”).
The DCRH’s modules collect all machine values
(pressures, contaminations, temperatures, etc.). If 9.3.7.4 Data exchange
any threshold value is exceeded, the DCRH will
send corresponding error messages, which are The engine is connected to the drive controller via
then displayed at the BCS screen. a SAE J1939 BUS. This interface is used to read
data generated by the sensors of the engines.
9.3.7.2 Technical data Data sent by the sensors are evaluated by the
CAMP system and displayed on the BCS screen.
The CPU module of the DCRH provides
 12 digital inputs 9.3.7.5 Installation and removal
 8 outputs (digital signal or pulse-width- Preparing the installation:
modulated, PWM, signal)  Switch off the engines.
 1 analogue output (0 – 20 mA).  Switch off the ignition.
3721490en - (01) Page 9.3 - 11

 Switch off the battery main switch and secure it the new controller is displayed correctly in tab
against unintended restart. “History”.
Via the BCS menu RH Engine Controller, you

can read out the current settings for the DCRH.
Furthermore, you can adjust the parameters for the
DCRH according to the actual requirements.
Via the BCS menu Controller Config (menu tab
“Eng. Cont. RH”), you have extended possibilities
to configure the DCRH according to the actual
requirements.

Fig. 20 Removing the controller - 642914
 Open the clamp on the left side of the control-

ler.
turning it left.
 Remove the connector on the right side of the
controller accordingly.
 Loosen the screws on the left side of the con-
troller. Use a Phillips screwdriver (PH2).
screws on the right side of the controller.
 Remove the controller by sliding it to the right
and lifting it out.

the left side.

Page 9.3 - 12 3721490en - (01)

9.3.8 Board Control System (BCS)
The BCS is a micro-processor-controlled system

for the acquisition and processing of measuring
data. Thus, the BCS is the man-machine interface
(MMI) of the CAMP system. The BCS is responsi-
ble for:
 Collecting data of the excavator operating con-
ditions
 Evaluating, storing and displaying these data to Fig. 21 BCS display screen - 642915
the excavator driver
 Providing error memory and troubleshooting For further information with respect to the BCS, for
steps example regarding the membrane keypad located
on the front side of the housing, please refer to the
The BCS has two primary interfaces: ANNEX of the “Operating Instructions” for the re-
 CAN bus interface to the CAMP control sys- spective hydraulic excavator.
tems and other CAMP main components
 USB interface that allows both transferring
stored data and updating software
The yellow LED flashes if the temperature inside
In the BCS, the actually measured values from the
the device lies outside the permissible range. The
sensors and transducers installed in the excavator
automatic heating system is then active. The BCS
are compared to the predefined reference values.
screen lights up as soon as the temperature is
Inadmissible deviations are indicated as fault mes-
within the operating range.
sages on the respective display screen. Sensor or
transducer defects or defective connecting cables
are detected and indicated by plain-text messages.  Operating ambient temperature:
Data from the engine electronics are acquired, -05 °C to +60 °C (-23 °F to +140 °F)
processed and displayed in the same way. Critical  Weight: 7.5 kg
states of operation are brought to the driver's at-  Power supply: 24 - 110 V DC ± 40%
tention by means of optical and acoustic warning
signals. 9.3.8.3 Terminal plan (connectors)
The display screen of the BCS is a touch-screen; Electric components that are connected to the
i. e. the surface is sensitive to touch. This feature BCS belong to group number 6 in the circuit dia-
supports the excavator driver or the service techni- gram. Examples would be 6A1 or 6A2.
cian in navigating through the menus of the BCS
software.
The following figure shows the principle appear-
ance of the BCS display screen.
3721490en - (01) Page 9.3 - 13

9.3.8.4 Installation and removal
BCS monitor

Deciding on the BCS software to be used after the

update:
 If the BCS memory card installed in the old
monitor is to be used after the update, remove
the memory card before the BCS monitor re-
placement, see replacing the memory card.
 If the new memory card enclosed to the new
monitor is to be used, proceed with “Removing
the BCS monitor”.
Removing the BCS monitor:
Fig. 23 Monitor connectors - 642654
 Open the control column and disconnect the

following connectors:
 USB (1)
 Power connector (2)
 Remote System Cat5 LAN (3, if applicable)
 Device cable (4)
Fig. 22 Open the control column - 642655
 Remove the two screws of the control column.

Use a socket head wrench (5/6).
Page 9.3 - 14 3721490en - (01)

Fig. 24 Open the monitor - 642916
Fig. 26 Adjusting the monitor - 642918

 Remove the screws on the back of the monitor.
 Make sure that the black adjusting screw is

correctly positioned in the notch (see circle).
Fasten the screw so that the monitor can be tilt
comfortably.
 Complete the installation in reverse order of the
de-installation.

Installing the memory card:

 If the BCS memory card installed in the old
monitor is to be used after the update, install
this memory card in the new monitor, see re-
placing the memory card.
 If the new memory card enclosed to the new
Fig. 25 Remove the monitor - 642917 monitor is to be used, write the data from the
controllers to the memory card.
 While carefully holding the monitor, remove the
screws in the black brackets (1). BCS memory card
 Move the monitor toward you and lift it out (2).
 Carefully slide the cables out of the cable duct. Preparing the installation:
Installing the monitor:  Switch off the ignition.
 Insert the monitor cables in the cable duct.  Switch off the battery main switch and secure it
 Bring the monitor in mounting position. against unintended restart.
 Install the black brackets.
3721490en - (01) Page 9.3 - 15

Removing the memory card:
Fig. 27 Open the monitor - 642919
 Remove the two screws on top of the BCS

monitor.
Fig. 28 Removing the memory card- 642920
 Remove the memory card.
Installing the memory card:

 Install the memory card in reverse order of the
de-installation.

Via the brightness buttons (+ / -) in the BCS menu

Service, you can adjust the brightness of the BCS
screen according to the actual situation.
9.3.8.6 Changing the program
Via the “BCS Update” menu (service level 2 pass-

word required), you can change the software ver-
sion of the BCS, i. e. make an update.
Page 9.3 - 16 3721490en - (01)

9.4 COMMUNICATION AND CONTROL LOOPS WITHIN CAMP
9.4.1.2 Technical data of the CAN bus

9.4 Communication and control
loops within CAMP The bit rate of CAN signals is 250 kbit/s on CAN
bus 1, 2, and 3. On SAE J1939, the bit rate is
9.4.1 Controller Area Network (CAN) 125 kbit/s.
Each CAN bus is connected with two 120 Ω termi-

CAN is a message-based communication protocol, nating resistors. The terminating resistors are con-
designed specifically for automotive applications. nected in parallel between CAN-High (white cable)
In 1983, CAN was developed by Robert Bosch and CAN-Low (blue cable).
GmbH to reduce the cable harness on vehicles.
1 2 3 4 5 6 7
9.4.1.1 CAN bus systems
The following figure shows an overview of the dif-

ferent CAN bus systems, CAN bus 1 and CAN
bus 2.
642634
Fig. 2 CAN bus system - 642634
1 Terminating resistor in the BCS; 120Ω

2 CAN – participant 1
3 CAN high
4 CAN low
6 CAN – participant …
Fig. 1 CAMP main components - 642639
7 Terminating resistor at the drive control
system; 120Ω
1 Hand Levers and Pedals The following figure shows the pin assignment of a
2 Can Bus 2 CAN bus connector.
4 Can Bus 1
5 Drive Controller Left Hand (DCLH)
6 SAE J1939 Left Hand
7 Left Engine ECM
8 Auxiliary System (AS)
9 Right Engine ECM
10 SAE J1939 Right Hand
12 ICN-V
13 Can Bus 3
14 Servo Controller (SC)
The drive controller and the respective engine

communicate via the SAE J1939 protocol over
another CAN bus. The bus systems on either en-
gine power train are identical, except that cables
and connectors on the left power train are marked
with red marks whereas blue marks are used on
the right power train.
3721491en - (01) Page 9.4 - 1

 The resistance between each of the CAN bus

lines (CAN-High or CAN-Low) and ground (ma-
chine chassis) is very high [MΩ], i. e. open-
circuit operation.
Please note: For resistance check, ignition has
to be off!
1 2 3 4 5 6 7
Fig. 3 CAN bus connector - 642640
1 Shield (metal cable)

2 + 24 VDC (red cable)
3 0 VDC (black cable)
4 CAN-High (white cable)
5 CAN-Low (blue cable)
8 8
9.4.1.3 CAN bus troubleshooting 642638
Fig. 5 Resistance CAN bus line / ground - 642638
In a correctly working CAN bus system on the ex-
cavator, the following rules apply:
 The total resistant of each CAN bus system on 1 Terminating resistor in the BCS; 120Ω
the excavator is about 60 Ω. 2 CAN – participant 1
Please note: For resistance check, ignition has 3 CAN high
to be off! 4 CAN low
1 2 3 4 5 6 CAN – participant …
6 7
system; 120Ω
8 Ground
642636
Fig. 4 Total resistant of each CAN bus - 642636

3 CAN high
4 CAN low
system; 120Ω
Page 9.4 - 2 3721491en - (01)

Possible error cases for the CAN bus are: 6 CAN – participant …
 One resistor is defective or missing. 7 Terminating resistor at the drive control
In this case, the total resistant of each CAN bus system; 120Ω
system on the excavator is about 120 Ω.
1 2 3 4 5 6 7 Please Note: For resistance check, ignition has to

be off!
9.4.2 Electronic Hydraulic Servo

Control (EHSC)
CAN_High
CAN_Low
Hand levers and pedals are the control units for
the EHSC. The desired operations are detected by
the hand levers and foot pedals and sent to the
Servo Control System (SCS). The components of
the SCS, the Servo Controller (SC) and the ICN-V,
642635 pass the information to the electro-hydraulic pro-
Fig. 6 Resistor missing - 642635 portional valves in the control valve assembly via
PWM signals.
3 CAN high
4 CAN low
system; 120Ω
 Three resistors are used in the CAN bus sys-

tem.
In this case, the total resistant of each CAN bus
system on the excavator is about 40 Ω.
Fig. 8 Overview EHSC - 642940
1 2 3 4 5 6 7
1 Hand levers and foot pedals
2 CAN Bus
3 Servo controller / ICN-V
4 Harness tree
5 Switch cabinet X24
6 Proportional valve current 70 – 650 mA;
maximum value might be reduced for
specific functions such as clam close.
7 Proportional valve
642633 Depending on the positions of the hand lever and

Fig. 7 Three resistors - 642633
foot pedal, the main pump flow is adjusted. Load-
limit regulation monitors the resulting load of the
engine and avoids overload situations.
2 CAN – participant 1 For detailed information see chapter “Hydraulic
3 CAN high System”.
4 CAN low
3721491en - (01) Page 9.4 - 3

9.4.2.1 Proportional valve block o Boom FS lower

o Rod Side BH
The servo controller communicates with the pro- o Rod Side FS
portional valve block via Pulse-Width Modulation 5: -2Y4 Float Valve Boom
(PWM) signals. o Float Valve Boom
o Float Valve BH
o Float Valve FS
6: -2Y5 Boom BH hoist
o Boom FS hoist
o Piston Side BH
o Piston Side FS
7: -2Y6 Stick BH in
o Stick FS in
o Piston Side BH
o Rod Side FS
8: -2Y16 Swing right BH
o Swing right FS
o Bal. Valve BH
o Bal. Valve FS
9: -2Y15 Swing left BH
o Swing left FS
Fig. 9 Proportional valve control - 642941 o Bal. Valve BH
o Bal. Valve FS
1 Controller 10: -2Y8 Stick BH out
2 Junction box o Stick FS out
3 Wire o Rod Side BH
4 Proportional valve o Piston Side FS
11: -2Y7 BH no Function
o Stick FS Float Valve
The functions and valves of the proportional valve o BH no Function
block are assigned as shown in the figure below. o Float Valve FS
12: -2Y14 Travel left for.
o Travel left for.
o Travel Valve
o Travel Valve
13: -2Y13 Travel left backward
o Travel left backward
o Travel Valve
o Travel Valve
14: -2Y12 Travel right for.
o Travel right for.
o Travel Valve
o Travel Valve
15: -2Y11 Travel right backward
o Travel right backward
Fig. 10 Proportional valve block - 642942 o Travel Valve
o Travel Valve
1: -2Y18 Switch-on Valve Servo on
o Clam FS close
2: -2Y1 Bucket BH fill
o BH no Function
o Bucket FS fill curl in
o Piston Side FS
o Piston Side BH
o Piston Side FS
o Clam FS open
3: -2Y2 Bucket BH empty
o BH no Function
o Bucket FS empty curl out
o Rod Side FS
o Rod Side BH
18: -2Y20 Switch-on Valve Track Tension
o Rod Side FS
4: -2Y3 Boom BH lower
Page 9.4 - 4 3721491en - (01)

9.4.3 Hand Levers and Pedals
For information on navigating the machine via

hand levers and control pedals see “Operating
Instructions”.
9.4.3.1 Installing and removing

with a padlock against unintended restart.
Removing the hand lever:
Fig. 12 Hand lever connector - 642944
 Disconnect the cable from the hand lever.

 Install it in reverse order of the de-installation.

9.4.3.2 Settings
Fig. 11 Removing the hand lever - 642943
 Remove the four screws (see circles).

 Carefully move the hand lever up and out (2).
Fig. 13 Hand lever settings - 642945
Address Table Hand Lever / Foot Pedals
Control Unit Address

Left Hand Lever 0
Right Hand Lever 1
Foot Pedal Left 2
Foot Pedal Middle 3
Foot Pedal Right 4
3721491en - (01) Page 9.4 - 5

9.4.4 Pump flow regulation
Each drive controller, DCLH and DCRH, regulates

the pump flow of the respective engine power train.
By regulating the pump flow, the drive controller
prevents overloading the engine.
The pump flow regulation is required as the exca-
vator’s maximum hydraulic power is larger than the
engine’s maximum power.
The regulation works as follows:

 The drive controller monitors the engine’s RPM.
 If the engine’s RPM is too low, the drive control-
ler initiates a reduction of the amount of oil in
the main pump hydraulic circuit.
 As a consequence of this reduction, the en- Fig. 14 Pump flow regulation - 642946
gine’s RPM will rise again.
 Then, the drive controller initiates an increase
of the amount of oil in the main pump hydraulic 1 Acceleration 0 - 100%; hand levers and
circuit. foot pedals
2 Signal via CAN bus
For detailed information on the pump flow regula- 3 Proportional valve block
tion mechanism, see chapter “Hydraulic system”. 4 Servo controller
5 Pump requirements from servo controller
via CAN bus
9.4.4.1 Overview pump control 6 Engine load
7 Engine temperature
By acceleration of hand levers and/or foot pedals 8 Hydraulic oil temperature
(1) a signal is generated that is sent to the servo 9 Intake manifold temperature
controller (4) via CAN-Bus. 10 Drive controller
Based on this signal, the servo controller sends the 11 Pump control current (150 – 850mA)
pump requirements (5) via CAN bus to the drive 12 Main pump (variable angle 0 – 15°)
controller (10). 13 Pump control pressure (5 - 43bar)
The drive controller sends the pump control current 14 Servo pressure
(11) to the proportional valve. Based on this cur-
rent, the proportional valve generates the required
pump control pressure (13) to change the angle of
the main pump (12). This causes the change of 9.4.4.2 Data transfer
their oil delivery rate.
The SAE J1939 BUS transfers data between the
For controlling the main pumps, the drive controller drive controller and the engine ECM such as:
takes into account:  engine oil pressure
 Pump requirements from servo controller  speed signal
 engine load  cooling water temperature
 engine temperature  speed adjusting signal
 hydraulic oil temperature
 intake manifold temperature 9.4.4.3 Reducing the Pump Control current /
pressure
The Pump Control current / pressure is reduced if

one of the following conditions is true:
 intake manifold temperature exceeds 83 °C
 engine coolant temperature exceeds 100 °C
 hydraulic oil temperature exceeds 80 °C
Page 9.4 - 6 3721491en - (01)

Fig. 16 Proportional valve control - 642948

Fig. 15 Reducing PMS current / pressure - 642947
1 Sensor – Hydraulic oil temperature

1 Acceleration 0 - 100%; hand levers and
2 Drive controller
foot pedals
3 Variable displacement oil cooling fan
2 Servo controller
pump
3 Intake manifold temperature exceeds
4 Fan oil cooling system
83 °C
5 Hydraulic oil temperature
4 Engine coolant temperature exceeds
6 High speed level fan (60°C)
100 °C
7 Low speed level fan (50°C)
5 Hydraulic oil temperature exceeds
8 Controller output current 50 – 650 mA
80 °C
6 Drive controller
7 Valve
8 Pump requirements from servo controller 9.4.4.5 Overview engine cooling
via CAN bus
9 Signal via CAN bus drive controller The engine (1) sends the following information to
the drive controller (4) via SAE J1939 bus:
 engine coolant temperature
9.4.4.4 Overview hydraulic oil cooling  intake manifold temperature
The temperature of the hydraulic oil is monitored Based on the data received from the engine, the
by a temperature sensor (1). Based on the data drive controller triggers the engine cooling pump
received from the temperature sensors, the drive (5) to run the fan of the engine water cooler system
controller (2) triggers the oil cooling fan pump (3) (6).
to run the fan of the oil cooling fan system (4). Due to fail safe reasons, a low controller output
Due to fail safe reasons, a low controller output current (10) is equivalent to a high speed level of
current (8) is equivalent to a high speed level of the fan (8).
the fan (6).
3721491en - (01) Page 9.4 - 7

9.4.5 Lubrication system
The Auxiliary system controls the greasing system

and the boarding and maintenance lights.
For detailed information on the lubrication system

see chapter “Central lubrication system”.
9.4.5.1 Lubrication system upper carriage
The machine is equipped with a two-line lubrication

system (line A and B). The lines are lubricated
alternately.
Fig. 17 Overview Engine cooling - 642949
The following figure shows the basic components
that control the greasing system of the upper car-
1 Engine riage.
2 Engine coolant temperature via SAE
J1939
3 Intake manifold temperature via SAE
J1939
4 Drive controller
5 Variable displacement of engine cooling
pump
6 Fan engine cooler
7 Temperature
8 High speed level fan
o Blue: Engine coolant 99°C
o Magenta: Intake manifold 62°C
9 Low speed level fan

o Engine coolant 89°C
o Intake manifold 56°C
10 Controller output current
Fig. 18 Lubrication sensors - 642950
-5Y3 Unloader valve upper carriage

-5B6 Lube pressure monitoring upper carriage
-5Y1 On/Off Grease pump upper carriage
-5Y2 Switch over valve A-B upper carriage
-5B4 Contamination monitoring greasing
pump
The two sensors -5B2 and -5B3 (line A and B)

detect whether grease reaches the grease distribu-
tor at the stick as this grease distributor is in a
protected area and further away from the grease
control panel than any other grease distributor.
A lubrication cycle consists of lubrication in line A

and line B. The lubrication cycle has been com-
pleted properly if all of the following conditions are
true:
 Sensors -5B2 and -5B3 have detected that the
grease has reached the grease distributor.
Page 9.4 - 8 3721491en - (01)

 Sensor -5B6 has detected that the predefined If the grease pump starts to work, the pressure has
lubrication pressure has been reached. to reach the lower switch point pressure at the
pressure sensor -5B7 within a predefined time.
If the lower switch point pressure has been
reached, the superior switch point pressure has to
be reached within a predefined time. If the pres-
sure increases too slowly, a leakage might be the
reason.
If the superior switch point pressure is reached, the
lubrication is completed. The lubrication system is
switched off and the pressure has to fall to the
lower switch point pressure within a predefined
time.
Fig. 19 Proximity switch lubrication - 642951
A fault message is triggered as soon as the lubri-

cation process for one of the two lines exceeds the
maximum lubrication time.
The following figure explains the lubrication cycle.
Fig. 21 Lubrication cycle under carriage - 642953
9.4.6 Lights
The auxiliary controller controls all of the following:

 Lighting Operators Cab
 Lighting Ladder
 Maintenance Light
The time delay for the lighting of the ladder is op-

erator-configurable.
Fig. 20 Lubrication cycle upper carriage - 642952
9.4.5.2 Lubrication system of the under car-

riage
The lubrication system of the under carriage con-

sists of a single-line system. Grease is pressed
into the rollers.
3721491en - (01) Page 9.4 - 9

Page 9.4 - 10 3721491en - (01)

9.5 ELECTRIC COMPONENTS
9.5.1.1 Left engine

9.5 Electric Components
9.5.1 Location of components
The following figure provides an overview of basic

components on the superstructure.
Fig. 2 Location components left engine - 643502
Sensor ID Description
-3B7 Swing Pump Contamination Switch
-3B3 Main Pump Contamination Switch
Fig. 1 Location components superstructure - 643147 -3B6 Swing Pump Contamination Switch
-3B15 Swing Pump Temperature Switch

No. Description
1 Oil coolers -3B14 Swing Pump Temperature Switch
2 Gear boxes with hydraulic pumps –
right hand side -3B16 Gearbox Oil Return Pressure
3 Engine– right hand side Switch
4 Engine radiator with hydraulically
driven fan– right hand side -3B11 Gearbox Oil Temperature Sensor
5 Batteries
6 Hydraulic tank -3B2 Main Pump Contamination Switch
7 Engine radiator with hydraulically
driven fan – left hand side -3B12 Swing Charge Pump Pressure
8 Engine – left hand side Sensor
9 Gear boxes with hydraulic pumps –
left hand side
10 Swing drives No. Description
11 Auxiliary Seat 1 Tank Level Sensor left
12 Operator’s seat 2 Hydraulic Oil
13 Left hand lever Circulation Pump
14 Foot pedals
15 Right hand lever
16 BCS Tower
17 Rotary distributor
3721504en - (00) Page 9.5 - 1

9.5.1.2 Right engine 9.5.1.3 Hydraulic oil tank
Fig. 3 Location components right engine - 643503
-4B16 Gearbox Oil Return Pressure Fig. 4 Location components hydraulic tank - 643240
Switch
-4B8 Gearbox Oil Contamination Switch Sensor ID Description

-5B1 Hydraulic Oil Level Maximum
-4B11 Gearbox Oil Temperature Sensor -4B22 Pressure Sensor Main Pump 3
-3B23 Pressure Sensor Main Pump 2
-4B2 Main Pump Contamination Switch -4B23 Pressure Sensor Main Pump 4
-3B22 Pressure Sensor Main Pump 1
-4B12 Swing Charge Pump Pressure V1/3 For information on allocation of
Sensor V2/4 valves in the event that the ma-
chine is running with one engine,
-4B3 Main Pump Contamination Switch see chapter “Hydraulic system”.
-2B8 Hydraulic Oil Filter Monitoring 1
-2B7 Pressure Sensor Servo: 35 bar
No. Description -5B5 Contamination Servo Filter
1 Tank Level Sensor right -2B10 Hydraulic Oil Level Minimum
2 Hydraulic Oil -2Y21 Logic Solenoid Valve
Circulation Pump -5B19 Pressure Sensor Servo: 50bar
-2B9 Hydraulic Oil Filter Monitoring 2
-4B13 PMS Pressure Sensor
-3B13 PMS Pressure Sensor
-4B18 Shut-Off Valve Hydraulic Tank Top
-3B19 Shut-Off Valve Hydr. Tank Down
-3B18 Shut-Off Valve Hydr. Tank Rear
Right
-4B10 Hydraulic Oil Temperature Sensor
-3B10 Hydraulic Oil Temperature Sensor
Page 9.5 - 2 3721504en - (00)

9.5.1.4 Swing engine 9.5.1.5 Ladder
Fig. 6 Location components ladder - 642959
-2B2 Proximity Switch Ladder UP
9.5.1.6 Tank lift
Fig. 5 Location components swing engine - 643236
No. / Sen- Description

sor ID
1 Swing drive No. 1
2 Swing drive No. 2
3 Swing drive No. 3
4 Forward moving direction of the ex-
cavator
-2B15 Level Switch Swing Gear 1
-2B19 Temperature Swing System
-2B18 Pressure Swing Motor swiveling right
-2B17 Pressure Swing Motor swiveling left Fig. 7 Location components tank lift - 642956
-5B9 Contamination Switch Swing Motor 1
-2B16 Level Switch Swing Gear 2
-5B10 Contamination Switch Swing Motor 2 Sensor ID Description
-2B28 Level Switch Swing Gear 3 -2B1 Pressure Switch Tank Lift UP
-5B11 Contamination Switch Swing Motor 3
The swing drives shown in Fig. 5 are arranged in

relation to the forward moving direction of the ex-
cavator.
3721504en - (00) Page 9.5 - 3

Page 9.5 - 4 3721504en - (00)

9.5.2.2 Relay single contact

9.5.2 List of components
For information on part numbers see circuit dia-

gram or spare parts list of the related machine.
9.5.2.1 Relay single contact
Fig. 9 Relay single contact - 642961
Possible names: -1K32, -2K2, -2K3, -2K4
Measurable values:
A1: 24V/0V relay on /off
A2: 0V / Ground
11 COM
12 NC contact
14 NO contact
Fig. 8 Relay single contact - 642960
Symbol in electric schematic:
Possible names: -1K1, -1K2, -1K4, -1K25, -2K1,
-2K4, -3K1, -3K2, -3K4, -4K1, -4K2, -4K4, -5K2,
-5K3, -5K4, -5K5, -5K6, -5K7,-5K8, -5K10, -5K11, -
5K12, -6K1
Measurable values:
A1: 24V/0V relay on /off
A2: 0V / Ground
11 COM
12 NC contact
14 NO contact
3721502en - (01) Page 9.5.2 - 1

9.5.2.3 Relay double contact 9.5.2.4 Contamination switch
Fig. 10 Relay double contact - 642962
Possible names: -1K5, -1K5.1, -1K6, -1K15,

-1K16, -1K17, -1K18, -1K26, -1K30, -3K2, -3K3, -
4K2, -4K3, -5K1, -5K9 Fig. 11 Contamination switch - 642963
Measurable values: Possible names: -3B2,-3B3, -3B4, -3B5, -4B2,

A1: 24V/0V relay on /off -4B3, -4B4, -4B5, -5B9, -5B10, -5B11, -5B12
A2: 0V / Ground
11 COM 1 Measurable values:
12 NC contact 1 Pin 1: 0V
14 NO contact 1 Pin 2: 0V when switch is contaminated
21 COM 2 open circuit when switch is clean
22 NC contact 2
24 NO contact 2 Symbol in electric schematic:
Page 9.5.2 - 2 3721502en - (01)

9.5.2.5 Contamination switch 9.5.2.6 Cable for controller
Fig. 13 Cable for Controller - 642964
Possible names: X200, X201, X202, X300, X301,

X400, X401, X500, X501
Fig. 12 Contamination switch - 642963
Required tools:
Possible names: -3B6, -3B7, -3B8, -4B6, -4B7,
Removal tool for connector pins P/N 3739002
-4B8
Measurable values:
Pin 1: 0V
Pin 2: 0V when switch is contaminated
open circuit when switch is clean

Pin arrangement:
Fig. 14 Pin arrangement - 642965
3721502en - (01) Page 9.5.2 - 3

9.5.2.7 Controller 9.5.2.8 Pressure sensor (0-400bar)
Fig. 16 Pressure sensor - 642967
Possible names: -2B17, -2B18, -3B22, -3B23, -

3B24, -3B25, -4B22, -4B23, -4B24, -4B25, -5B6, -
5B7
Fig. 15 Controller - 642966
Measurable values:
Pin1: 24V
Possible names: -2A1
Pin2: 4-20mA (0-400bar)
Pin arrangement:
Page 9.5.2 - 4 3721502en - (01)

9.5.2.9 Pressure sensor (0-2,5bar) 9.5.2.10 Pressure sensor (0-100bar)
Fig. 17 Pressure sensor - 642967 Fig. 18 Pressure sensor - 642967
Possible names: -2B8, -2B9 Possible names: -2B7, -3B12, -3B13, -4B12,
-4B13, -5B19
Measurable values:
Pin1: 24V Measurable values:
Pin2: 4-20mA (0-2,5bar) Pin1: 24V
Pin2: 4-20mA (0-100bar)
Pin arrangement:
Pin arrangement:

3721502en - (01) Page 9.5.2 - 5

9.5.2.11 Temperature sensor 9.5.2.12 Proximity switch
Fig. 19 Temperature sensor - 642968
Possible names: -2B19, -3B10, -3B11, -3B29, -

4B10, -4B11, -4B29, -5B8 Fig. 20 Proximity Switch - 642969
Measurable values: Possible names: -2B2, -3B18, -3B19, -4B18

Pin1: 24V
Pin2: 4-20mA (-50°C - +150°C) Measurable values:
Pin1: +24VDC
Pin arrangement: Pin2: not used
Pin3: 0VDC
Pin4: +24VDC when switch is activated
+0VDC when switch is deactivated
Pin arrangement:
Page 9.5.2 - 6 3721502en - (01)

9.5.2.13 Switch / Spring loaded one side 9.5.2.14 Switch / Spring loaded two sides
Fig. 21 Switch, spring loaded - 642970 Fig. 22 Switch, spring loaded - 642970
Possible names: -2S5, -2S7, -3S1, -3S2, -3S3, Possible names: -3S5, -4S5, -5S1
-4S1, -4S2, -4S3, -5S2, -5S7, -5S8
Measurable values:
Measurable values: Pin 1: Continuity between Pin 1 and 2 or
Pin 2: Continuity between Pin 2 and 3 Pin 2: Continuity between Pin 2 and 3
Pin 3: when switch is pushed Pin 3: when switch is pushed left/right
Pin 7: +24VDC when key switch is on Pin 7: +24VDC when key switch is on
Pin 8: 0VDC when key switch is on Pin 8: 0VDC when key switch is on
Pin 9: 0VDC Pin 9: 0VDC

Pin 10: 24VDC when corresponding Pin 10: 24VDC when corresponding
output is active output is active
Symbol in electric schematic: Symbol in electric schematic:
3721502en - (01) Page 9.5.2 - 7

9.5.2.15 Switch one side 9.5.2.16 Switch one side 2pin
Fig. 23 Switch, spring loaded - 642970 Fig. 24 Switch, spring loaded - 642970
Possible names: -1S16, -2S1, -2S2, -2S3, -2S4, Possible names: -1S10, -1S11, -1S12, -1S13
-3S4, -3S6, -4S6
-1S14
Measurable values:
Pin 2: Continuity between Pin 2 and 3 Measurable values:
Pin 3: when switch is activated Pin 2: Continuity between Pin 2 and 3
Pin 3: when switch is activated
Pin 7: +24VDC when key switch is on
Pin 8: 0VDC when key switch is on Pin 5: Continuity between Pin 5 and 6
Pin 6: when switch is activated
Pin 9: 0VDC
Pin 10: 24VDC when corresponding Pin 7: +24VDC when key switch is on
output is active Pin 8: 0VDC when key switch is on
Symbol in electric schematic: Pin 9: 0VDC

Pin 10: 24VDC when corresponding
output is active
Page 9.5.2 - 8 3721502en - (01)

9.5.2.17 Switch wiper 9.5.2.18 Slewing gear level sensor
Fig. 26 Slewing gear level sensor - 642971

Fig. 25 Switch, spring loaded - 642970
Possible names: -1S15 Possible names: -2B15, -2B16, -2B28, -2B29
Measurable values: Measurable values:

Pin 1: Continuity between Pin 1 and 2 Pin 1: +24VDC
when switch is activated to RH side
Pin 3: 0VDC
Pin 2: Continuity between Pin 2 and 3 Pin 4: open circuit when oil level in slew drive
Pin 3: when switch is activated to LH side gearbox is low
+24VDC when oil level in slew drive
Pin 5: Continuity between Pin 5 and 6 gearbox is correct
Pin 6: when switch is activated to LH side
Pin arrangement:
Pin 4: Continuity between Pin 4 and 5
when switch is activated to RH side
Pin 7: +24VDC when key switch is on

Pin 8: 0VDC when key switch is on
Pin 9: 0VDC
Pin 10: 24VDC when corresponding
output is active
3721502en - (01) Page 9.5.2 - 9

9.5.2.19 Temperature switch swing/main pump 9.5.2.20 Pressure switch 20 bar
Fig. 27 Temperature switch swing / main pump - 642972
Possible names: -3B14, -3B15, -4B14, -4B15,

-2B20, -2B21, -2B22, -2B23, -2B24, -2B25, -2B26
-2B27
Fig. 28 Pressure switch - 642973
Measurable values:
Pin 1: 0VDC
Possible names: -2B1
Pin 2: open circuit when switch is open
0VDC when switch is closed Measurable values:
Pin 1: +24VDC
Switch closes at 92°C
Switch opens at 87°C Pin 2: open circuit when switch is open
+24VDC when switch is closed
Switch closes at 20bar Servo pressure
when tank lift valve is in the UP position
Page 9.5.2 - 10 3721502en - (01)

9.5.2.21 Float Switch / Bedia Sensor / Gearbox 9.5.2.22 Fuel Level sensor
minimum
Fig. 30 Fuel level sensor - 642975
Fig. 29 Float switch - 642974 Possible names: -3B9, -4B9
Measurable values:
Possible names: -3B17, -3B33, -4B17, -4B33 Pin 1: +24VDC
Measurable values: Pin 2: 0VDC

Pin +: +24VDC
Pin 3: 0-10VDC
Pin -: 0VDC 0VDC: cable break
+1VDC: tank empty
Pin S: open circuit when switch is open +10VDC: tank full
0VDC when switch is closed
Pin 4: 0VDC when tank is full
Switch closes when oil level is correct
Switch opens when oil level is low Symbol in electric schematic:
3721502en - (01) Page 9.5.2 - 11

9.5.2.23 Relay / battery main switch 9.5.2.24 Float switch / Bedia Sensor
Fig. 32 Float switch - 642974
Possible names: -2B10, -5B1, -5B17, -5B18
Measurable values:
Pin +: +24VDC
Fig. 31 Relay / battery main switch - 642976
Pin -: 0VDC
Possible names: -1K0.1, -1K0.2 Pin S: open circuit when switch is open
0VDC when switch is closed
Measurable values:
A1: +24VDC to activate relay Switch closes when oil level is correct
Switch opens when oil level is low
A2: 0VDC
Contact 1: Continuity between Contact 1 and
Contact 2 when relay is active
Contact 2:
Page 9.5.2 - 12 3721502en - (01)

9.5.2.25 Float switch / Bedia Sensor water lev- 9.5.2.26 Pressure switch 0,5 bar
el
Fig. 34 Pressure switch - 642978
Possible names: -3B16, -4B16
Fig. 33 Float switch - 642977 Measurable values:

Engines stopped:
Possible names: -3B1, -4B1 Continuity between Pin 1 + Pin 2
Measurable values: Engines running:

Pin +: +24VDC
Open circuit between Pin 1 + Pin 2
Pin -: 0VDC (Switch opens at 0,5bar gearbox oil pres-
sure)
Pin S: open circuit when switch is open
0VDC when switch is closed Symbol in electric schematic:
Switch closes when water level is correct

Switch opens when water level is low
3721502en - (01) Page 9.5.2 - 13

9.5.2.27 Pressure switch air cleaner 9.5.2.28 Relay 24V max 150A
Fig. 36 Relay 24V max 150A - 642980
Fig. 35 Pressure switch air cleaner - 642979

Possible names: -1K8, -1K24
Possible names: -3B20, -3B21, -3B31, -3B32, - Measurable values:
4B20, -4B21, -4B31, -4B32 A1: +24VDC to activate relay
Measurable values: A2: 0VDC
Pin 1: +24VDC
Pin 2: open circuit when switch is open Contact 2 when relay is active
+24VDC when switch is closed Contact 2:
Switch closes at Symbol in electric schematic:
restriction of 508.0mm H2O / 20” H2O
Pin 1: +24VDC
Page 9.5.2 - 14 3721502en - (01)

9.5.2.29 Relay 24V max 50A 9.5.2.30 Diode
Fig. 37 Relay 24V max 50A - 642981
2 1 643126
Possible names: -1K19, -1K20
Fig. 38 Diode - 643126
Measurable values:
A1: +24VDC to activate relay Possible names: V55, V55.1, V56, V56.1, -1K8, -
1K10, - 1K11
A2: 0VDC
Measurable values:
Contact 2 when relay is active
Contact 2:
Fig. 39 Diode is O.K.- 643127
Fig. 40 Diode is not O.K. - 643141
3721502en - (01) Page 9.5.2 - 15

9.5.2.31 Diode
9.5.2.32 Voltage converter 24V / 12V
Fig. 41 Diode - 642983 Fig. 44 Voltage converter 24V / 12V - 642984
Possible names: -1A10, -6A1

Possible names: -1V1, -1V2, -2V1, -3H5, -3H6, -
3V1, -3V2, -3V3, -4H5, -4H6, -4V1, -4V2, -4V3, - Measurable values:
5V1, -5V2, -5V3 Plug 1+: +24VDC
Plug 1-: 0VDC
Measurable values:
Plug 2+: +12VDC
Fig. 42 Diode is O.K.- 643127
Fig. 43 Diode is not O.K. - 643141
Page 9.5.2 - 16 3721502en - (01)

9.5.2.33 Initiator cut off system 9.5.2.34 Seat contact switch
Fig. 46 Seat contact switch - 642986
Fig. 45 Initiator cut off system - 642985 Possible names: -2S6
Measurable values:
Possible names: -2B11, -2B12, -2B13 Pin 1: +24VDC
Measurable values: Pin 2: open ccircuit when switch is open
Pin1: +24VDC +24VDC when switch is closed
Pin2: not used
Pin3: 0VDC Switch closes when operator sits in
Pin4: +24VDC when switch is activated the seat
+0VDC when switch is deactivated
Pin arrangement:
3721502en - (01) Page 9.5.2 - 17

9.5.2.35 Servo block proportional valve 9.5.2.36 Seat contact valve servo block
Fig. 47 Servo block proportional valve (old and new

Block) - 642987
Possible names: -2Y1, -2Y2, -2Y3, -2Y4, -2Y5,

-2Y6, -2Y7, -2Y8, -2Y9, -2Y10, -2Y11, -2Y12,
-2Y13, -2Y14, -2Y15, -2Y16
Measurable values:
Pin 1: 0-650mA Fig. 48 Seat contact valve servo block - 642988
Pin 2: 0VDC
Possible names: -2Y18
Resistance between pins (coil re-
sistance): 23Ω Measurable values:
Pin 1: 24VDC (to activate valve)
Pin 2: 0VDC

sistance): 19Ω
Page 9.5.2 - 18 3721502en - (01)

9.5.2.37 Track tensioning valve servo block 9.5.2.38 Plug 64 PIN
Fig. 50 Plug 64 PIN - 642991
Possible names: -X160, -X161, -X130, -X140

-X110
Required tools:
Crimp tool P/N 6001880

Fig. 49 Track tensioning valve servo block - 642990 Pin removal tool P/N 3685377

Possible names: -2Y20
Measurable values:
Pin 1: 24VDC (to activate valve)
Pin 2: 0VDC

sistance): 26Ω
3721502en - (01) Page 9.5.2 - 19

9.5.2.39 Plug 40 PIN 9.5.2.40 Plug 6 PIN
Fig. 51 Plug 40 PIN - 642992
Possible names: -X102, -X109.1, -X101, -X120

-X100, -X109, -X131, -X141, -X105 Fig. 52 Plug 6 PIN - 642993
Required tools:
Crimp tool P/N 6001880 Possible names: -X309, -X188, -X108.1, -X108.2
Pin removal tool P/N 3685377 -X108.3, -X111
Symbol in electric schematic: Required tools:

Crimp tool P/N 6001880
Page 9.5.2 - 20 3721502en - (01)

9.5.2.41 Proportional valve pump 9.5.2.42 Proportional valve pump regulation
Fig. 53 Proportional valve pump - 642994
Possible names: -3Y2, -3Y3, -3Y6, -4Y2, -4Y3,

-4Y6
Measurable values:
Pin 1: 150mA-650mA
Pin 2: 0VDC
Resistance between pins (coil re- Fig. 54 Proportional valve pump regulation - 642995
sistance): 23Ω
Possible names: -3Y1, -4Y1
Measurable values:
Pin 1: 150mA-820mA
Pin 2: 0VDC

sistance): 23Ω
3721502en - (01) Page 9.5.2 - 21

9.5.2.43 Grease container level sensor (empty) 9.5.2.44 Grease container level sensor (full)
Fig. 55 Grease container level sensor (empty) - 642996 Fig. 56 Grease container level sensor (full) - 642997
Possible names: -5B13, -5B14 Possible names: -5B15, -5B16
Measurable values: Measurable values:

brown wire: +24VDC brown wire: +24VDC
blue wire: 0VDC blue wire: 0VDC
black wire: +24VDC when container is empty black wire: +24VDC when container is full
0VDC when container is not emp- 0VDC when container is not full
ty
Page 9.5.2 - 22 3721502en - (01)

9.5.2.45 Initiator grease system
Fig. 57 Initiator grease system – 642261; 642447
Possible names: -5B2, -5B3
Measurable values:
Pin 1: brown wire +24VDC
Pin 3: blue wire 0VDC
Pin 4: black wire +24VDC if activated
3721502en - (01) Page 9.5.2 - 23

Page 9.5.2 - 24 3721502en - (01)

9.6 BCS SOFTWARE
9.6 BCS Software 9.6.1 Overview of the menus

As soon as the key switch is turned on and all
electronic units of the CAMP system have started This section introduces the menu tree and lists the
successfully, the Main menu appears on the BCS name of each menu. In addition, the menu tree
display screen. The Main menu shows the most illustrates the menu categories and the role con-
important operational values in analogue gauge cept for accessing them.
and digital form such as: The BCS menus are subdivided into the catego-
 Engine oil pressure ries:
 Water temperature  Service and Fault storage menus, available for
 Fuel level everybody.
 Hydraulic oil temperature  Setup menus, password protected and avail-
 Battery voltage able for on-site service personnel.
 Engines RPM  Setup level 2 menus, password protected and
Additional values can be checked by using the available for manufacturers’ service personnel
touch screen to move through the menus of the only.
BCS software.
The BCS is a passive real-time monitoring device The figure shows the menu tree. Each menu is
which monitors critical and non-critical functions of marked by a number. The following list maps the
the machine and its components. It delivers audi- name of the menu to the number.
ble and visual warnings as soon as the threshold
for any of the machines operating parameters is
exceeded.
Because the BCS instantly notifies the operator of
any abnormalities, the operator can concentrate on
operating the machine without checking the in-
struments constantly and deciding on how to react
on the displayed values.
3721505en - (00) Page 9.6 - 1

9.6 BCS SOFTWARE
Page 9.6 - 2 3721505en - (00)

Main Menu
1.0
Service Fault Storage

Help
2.0 Locked Setup Fault Table Fault Detail Ringbuffer
8.0
9.0 10.0 11.0

12.0
Fault Location
Engine Hydraulic Lubrication Servosystem Signal Table
10.1
3.0 4.0 5.0 6.0 7.0
Controllers Locked BUCYRUS

Help
3.1 21.0 Change
7.1 16.0 Access Code
8.0
26.0
3.2 7.2
Copy Files Controller Config CAN Monitor
23.0 24.0 25.0

Servo Controller Auxillary Controller LH Engine Controller RH Engine Controller
3.3 18.0 20.0

17.0 19.0
BCS Update 24.1

BCS Configuration Operating Hours Signal Config 25.1
22.0
About BCS 13.0 14.0 15.0 17.1 18.1 19.1 20.1
13.1 Location
10.1 24.2
Service Interval Signal List

17.2 18.2 19.2 20.2
Callibration Menu 14.1 15.1
24.3
13.2 13.3 13.4
17.3 18.3 19.3 20.3
Calibration 24.4
13.5
17.4 19.4 20.4
24.5
17.5 19.5 20.5
24.6
643139
9.6 BCS SOFTWARE
1.0 Main menu 18.0 Auxiliary Controller – Subunit I/O

18.1 Subunit CPU_F
2.0 Service menu 18.2 Settings
3.0 Engine - left 18.3 History
3.1 Engine - right 19.0 LH Engine Controller – Analog
3.2 SAE Diagnostic Trouble Codes 19.1 Digital
3.3 Copy to USB stick 19.2 Settings
4.0 Hydraulic 19.3 Fan regulation
5.0 Lubrication 19.4 Shutdown
6.0 Servosystem 19.5 History
7.0 Signal Table 20.0 RH Engine Controller - Analog
7.1 Diagram 20.1 Digital
7.2 Diagram configuration 20.2 Settings
8.0 Help 20.3 Fan regulation
9.0 Fault Table 20.4 Shutdown
10.0 Fault Detail 20.5 History
10.1 Fault Location 8.0 Help
11.0 Ringbuffer
21.0 Service level 2 menu
12.0 Setup menu 22.0 BSC Update
13.0 BCS Configuration 23.0 Copy Files
13.1 About BCS 24.0 Controller Config – Factory Settings
13.2 MT 7 Software Control Panel – 24.1 Servo Contr.1
Main 24.2 Servo Contr.2
13.2.1 Touch Settings 24.3 Servo Contr.3
13.2.2 Tools 24.4 Eng. Cont. LH
13.3 Calibration 24.5 Eng. Cont. RH
14.0 Operating Hours 24.6 Aux. Contr.
14.1 Service Interval 25.0 CAN Monitor
15.0 Signal Config 25.1 Connect over Tcp/IP to …
10.1Location
15.1 Signal List
16.0 Controllers
17.0 Servo Controller – Subunit CPU1
17.1 Subunit CPU2
17.2 Subunit ICN V
17.3 Controller Configuration
17.4 Cyl. Cutoff
17.5 History
3721505en - (00) Page 9.6 - 3

9.6 BCS SOFTWARE
9.6.2 Start screen
1.0 Main menu
1 2 3 4 5 6 7 8 9 10 11 12
17 16 15 14 13
642998
Fig. 1 1.0 Main menu - 642998
The main menu is the standard view for the operator of the machine. It provides information on the most
common and most important operational values at a glance.
No. Description Symbol

1 Left engine monitoring
 Grayed: Inactive
 Yellow: Motor warning
 Red: Motor stop
For information on active faults see “Status line Fault messages”.

Tap on the symbol to enter the “Engine – left” menu.
Page 9.6 - 4 3721505en - (00)

9.6 BCS SOFTWARE

2 Lubrication system monitoring
 Yellow: Lubrication in progress
 Red: Fault occurred, see “Status line Fault messages”
Tap on the symbol to enter the “Lubrication” menu.
3 Dumper counter
 Press the push-button at the right hand-lever to increment the loaded
dumper count by one, see “Operating manual”.
 Reset the loaded dumper with the related push-button at the BCS tower,
see “Operating manual”..
4 Travelling speed
 Grayed: 1st travelling stage; travelling forwards / backwards is possible
 Green: 2nd travelling stage, only parallel forward travel is possible
If 2nd travelling stage is triggered during backward travel and cornering, the
machine switches back automatically into the 1st travelling stage.
5 Hydraulic system monitoring

 Green: Normal operation
 Red: Fault occurred, see “Status line Fault messages”
Tap on the symbol to enter the “Hydraulic” menu.
6 Operating hours meter
7 Right engine monitoring

 Yellow: Motor warning
 Red: Motor stop
For information on active faults see “Status line Fault messages”.

Tap on the symbol to enter the “Engine – right” menu.
8 Service station monitoring
 Grayed: Service station in upper position
 Red: Service station lowered
CAUTION!
Swinging superstructure or travelling the machine
not possible if the service station is lowered.
9 Hydraulic ladder monitoring
 Grayed: hydraulic ladder in upper position
 Red: Hydraulic ladder lowered
CAUTION!
Swinging superstructure or travelling the machine
not possible if the service station is lowered.
10 Track parking brakes monitoring
 Grayed: Brake released
 Red: Brake applied
3721505en - (00) Page 9.6 - 5

9.6 BCS SOFTWARE

11 Superstructure holding brakes monitoring
 Grayed: Brake released
 Red: Brake applied
12 Servo-switch inside seat monitoring

 Grayed: Seat occupied
 Red: Seat empty
13 Current Time
14 Status line Fault messages

Each fault message includes
 Error code number
 Error description
Tap on the line to open the list of active faults and to scroll through the list.
For detailed information on the faults tap on the “Fault” button to enter the
“Fault storage” menu.
15 Open “Fault storage” menu
16 Open “Setup” menu
17 Open “Service” menu

Password required.
Page 9.6 - 6 3721505en - (00)

9.6 BCS SOFTWARE
18
19 19
20 20
21 21
22 22
24 23 642999
Fig. 2 1.0 Main menu (second part) -642999
3721505en - (00) Page 9.6 - 7

9.6 BCS SOFTWARE

18 Hydraulic oil temperature in degrees Celsius, displayed graphically and
numerically
 Blue: Cold
 Red: Hot
Left arrowhead-shaped symbol: Trailing pointer, slides up as soon as a new
maximum temperature is reached in the monitored timeframe. The symbol is
reset in the event of a restart. In addition, it can be reset manually by press-
ing the triangle.
Halfed arrowhead symbol: Indicates the current temperature by sliding up
and down according to the measured value.
19 Oil pressure in bar, engine left / right
20 Revolutions Per Minute (RPM) engine left / right
21 Cooling water temperature in degrees Celsius engine left / right

 Blue: Cold
 Red: Hot
Left arrowhead-shaped symbol: Trailing pointer, slides up as soon as a new
maximum temperature is reached in the monitored timeframe. The symbol is
reset in the event of a restart. In addition, it can be reset manually by press-
ing the triangle.
Halfed arrowhead symbol: Indicates the current temperature by sliding up
and down according to the measured value.
22 Fuel level engine left / right
23 Maintenance interval
 Green: normal operation
 Yellow: Service will be needed soon
 Red: Service is to be done
See “Operating manual” for maintenance intervals.
2 On-board voltage in Volt, displayed graphically and numerically
Page 9.6 - 8 3721505en - (00)

9.6 BCS SOFTWARE
9.6.3 Service menus
2.0 Service menu
1 2 3
1 2 10 10 8 8 7 6
643000
Fig. 3 2.0 Service Menu - 643000

1 Open “Engine” menu
2 Open “Hydraulic” menu
3 Open “View documents” menu for on-board documentation
3721505en - (00) Page 9.6 - 9

9.6 BCS SOFTWARE

4 Adjust the brightness of the screen
 +: bright
 -: dark
5 Automatically adjustment of the screen brightness to the light

intensity in the cabin triggered by a sensor.
6 Exit the current menu and enter the previous menu
7 Open the “Signal Table” menu
8 Open the “Servosystem” menu
9 Open the “Lubrication” menu
Page 9.6 - 10 3721505en - (00)

9.6 BCS SOFTWARE
3.0 / 3.1 Engine left (3.0) / Engine right (3.1)
Fig. 4 3.0 / 3.1 Engine left (3.0) / Engine right (3.1) - 643183
This menu provides information on the most common and most important data for the selected engine
(left or right).

1 Common engine data
Use this menu to check for instance:

 Fuel consumption: Actual consumption of fuel
 Fuel rate: Fuel consumption per hour
2 Total operating hour
Click on the display to get information on:

 Engine: Number of hours the engine has been switched on
 Working: Overall time the engine has been working
 Load: Overall time the engine has been working under full load
 Driving: Overall time the engine has been working for driving the ma-
chine
3721505en - (00) Page 9.6 - 11

9.6 BCS SOFTWARE

3 Oil change information:
 Graphical bar indicating the number of hours up to the next oil change
 Engine: Number of hours the engine has been switched on
 Interval, see “BCS Configuration” menu (service level 1 password re-
quired) for changing the interval
 Number of hours since the last oil change
 Number of hours up to the next oil change
4 Reset counter for number of hours since the last oil change
 Use this button to reset the counter after the oil change (service level 1
password needed).
5 Information on active faults and malfunctions. Fault description follows the

SAE J1939 standard.
 Use this menu to get an overview of trouble codes for an individual en-
gine.
 Open the “SAE diagnostic trouble codes” menu for detailed information
on a fault or male function.
7 Open “SAE diagnostic trouble codes” menu
8/9 Switch over from left to right engine

 The selected engine is displayed in the menu title.
 The button for the selected machine is highlighted (color reversing).
o Selected:
o Deselected
10 Open menu for copying engine data to a USB stick.
Page 9.6 - 12 3721505en - (00)

9.6 BCS SOFTWARE
3.2 SAE Diagnostic trouble codes

1
3 2
643002
Fig. 5 3.2 SAE Diagnostic Trouble Codes -643002
This menu provides a list of all SAE diagnostic trouble codes.
 SPN Number = Suspect Parameter Number

 FMI = Failure Mode Identifier.

1 Search for an individual trouble code as follows:
 Enter the SPN and FMI number via the operator panel.
 Tap on the button.
3721505en - (00) Page 9.6 - 13

9.6 BCS SOFTWARE

3 Scroll in the list of codes.
 First line
 Reverse
 Forward
 Last line
Page 9.6 - 14 3721505en - (00)

9.6 BCS SOFTWARE
3.3 Copy to USB stick
3 2
643003
Fig. 6 3.2 Copy to USB stick - 643003
Use this menu for copying information on a USB stick. Insert the USB stick in the USB port on the right hand
side of the control column.

1 Open the file structure for getting an overview of data stored on the USB
stick.
3 Save the displayed data as text-file to the USB stick
3721505en - (00) Page 9.6 - 15

9.6 BCS SOFTWARE
4.0 Hydraulic
2 1
643004
Fig. 7 4.0 Hydraulic -643004
This menu shows data of the hydraulic system at a glance.

 Use this menu to control the values in the event of problems such as:
o A pump seems to be defective.
o The engine output seems to be too low.
 For adjusting the valves of the hydraulic system, two persons are required. One person works on the
valve, the second persons monitors the result on the engine data on the “Hydraulic” menu.

Page 9.6 - 16 3721505en - (00)

9.6 BCS SOFTWARE
5.0 Lubrication
643006
Fig. 8 5.0 Lubrication (engine speed) - 643006
This menu shows information on the central lubrication system. Lubrication can only be triggered if the en-
gine Speed is higher than 1300 rpm. That is, information sent by sensors is only interpreted as faults if the
engine speed is higher than 1300 rpm.
For a detailed description of the lubrication system, see section “Central lubrication system”. For information
on controlling the lubrication system via CAMP, see section “Communication and control loops within
CAMP”.
3721505en - (00) Page 9.6 - 17

9.6 BCS SOFTWARE
1 2 3
5
6
9 8
643005
Fig. 9 5.0 Lubrication - 643005
Page 9.6 - 18 3721505en - (00)

9.6 BCS SOFTWARE

1 Data related to the lubrication system of the upper carriage
2 Steps of the lubrication cycle for the upper carriage.
 Use this menu to monitor the lubrication cycle and to track the source of
a fault. The digits in brackets indicate the sensor that monitors the indi-
vidual process.
 Lubrication on (5Y1):
o Gray: Inactive, no lubrication in progress
o Green: Lubrication in progress
 Initiator 1 (5B2):
o Gray: Inactive
o Green: Lubrication in line A in progress
 Initiator 2 (5B3):
o Gray: Inactive
o Green: Lubrication in line B in progress
 Switch A <-> B (5Y2): Sensor monitoring the switch of lubrication in line
A to lubrication in line B.
o Gray: Valve inactive and line A open.
o Green: Valve active and line B open.
 Relief Valve (5Y3):
o Gray: Valve open, no lubrication in progress
o Green: Valve closed, lubrication in progress
 Grease container full (5B15): Use this information to monitor the filling of
the lubrication container with grease.
Initiators 1 and 2 are located at the stick that is they have the maximum
distance from the valve controlling the switch between line A and line B. A
fault is generated if the grease does not reach the initiator within a prede-
fined time after the switch between the lines has been triggered.
3 Current lubrication pressure for the lubrication system of the upper carriage
3721505en - (00) Page 9.6 - 19

9.6 BCS SOFTWARE

4 Faults related to the lubrication system of the upper carriage
 Gray: Inactive
 Red: Active fault
 Lube pump filter contaminated: Filter for the oil pump powering the lu-
brication system contaminated.
 Initiator 1 no signal: Grease did not reach the stick in line A within a
predefined time after the lubrication in line A has been triggered.
 Reasons might be:
o Grease level low
o Pressure low
o Hose is torn off / damaged
 Initiator 2 signal stuck: Initiator for switching the grease to line B has
been stuck.
 Initiator 1 signal stuck: Initiator for switching the grease to line A has
been stuck.
 Initiator 2 no signal: Grease did not reach the stick in line B within a
predefined time after the lubrication in line B has been triggered.
Reasons might be:
o Grease level low
o Pressure low
o Hose is torn off / damage.
 Line A max. pressure not reached: Reasons might be:
o Grease level low
o Grease too viscous
o Hose is torn off / damage.
 Bucket cylinder stop: Cylinder cannot be moved
 Grease container empty
5 Status information on the overall lubrication process
 Time before error: The lubrication cycle needs to be completed within a
predefined time.
Use the time before error to cross-check whether the active step of the
lubrication cycle matched to the timeline for the lubrication cycle.
 Next lubrication in: In general, lubrication is started if the machine has
moved (driving or loading) for 400 s. This bar indicates the time up to
the next lubrication. For new machines, the interval is 300 s.
 Cylinder cut off in: As soon as the lubrication cycle is interrupted, the
counter starts. 15 minutes after the interruption, swiveling the shov-
el/bucket is blocked. The machine needs to be brought into a safe place
for maintenance purposes.
6 Data related to the lubrication system of the under carriage
 Lubrication on: Lubrication in progress There is only one status infor-

mation for both of:
o 5Y4: Valve of the lubrication pump
o 5Y5: Relief valve
Page 9.6 - 20 3721505en - (00)

9.6 BCS SOFTWARE

7 Information on the time limit of the lubrication cycle:
Data related to the under carriage:
 Press. Decrease 100 bar - 30bar:
If the superior switch point pressure is reached, the lubrication is com-
pleted. The lubrication system is switched off and the pressure has to
fall to the lower switch point pressure within the “wait time sup. To lower
press”.
 Press. Build up 0bar – 30bar:
If the grease pump starts to work, the pressure has to reach the lower
switch point pressure at the pressure sensor -5B7 within the “wait time
lower pressure”.
 Press build up 30bar – 180bar:
If the lower switch point pressure has been reached, the superior switch
point pressure has to be reached within the “wait time superior pres-
sure”.
If the pressure increases too slowly, a leakage might be the reason.

In addition, sensor -5B7 detects whether the lubrication pressure exceeds
the maximum lubrication pressure.
9 Current lubrication pressure for the lubrication system of the lower carriage
3721505en - (00) Page 9.6 - 21

9.6 BCS SOFTWARE
6.0 Servo system
1 2 1
5 4 3
643007
Fig. 10 6.0 Servo System - 643007
This menu shows the characteristic curves of control levers and control pedals (2). The values are adjusta-
ble via “Controller configuration” menu (password protected).

1 Control lever
2 Control pedal
Page 9.6 - 22 3721505en - (00)

9.6 BCS SOFTWARE

4 Curve characteristics
Control pedals: up / down deflection

Hand levers: up / down and left / right deflection
%: Percentage of deflection
Green: Set value
Black: Current value
The proportional valve current for the servo system should be in the range
of 70mA – 650mA.
 70mA – Ignition on – Joystick 0%
 650mA – Ignition on – Joystick 100%
 Grey line: Indicates movements requiring pressure.

 Yellow line: Indicates pressure less movements. Press the button on the
underside of the hand lever to trigger movement in the direction in ques-
tion (the color changes to grey).
5 Buttons on the hand level
3721505en - (00) Page 9.6 - 23

9.6 BCS SOFTWARE
7.0 Signal table
1 2
5 4 3
643010
Fig. 11 7.0 Signal Table - 643010
This menu provides a list of all the signal sources that are connected to the BCS- and CAMP-system.
Page 9.6 - 24 3721505en - (00)

9.6 BCS SOFTWARE

1 Tap on this symbol to get to the first line or last line of the list
2 Information on the signal sources

 ID: Error ID
 Name: Description
 Code: Name of the sensor / unit
 Unit: Unit of measurement
 Data: Current value at the sensor
 Status:
o Green: O.K.
o Red: Malfunction
o “-“: Not applicable
4 Open the “Diagram” menu
5 Displays a photo of the sensor to identify and locate it.

 Green: Photo available
 Grey: No photo available
Tap on the photo to close it.
3721505en - (00) Page 9.6 - 25

9.6 BCS SOFTWARE
7.1 Diagram
5 7
8
4 9
3
10
2
11
643009
Fig. 12 7.1 Diagram - 643009
This menu displays a diagram showing the data coming from four signal sources (sensors) for a longer pe-
riod of time.

1 Opens the diagram configuration menu to select the signal sources to be
displayed.
2 Data on the selected signal sources:

 Actual value
 Channel: ID and description of the signal; the color indicates the chan-
nel related to the signal
 Value at the cursor in the diagram
3 Write direct log-file to CF-card. Use this function to evaluate the stored data
in other programs such as excel
Page 9.6 - 26 3721505en - (00)

9.6 BCS SOFTWARE

4 Buttons to control recording data.
 Rec: Starts recording the data from the selected

sources.
 Stop: Stops recording data.
 Rev: Scrolls the diagram in reverse.
 Fwd: Scrolls the diagram forwards.

5 Diagram window to display the data from four sources as four lines in differ-
ent colors.
6 Buttons to handle recorded data.
 Save: Save data to memory.
 Load: Load older data from memory.
 Delete: Delete data displayed.
7 Buttons to navigate in the diagram window.
 Scroll up
 Scale up
 Reset to base setting
 Scale down

 Scroll down
8 Select signal source for which the graduation on the right side of the dia-
gram matches (channel 1-4)
9 Scroll through the time scale.
10 Logfile sample time: Select 50 or 100 ms
3721505en - (00) Page 9.6 - 27

9.6 BCS SOFTWARE
7.2 Diagram configuration
3 2 643008
Fig. 13 7.2 Diagram configuration -643008
This menu lists all the signal sources available for BCS and CAMP. Use this menu to select the signal
sources to be displayed in the “Diagram” menu.

1 Available data on the signal source:
 ID: Signal identifier
 Signal: Description
 Min: Enter the minimum value via the control panel
 Max: Enter the maximum value via the control panel
 Unit: Unit of measurement
 Channel: Enter the channel number the signal is to be displayed via the
control panel
 Log: Enter the channel number via the control panel
3 Confirm the selected data
Page 9.6 - 28 3721505en - (00)

9.6 BCS SOFTWARE
8.0 Help
2
643011
Fig. 14 8.0 Help - 643011
This menu provides access to the technical documentation of the machine.

1 Tap on the document in question to open the pdf file.
3721505en - (00) Page 9.6 - 29

9.6 BCS SOFTWARE
9.6.4 Fault storage menus
If the threshold for any operating parameter is exceeded, the operator is notified immediately and the rele-
vant information is recorded in a central memory bank called BCS fault storage.
In addition, the BCS advises the operator on how to react on the problem:
 “please check”: This is the advice for faults that are not critical.
 “stop engine”: This is the advice for faults that are critical and detrimental to machine operation.
This fault storage information can be called up at any time by all mine personnel.
9.0 Fault table
1 2 3
8 7 6 5
643012
Fig. 15 9.0 Fault Table - 643012
This menu provides information on currently active faults. In addition, the storage on information on faults
can be configured, that have been active at least once.
Page 9.6 - 30 3721505en - (00)

9.6 BCS SOFTWARE

1 Select the type of faults to be listed:
 Active: All faults that are currently active
 Inactive: All faults that have been active at least once
 All: Active and inactive faults
2 Information on faults:
 Code: Fault ID
 Stat: Status:
o Red: Active
o Dark gray: Inactive
 Beep: Acoustic signal
o Loudspeaker, red background: Signal active
o Loudspeaker crossed out, gray background: Signal deactivated
Tap on the loudspeaker symbol to deactivate the acoustic signal.
 Description: fault description
 First occurrence: Time stamp indicating the first occurrence of the fault.
 Tot.: Number of times the fault was active
 Latest occurrence: Time stamp indicating the last occurrence of the
fault.
4 Control of the fault storage

 Last erase: Time stamp for the last time the list was cleared.
 Filling degree: Indicates the remaining capacity for storing new faults in
percentage and as graphic bar. Gives some orientation for
o number of entries in the list
o need for clearing the list.
7 Update of the list.
8 Delete the list.
3721505en - (00) Page 9.6 - 31

9.6 BCS SOFTWARE
10.0 Fault detail
1 2
7 6 5 4 3
643013
Fig. 16 10.0 Fault Detail - 643013
This menu provides detailed information on an individual fault.
Page 9.6 - 32 3721505en - (00)

9.6 BCS SOFTWARE

1 Information on the displayed alarm:
Information on faults:
 Status of the fault
o Red: Active
o Dark gray: Inactive
 Code: Fault ID
 Description: fault description
 Alarm condition: Specifies the signal that indicates that the alarm is ac-
tive.
 ID of the sensor that triggered the fault
 Beep: Acoustic signal
o Loudspeaker, red background: Signal active
o Loudspeaker crossed out, gray background: Signal deactivated
Tap on the loudspeaker symbol to deactivate the acoustic signal.
 Start time and date: Time stamp indicating when the fault has been trig-
gered
 Tot.: Number of times the fault was active
 Hour at start: Timestamp indicating the point in time when the fault be-
came active.
 Duration: Information on how long the fault has been active.
Use the buttons to scroll in the listed information
o Up
o Down
o Button not applicable.

6 Update of the information.
7 Delete the information.
3721505en - (00) Page 9.6 - 33

9.6 BCS SOFTWARE
Page 9.6 - 34 3721505en - (00)

9.6 BCS SOFTWARE
9.6.5 Setup menus
The Setup menus are designed for monitoring and/or changing parameter values for an individual machine
on site. The level 1 service code is required to access the “Setup” menus. This code is only available for
service personnel.
Integral system parameters can only be monitored. For changing them, the level 2 service code is required.
This code is available for manufacturers’ service personnel only.
3721506en - (01) Page 9.6.5 - 1

9.6 BCS SOFTWARE
12.0 Setup menu
Fig. 17 12.0 Setup menu - 643014a
Page 9.6.5 - 2 3721506en - (01)

9.6 BCS SOFTWARE

1 The “Common setup” buttons open the “BSC configuration”
menu.
2 Open “Operating hours” menu
5 Open “Service Level II” menu
6 Open “Controller” menu
7 Open “Signal configuration” menu
3721506en - (01) Page 9.6.5 - 3

9.6 BCS SOFTWARE
13.0 BCS Configuration
1
2
3
5
6
11 10 9 8
643015
Fig. 18 13.0 BCS Configuration - 643015
This menu is to specify basic data for the machine such as number of the excavator and service interval.
Page 9.6.5 - 4 3721506en - (01)

9.6 BCS SOFTWARE

1 BCS characteristics
2 Current version of the BCS software
 Tipp on the button to open the list of all available software versions and
the change history for each version.
 Use this information if two machines react different on the same com-
mands. They might have different software versions installed.
3 Type of the excavator and serial number

 You will find the serial number on the identification plate.
4 Data related to the BCS display
 Select the language of the menus.
 Specify the date and the local time.
5 Service interval and oil change interval.
 Specify the service interval and the oil change interval to be used for
monitoring the machine.
 For types of service intervals and related maintenance tasks applicable
for the machine see “Operating instructions”. In general, an interval of
1000 h is specified here.
 For motor-specific information, see the documentation of the motor.
6 Remote access and logging configuration
 The remote transmit rate depends on the mode of transmission. Cross-
check the rate applicable for the installed system.
7 Level 1 service code for accessing the setup menus
 Use this menu to change the service code. Make sure that you recog-
nize the new code.
9 Open the “MT7 Software Control Panel” menu

 Use these menus to calibrate the touch display.
11 Open the pop-up window for writing back the modified data.
 If you have changed any of the data, tip “yes” to enable the modification.
3721506en - (01) Page 9.6.5 - 5

9.6 BCS SOFTWARE
13.2 MT 7 Software Control Panel Main
643016
Fig. 19 13.2 MT 7 Software Control Panel – Main - 643016
This menu is used to calibrate the touch display so that it is suitable for your fingers.
 The “calibrate” button opens the “Calibration” menu.
643017
Fig. 20 Calibration menu - 643017
 Perform the test while sitting in a position you will take during normal operation.
 In consecutive steps you will be asked to tap on the indicated screen position until the color of the icon
changes from green to red.
 Test the new settings. If they suit to your fingertips, activate the settings. Exit the “Test” menu by using
the door symbol.
If you have managed to get a setting where the movements of the cursor do not suit to the movements on
the touch screen, proceed as follows:
 Connect a mouse via the USB connector on the right side of the control column
 Open the “MT7 Software Control Panel – Main” menu.
 Tap on the “calibrate” button to open the “Calibration” menu.
 Start calibration
Page 9.6.5 - 6 3721506en - (01)

9.6 BCS SOFTWARE
14.0 Operating Hours
4
5
8 7 6
643018
Fig. 21 14.0 Operating Hours - 643018
This menu provides detailed information on operating hours.
3721506en - (01) Page 9.6.5 - 7

9.6 BCS SOFTWARE

1 Running: Operating hours the engines were running
 Total: Overall hours at least one of the engines was running.
o Use the displayed minutes to check whether the engine is running
and the display works properly.
 ECM: The data of the ECM (Engine Control Module) in the left and the
right engine is readout and displayed.
 OffSet: If the engine is replaced by a new one, the new ECM starts by
zero.
o Use the offset to track the overall operating hours for the left and the
right hand side.
2 Working: Operating hours the machine was moving
 Total: At least one of the engines were working to move the machine
 Engine LH: Engine on the left hand side
 Engine RH: Engine on the right hand side
3 Under load limit: Operating hours the engine were working with maximum
load so that the PSM (pump management) was active.
4 Driving: Operating hours the machine was driving
 The trigger is the signal sent by the foot pedals for travel left / right track.
5 Slewing: Operating hours the machine was slewing
 The trigger is the signal sent by the hand levers.
Page 9.6.5 - 8 3721506en - (01)

9.6 BCS SOFTWARE
14.1 Service Interval
Fig. 22 14.1 Service Interval - 643151a
This menu provides detailed information on service intervals.
3721506en - (01) Page 9.6.5 - 9

9.6 BCS SOFTWARE

1 Number of hours up to the next service interval for:
 Total:
 Engine left hand side
 Engine right hand side
2 Information on the oil change interval for the left and the right engine.
 Use this menu to confirm that the service has been done.
 Use the “BCS Configuration” menu to specify the service interval.
4 Confirmation button for a performed service.
6 Information on the service interval.

 Use this menu to confirm that the service has been done.
 Use the “BCS Configuration” menu to specify the service interval.
Page 9.6.5 - 10 3721506en - (01)

9.6 BCS SOFTWARE
15.0 Signal Configuration
5 4 3
643020
Fig. 23 15.0 Signal Configuration - 643020
This menu provides detailed information for the settings of an individual signal. There is one ID specified for
each signal generated by any of the sensors on any of the machines. The list of signals includes all signals
specified for any of the machines.
In the commissioning phase, those signals are configured that are applicable for the type of excavator and
the option of an individual machine.
3721506en - (01) Page 9.6.5 - 11

9.6 BCS SOFTWARE

1 Key data of an individual signal:
 Signal Identifier
 Description of the signal
 Identifier of the related sensor
Select an individual signal by scrolling in the list of signals:
 First line
 Reverse
 Forward
 Last line
2 Data provided for each signal:

 Active:
o Checkmark set: The signal is active in the machine at hand
o Otherwise: The signal is not applicable
 Analog:
o Checkmark set: An analog sensor generates the signal.
o Otherwise: A digital sensor generates the signal.
 Type and Unit (analog sensors only):
o Indicates the type of information monitored by the sensor and the
unit of measurement.
o Cross-check that the information for the type and the unit match.
 Conversion factor (analog sensors only):
Correlation between the measured signal and the displayed value.
 Min / Max (analog sensors only):
Minimum/maximum value to be displayed. If the currently measured val-
ue falls below/exceeds the specified value, the min/max value is dis-
played instead of the currently measured value.
Example: The maximum value specified for the pressure is 400 mbar. If
the currently measured value is 410 mbar, the display still shows 400
mbar.
 Error Type:
Fault category to be displayed in the main menu if the signal value
reaches the specified check conditions.
o Engine Stop LH
o Engine Stop RH
o Engine Warning LH
o Engine Warning RH
o Hydraulic
o Lubrication
 Auto Logg File: Not applicable
 Check:
o Checkmark set: Criteria can be specified for triggering a fault mes-
sage.
o Otherwise: No fault message is correlated with the signal.
 Limit (analog sensors only):
Value of the threshold for triggering an fault message
Page 9.6.5 - 12 3721506en - (01)

9.6 BCS SOFTWARE

 Logic: Specifies whether the limit indicates the upper or lower limit.
o Digital sensors:
Checkmark set: fail save
Otherwise: active high
o Analog sensors:
Checkmark set: upper limit
Otherwise: lower limit
 Condition: For some signals a precondition needs to be fulfilled to gen-
erate a signal within the limits specified for normal operation:
o Hydraulic oil temperature > 40 °C
o Speed LH > 0
o Speed LH > 850
o Speed LH > 1200
o Speed LH > 1600
o Speed RH > 0
o Speed RH > 850
o Speed RH > 1200
o Speed RH > 1600
A fault messages is only generated if both of the following criteria are
true:
o The signal value reaches the specified threshold
o The condition for measuring the value is fulfilled
 Beep Alarm: Acoustic signal indicating that the fault is active.
 Time delay – Fault active: Specifies how long the threshold must be
reached before the fault becomes active.
 Time delay – no Fault active: Specifies how long the value of the signal
must be back in the range for normal operation so that the fault be-
comes inactive.
 Implication: Specifies whether an engine stop / shut down is correlated
with the fault message.
o Specify the shutdown conditions for the engine in the “Engine con-
troller“ menu under “shutdown“.
The engine is only shut down in the event of a fault if both of the fol-
lowing criteria are true:
o The Implication for this fault is set to shut down.
o The shutdown of the engine is enabled in the “Engine controller”
menu.

 Changing the data of this menu requires the level 2 service code.
3721506en - (01) Page 9.6.5 - 13

9.6 BCS SOFTWARE
15.1 Signal List
4 3
643021
Fig. 24 15.1 Signal List - 643021
This menu provides information on data for several signals at a glance.
Page 9.6.5 - 14 3721506en - (01)

9.6 BCS SOFTWARE

1 Data provided for each analog signals
 ID: Signal identifier (please note that the display shows only the first
three digits)
 Active:
 Name: Description of the signal
 Unit:
o Indicates the type of information monitored by the sensor and the
unit of measurement.
o Cross-check that the information for the type and the unit match.
 Min / Max:
Minimum/maximum value to be displayed. If the currently measured val-
ue falls below/exceeds the specified value, the min/max value is dis-
played instead of the currently measured value.
Example: The maximum value specified for the pressure is 400 mbar. If
the currently measured value is 410 mbar, the display still shows 400
mbar.
 Check:
sage.
 Limit: Value of the threshold for triggering an fault message
 Upper limit:
o Checkmark set: upper limit
o Otherwise: lower limit
 On Time: Specifies how long the threshold must be reached before the
fault becomes active.
 Off Time: Specifies how long the value of the signal must be back in the
range for normal operation so that the fault becomes inactive.
o 1: Hydraulic oil temperature > 40 °C
o 2: Speed LH > 0
o 3: Speed LH > 850
o 4: Speed LH > 1200
o 6: Speed RH > 0
o 7: Speed RH > 850
o 8: Speed RH > 1200
true:
 factor: Correlation between the measured signal and the displayed val-
ue.
3721506en - (01) Page 9.6.5 - 15

9.6 BCS SOFTWARE

2 Data provided for digital signals:
 ID: Signal identifier (please note that the display shows only the first
three digits)
 Active:
 Name: Description of the signal
 Check:
sage.
o 1: Hydraulic oil temperature > 40 °C
o 2: Speed LH > 0
o 3: Speed LH > 850
o 6: Speed RH > 0
o 7: Speed RH > 850
true:
 Fail safe
o Checkmark set: fail save
o Otherwise: active high
 Time delay – Fault active: Specifies how long the threshold must be
reached before the fault becomes active.
 Time delay – no Fault active: Specifies how long the value of the signal
must be back in the range for normal operation so that the fault be-
comes inactive.
Page 9.6.5 - 16 3721506en - (01)

9.6 BCS SOFTWARE
16.0 Controllers
3
6
6 5 3 2 4
643022
Fig. 25 16.0 Controllers - 643022
This menu is the starting point for information on controllers. Level 1 service password is sufficient for read-
ing the data. For changing the settings, the level 2 password is required.
3721506en - (01) Page 9.6.5 - 17

9.6 BCS SOFTWARE

2 Open “Engine Controller –right -” menu
3 Open “Engine Controller –left –“ menu
5 Open “Auxiliary Controller” menu
6 Open “Servo Controller” menu
Page 9.6.5 - 18 3721506en - (01)

9.6 BCS SOFTWARE
17.0 Servo Controller Subunit CPU1
1 2 3
6 5
643023
Fig. 26 17.0 Servo Controller Subunit CPU1 - 643023
This menu provides information on the sensors connected to CPU1 of the servo controller.

1 Sensors are connected to the X1 cabinet located underneath the operators
cabin.
2 Sensors with digital input:
 Sens. (Mode A): Sensor identifier
 Term. (Mode B): Terminal identifier the sensor is connected to in the
control cabinet
 Name of the sensor
o green: Active
o red: Fault
o light grey: inactive but no fault
o dark grey: sensor not applicable for this machine
3721506en - (01) Page 9.6.5 - 19

9.6 BCS SOFTWARE

3 Sensors with PWM (pulse wide modulation) output:
control cabinet
 Measured Current for the proportional valve in mA
The basic current is 70 mA as the valve reacts faster with the basic current
applied in rest position.
A high value for the sensor indicates fast movements.

 If the movements are slower than expected, cross-check for the related
sensor the specified value, the displayed value and the value measured
at the valve.
 If all the values match, check the hydraulic system.
4 Sensors with analog input:
control cabinet
 Monitored value in bar /mbar (Mode A)
 Measured current in mA (Mode B)
The servo sensor measures the servo pressure in bar.

The hydraulic filters 1 / 2 sensors are differential pressure switches. They
indicate the contamination of the filters. For thresholds specified for the sen-
sors see “signal configuration” menu.
 If a fault is active first change the filter. If the fault is still active, check
the functionality of the sensor.
6 Switch between the two modes to identify the sensor:

 Mode A (dark red): Sensor identifier
 Mode B (blue): Terminal identifier the sensor is connected to in the con-
trol cabinet
The Mode button shows the currently active mode.
Page 9.6.5 - 20 3721506en - (01)

9.6 BCS SOFTWARE
17.1 Servo Controller Subunit CPU2
1 2 3
6 5
643024
Fig. 27 17.1 Servo Controller Subunit CPU2 - 643024
This menu provides information on the sensors connected to CPU2 of the servo controller.

cabin.
control cabinet
o green: Active
o red: Fault
3721506en - (01) Page 9.6.5 - 21

9.6 BCS SOFTWARE

control cabinet
A base current of 70 mA is used for the valve in rest position so that it is

magnetized and can react on parameter changes without dead time.

at the valve.
control cabinet
 Monitored value in bar / °C (Mode A)

trol cabinet
Page 9.6.5 - 22 3721506en - (01)

9.6 BCS SOFTWARE
17.2 Servo Controller Subunit ICN V
1 2 3
5 4
643025
Fig. 28 17.2 Servo Controller Subunit ICN V -643025
This menu provides information on the sensors connected to the ICN-V-Unit of the servo controller.
3721506en - (01) Page 9.6.5 - 23

9.6 BCS SOFTWARE

cabin.
control cabinet
o green: Active
o red: Fault
3 Sensors with digital output:
control cabinet
 green: Active
 red: Fault
 light grey: inactive but no fault
 dark grey: sensor not applicable for this machine

trol cabinet
Page 9.6.5 - 24 3721506en - (01)

9.6 BCS SOFTWARE
17.3 Controller Configuration
1 2 3
10
9 8 7 6 5
643026
Fig. 29 17.3 Controller Configuration - 643026
This menu is used to specify parameters controlling the movements of machine components.
3721506en - (01) Page 9.6.5 - 25

9.6 BCS SOFTWARE

1 Machine type and function
 Select the movement to be configured for an individual machine type.
2 Parameter available for controlling the movement
 Ascent / descent: Specifies how fast the proportional valve opens and
closes. The delay for opening and closing the valve reduces the me-
chanical load during the adjustment.
o Low value – slow reaction (1000 – 3000)
o High value – faster reaction (3001 – 5000)
Make sure that the time for adjusting the valve suits to the timeframe of
the movement controlled by the valve. If, for example, the valve closes
very slowly, the machine cannot react fast enough in a critical situation.
Example:
o Value 1 (mA/s): The valve would need 650 seconds to open.
o Value 650 (mA/s): The valve would need 1 second to open.
 Interm. Position: Percentage of the hand lever movement up to which
precision control is possible via hand lever. Above the intermediate po-
sition, coarse adjustment starts.
o A higher value gives a longer way of fine control.
 Basis current: All proportional valves are supplied with 70mA to keep
the caps of the main control valves constantly full of oil to get a better
response of the machine.
 Start current: The current which is sent to the proportional valve as soon
as the dead travel of the joystick/foot pedal is exceeded.
o All joysticks and foot pedals have a dead travel of 15%.
 Interm Current: Current triggered by the hand lever move up which pre-
cision control is possible. Above the intermediate current, coarse ad-
justment starts.
o A higher value gives a quicker current raise at less controller move-
ment.
 End current: The current which is sent to the proportional valve as soon
as joystick/foot pedal stroke is 100%.
o The maximum setting for the End Current is 720mA. Some functions
like clamp close, boom down etc. might be reduced to slow down
these individual functions.
o Adjust the maximum current to the degree of speed applicable to the
location. Make sure that the driver can control the machine move-
ments in all situations.
3 Data sets for the parameters:
 Actual: Currently active values
 Factory setting: Default setting configured in the factory. These settings
cannot be changed.
 Mode A / B / C: Three parameter sets can be configured for different
purposes. Level 2 service code is required to specify the parameter sets
and to select the one that is active.
Page 9.6.5 - 26 3721506en - (01)

9.6 BCS SOFTWARE

4 Diagram illustrating the key characteristics of mode A, B, or C compared to
the factory mode.
2 3
1. Basis current
2. Start current
3. Left/right: Intermediate position
Up/down: Itermediate current
4. End current
5 Exit the current menu and enter the “Servo controller” menu.
6 Check SDO: Check of the current value against the mode specified with
„Set Mode”. The value that does not match is displayed next to the “Check
SDO” button.
7 Retry: The values currently used in the controller are displayed.
10 Set the active mode

 Use the retry button to write the factory setting to mode A, B, or C.
 To get back to the factory settings select “Factory” button and write this
data back to the controller.
3721506en - (01) Page 9.6.5 - 27

9.6 BCS SOFTWARE
17.4 Servo Controller Cyl. Cutoff
5 4
643027
Fig. 30 17.4 Servo Controller Cyl. Cutoff - 643027
This menu is used to specify the behaviour of the shovel and the stick when it reaches the mechanical stop.

1 Tap on the figure to see the details of the induction switch at the stick
2 Tap on the figure to see the details of the induction switch at the shovel
3 Movements with mechanical stops are:
 Stick out
 Shovel in
 Shovel out
 Reduction in percentage: Specifies the percentage of current used to

control the movement next to the mechanical stop.
 Rate (mA/s): Delay for adjusting the current. In other words, the current
is reduced within a defined period of time.
Page 9.6.5 - 28 3721506en - (01)

9.6 BCS SOFTWARE
17.5 Servo Controller History
1
5
4 3
643028
Fig. 31 17.5 Servo Controller History - 643028
This menu provides information on CPUs and software versions of the Servo controller.
3721506en - (01) Page 9.6.5 - 29

9.6 BCS SOFTWARE

1 Information on the two CPUs of the Servo controller:
 Serial No.: Serial number of the CPU according to the manufacturer of the
CPU hardware
 Firmware Version: Version of the basic controller software provided by
the software supplier
 Software Version: Version of the CAMP software
2 Current software version of the servo controller and the change history for all
previous versions.
5 Last update of the servo controller parameter
Page 9.6.5 - 30 3721506en - (01)

9.6 BCS SOFTWARE
18.0 Auxiliary Controller Subunit I/O
1 2 3 4
6 5
643029
Fig. 32 18.0 Auxiliary Controller Subunit I/O - 643029
This menu shows information on sensors controlled by the extension card of the auxiliary controller.

cabin.
control cabinet
 green: Active
 red: Fault
3721506en - (01) Page 9.6.5 - 31

9.6 BCS SOFTWARE

control cabinet
o green: Active
o red: Fault
4 Sensors with analog output:
control cabinet
o green: Active
o red: Fault
 Monitored value in bar (Mode A)

trol cabinet
Page 9.6.5 - 32 3721506en - (01)

9.6 BCS SOFTWARE
18.1 Auxiliary Controller Subunit CPU_F
1 2 3 4
6 5
643030
Fig. 33 18.1 Auxiliary Controller Subunit CPU_F - 643030
This menu shows information on sensors controlled by the auxiliary controller.

cabin.
control cabinet
 green: Active
 red: Fault
3721506en - (01) Page 9.6.5 - 33

9.6 BCS SOFTWARE

control cabinet
o green: Active
o red: Fault
control cabinet
o green: Active
o red: Fault
 Monitored value in bar (Mode A)

trol cabinet
Page 9.6.5 - 34 3721506en - (01)

9.6 BCS SOFTWARE
18.2 Auxiliary Controller Settings
Fig. 34 18.2 Auxiliary Controller Settings - 643152
This menu is for specifying parameters related to the lubrication cycle and the light. The amount of grease
required for an individual component is set at the grease distributors.
3721506en - (01) Page 9.6.5 - 35

9.6 BCS SOFTWARE

1 Select the lubrication system applicable to the machine.
2 The left hand side and the right hand side of the machine (line A and B) are
lubricated alternately.
Data related to the upper carriage:

 Wait time to next lub: Time between two lubrication processes, applica-
ble to all components connected to the central lubrication system.
 Max. lubrication time: A fault message is triggered as soon the lubrica-
tion process for one of the two lines exceeds the maximum lubrication
time.
 Alarm rejection: Time the trigger conditions for the alarm need to be
exceeded before the alarm is triggered.
 Sensor press: Not applicable
3 The lubrication system of the under carriage consists of a single-line sys-
tem. Grease is pressed into the rollers.
Data related to the under carriage:

 lower switch point pressure / wait time lower pressure:
If the grease pump starts to work, the pressure has to reach the lower
switch point pressure at the pressure sensor -5B7 within the wait time
lower pressure.
 Superior switch point pressure / wait time superior pressure:
If the lower switch point pressure has been reached, the superior switch
point pressure has to be reached within the wait time superior pressure.
If the pressure increases too slowly, a leakage might be the reason.
 Wait time sup. To lower press:
If the superior switch point pressure is reached, the lubrication is com-
pleted. The lubrication system is switched off and the pressure has to
fall to the lower switch point pressure within the wait time sup. To lower
press.
 Sensor pressure offset: not applicable
4  Error time before stop bucket:
To prevent damages at the machine, the bucket function is switched of if
the lubrication system does not work. This parameter specifies the time
between the triggering of the alarm and the stop of the bucket.
 Lighting Ladder Time Delay:

The lights are switched on from the ground by means of a pull-rope be-
neath the superstructure. They turn off automatically after the time speci-
fied here.
If you have changed any of the data, tip “yes” to enable the modification.
Page 9.6.5 - 36 3721506en - (01)

9.6 BCS SOFTWARE
18.3 Auxiliary Controller History
1
2
5 4
643032
Fig. 35 18.3 Auxiliary Controller History - 643032
This menu provides information on CPU and software versions of the Auxiliary controller.

1 Information on the CPU of the controller:
 Serial No.: Serial number of the CPU according to the manufacturer of
the CPU hardware
2 Last update of the auxiliary controller parameters
3 Current software version of the servo controller and the change history for
all previous versions.
3721506en - (01) Page 9.6.5 - 37

9.6 BCS SOFTWARE
19.0 LH Drive Controller Analog
Fig. 36 19.0 LH Engine Controller Analog - 643184
This menu provides information on analog sensors connected to the LH engine controller.
Page 9.6.5 - 38 3721506en - (01)

9.6 BCS SOFTWARE

1 Sensors are connected to the X30 cabinet located next to the left hand side
engine.
control cabinet
All proportional valves are supplied with 70mA to keep the caps of the main
control valves constantly full of oil to get a better response of the machine.

at the valve.
Sensors:
 PV pump control: Monitors the regulation of the pump. The regulator is
controlled by a proportional valve connected to the electronic load-limit
regulator.Water cooler fan reg.: Monitors the regulation of the radiator
fan for the cooling water circuit of the engine. The proportional valve
regulates the rotation speed of the radiator fan.
 Oil cooler fan reg.: Monitors the regulation of the fans for cooling the
hydraulic oil.
The failsafe systems for the fans is set up as follows:

 A low controller output current initiates a high speed level of the fan.
 A high controller output current initiates a low speed level of the fan.
Due to this setting, the fans run at full speed in the event of a low current in
the event of an error for example due to damages at the cable.
3721506en - (01) Page 9.6.5 - 39

9.6 BCS SOFTWARE

control cabinet
 Monitored value in V / bar / °C (Mode A)
Sensors:
 Fuel level: in percentage; the sensor sends between 0 and 10 V to the
controller.
 R-Contact: The R-Contact is located at the alternator of the engine. If
the R-Contact sends a signal, it can be assumed that the engine is run-
ning. This signal is used as indicator for a running engine within the con-
trol system
 Recognition LH/RH: Sets the actuator to LH or RH.
 Hydraulic Oil temp: Monitors the temperature of the hydraulic oil
 PTG Oil Temp: Monitors the temperature of the pump transfer gearbox
 Feed pump slewing press.: Monitors the pressure of the slewing de-
vice’s feed pump
 Pump control pressure: Monitors the pressure in the pump valves

trol cabinet
6 Switch between the menu for the left and the right system.
Green: engine is running

Grey: engine is switched off
7 In the test mode, the signal of a running engine is generated for testing pur-
poses
 Use this mode to test sensors which only work, if they receive an ‘En-
gine Running’-signal.
8 Open menu for copying data to a USB stick.
Page 9.6.5 - 40 3721506en - (01)

9.6 BCS SOFTWARE
19.1 LH Drive Controller Digital
Fig. 37 19.1 LH Engine Controller Digital - 643185
This menu provides information on digital sensors connected to the LH engine controller.

1 Sensors are connected to the X30 cabinet located underneath the opera-
tors cabin.
control cabinet
o green: Active
o red: Fault
3721506en - (01) Page 9.6.5 - 41

9.6 BCS SOFTWARE

control cabinet
o green: Active
o red: Fault
control cabinet
o green: Active
o red: Fault

 Mode B (blue): Terminal identifier the sensor is connected to in the
control cabinet

8 In the test mode, the signal of a running engine is generated for testing
purposes
9 Open menu for copying controller data to a USB stick.
Page 9.6.5 - 42 3721506en - (01)

9.6 BCS SOFTWARE
19.2 LH Drive Controller Settings
Fig. 38 19.2 LH Engine Controller Settings - 643186
3721506en - (01) Page 9.6.5 - 43

9.6 BCS SOFTWARE

1 Load limit parameters
 Start point: Start current for the Proportional Valves (Pump Flow) when
Pump Management System Start action.
 Increase: Increasing current (250mA per second) Current for the Pro-
portional Valves when Pump Management is in action.
 Proportional gain: Controller adjustment cruise, mA/per 100 rpm differ-
ence of the real engine speed an the set rotation speed.
 Integral action time: Time readjusting to the current value
 Derivative time: not applicable
 High: Upper idle engine
 Rated speed at % of full load speed fixed speed barrier: Computational
variable for calculation of the speed set point
 Turn on speed: Speed set point
 % fraction: Percent value for calculation of the turn off speed. Percent
value from fixed speed barrier
 Turn OFF speed: Turn off speed controller
2 Current characteristic curve over time in mA
3 System state
 No. of mean val. / Fact. Current ampli.: Computational variable for cal-
culation hydraulic countermeasures. (Currently only used in
RH70)
 Contr. Stat: Switch on/off Controller Pump Management
 Superpos.: Switch on/off Superposition System
 Actuating variable: Actual current proportional valve pumps
 Controller: Controller on/off
 Ramp: Hand lever controlling on/off

poses
Page 9.6.5 - 44 3721506en - (01)

9.6 BCS SOFTWARE
19.2.1 Diagram
5 7
8
4 9
3
10
2
11
643009
Fig. 39 Diagram -643009
riod of time. When opened from the “Engine Controller Settings” menu, the following signal sources are pre-
selected:
 Speed
 Prop. Current
 Prop. Pressure
 Main pump pressure
3721506en - (01) Page 9.6.5 - 45

9.6 BCS SOFTWARE

displayed.

 Actual value
in other programs such as excel.

sources.

ent colors.
 Scroll up
 Scale up
 Scale down

 Scroll down
9 Scroll through the time scale
10 Log file sample time: Select 50 or 100 ms
19.2.2 Log file
Not applicable.
Page 9.6.5 - 46 3721506en - (01)

9.6 BCS SOFTWARE
19.3 LH Drive Controller Fan Regulation
Fig. 40 19.3 LH Engine Controller Fan regulation - 643187
3721506en - (01) Page 9.6.5 - 47

9.6 BCS SOFTWARE

1 Engine cooling
 Monitored parameters are the temperature of the engine coolant and
the Intake Manifold Temperature (IMT). The one of both parameters that
has a higher value triggers the speed level of the fan.
 Specify the ramp for fan regulation via the upper, the lower and the av-
erage value.
 Current values are displayed in the black boxes (in mA for the current
and °C for the temperature)
erage value.

poses
Page 9.6.5 - 48 3721506en - (01)

9.6 BCS SOFTWARE
19.4 Shutdown
Fig. 41 19.4 Shutdown - 643188
3721506en - (01) Page 9.6.5 - 49

9.6 BCS SOFTWARE

1 Condition for shutting down the engine:
 Only if both engines are running: An engine can only be shut down if the
other engine is still running. This mode allows the driver to leave the
danger zone with the machine.
 Always: Shut down the engine as soon as the trigger conditions are
reached.
 After x seconds: The engine shuts down a specified time after the trig-
ger conditions for shutting down the engine are fulfilled. This mode al-
lows the driver to leave the danger zone with the engine.
2 Cold area warm up mode:
 The engine speed goes to 1300rpm and the pumps go to maximum
deflection (if lowering speed automatic is active)
 Specify thresholds for the water temperature and the hydraulic tempera-
ture to start cold area warm up mode.
This mode is only active if the engine is running. Trigger conditions are:
 The coolant temperature is below 70 °C
 The hydraulic oil temperature is below 20 °C
As soon as the excavator starts to work, the mode is switched off.

poses
Page 9.6.5 - 50 3721506en - (01)

9.6 BCS SOFTWARE
19.5 LH Drive Controller History
Fig. 42 19.5 LH Engine Controller History - 643189
3721506en - (01) Page 9.6.5 - 51

9.6 BCS SOFTWARE

 Serial No.: Serial number of the CPU according to the manufacturer of
the CPU hardware
2 Last update of the LH engine controller parameters
3 Current software version of the servo controller and the change history for
all previous versions.

poses
Page 9.6.5 - 52 3721506en - (01)

9.6 BCS SOFTWARE
20.0 RH Engine Controller Analog
Fig. 43 20.0 RH Engine Controller Analog - 643190
This menu provides information on analog sensors connected to the RH engine controller.
3721506en - (01) Page 9.6.5 - 53

9.6 BCS SOFTWARE

1 Sensors are connected to the X40 cabinet located next to the left hand side
engine.
control cabinet
 Monitored value in V / bar / °C (Mode A)
Sensors:
 Fuel level: in percentage; the sensor sends between 0 and 10 V to the
controller.
 R-Contact: The R-Contact is located at the alternator of the engine. If
the R-Contact sends a signal, it can be assumed that the engine is run-
ning. This signal is used as indicator for a running engine within the con-
trol system
 Recognition LH/RH: Sets the actuator to LH or RH.
 Hydraulic Oil temp: Monitors the temperature of the hydraulic oil
 PTG Oil Temp: Monitors the temperature of the pump transfer gearbox
 Feed pump slewing press.: Monitors the pressure of the slewing de-
vice’s feed pump
 Pump control pressure: Monitors the pressure in the pump valves
control cabinet
All proportional valves are supplied with 70mA to keep the caps of the main
control valves constantly full of oil to get a better response of the machine.

at the valve.
Sensors:
 PV pump control: Monitors the regulation of the pump. The regulator is
controlled by a proportional valve connected to the electronic load-limit
regulator.Water cooler fan reg.: Monitors the regulation of the radiator
fan for the cooling water circuit of the engine. The proportional valve
regulates the rotation speed of the radiator fan.
 Oil cooler fan reg.: Monitors the regulation of the fans for cooling the
hydraulic oil.
The failsafe systems for the fans is set up as follows:

 A low controller output current initiates a high speed level of the fan.
 A high controller output current initiates a low speed level of the fan.
Due to this setting, the fans run at full speed in the event of a low current in
the event of an error for example due to damages at the cable.
Page 9.6.5 - 54 3721506en - (01)

9.6 BCS SOFTWARE


trol cabinet

poses
3721506en - (01) Page 9.6.5 - 55

9.6 BCS SOFTWARE
20.1 RH Drive Controller Digital
Fig. 44 20.1 RH Engine Controller Digital - 643191
This menu provides information on digital sensors connected to the RH engine controller.

1 Sensors are connected to the X40 cabinet located underneath the opera-
tors cabin.
control cabinet
o green: Active
o red: Fault
Page 9.6.5 - 56 3721506en - (01)

9.6 BCS SOFTWARE

control cabinet
o green: Active
o red: Fault
control cabinet
o green: Active
o red: Fault

 Mode B (blue): Terminal identifier the sensor is connected to in the
control cabinet

8 In the test mode, the signal of a running engine is generated for testing
purposes
3721506en - (01) Page 9.6.5 - 57

9.6 BCS SOFTWARE
20.2 RH Drive Controller Settings
Fig. 45 20.2 RH Engine Controller Settings - 643192

1 Load limit parameters
 Start point: Start current for the Proportional Valves (Pump Flow) when
Pump Management System Start action.
 Increase: Increasing current (250mA per second) Current for the Pro-
portional Valves when Pump Management is in action.
 Proportional gain: Controller adjustment cruise, mA/per 100 rpm differ-
ence of the real engine speed and the set rotation speed.
 Integral action time: Time readjusting to the current value
 Derivative time: not applicable
 High: Upper idle engine
 Rated speed at % of full load speed fixed speed barrier: Computational
variable for calculation of the speed set point
 Turn on speed: Speed set point
 % fraction: Percent value for calculation of the turn off speed. Percent
value from fixed speed barrier
 Turn OFF speed: Turn off speed controller
Page 9.6.5 - 58 3721506en - (01)

9.6 BCS SOFTWARE
2 Current characteristic curve over time in mA

3 System state
 No. of mean val. / Fact. Current ampli.: Computational variable for cal-
culation hydraulic countermeasures. (Currently only used in
RH70)
 Contr. Stat: Switch on/off Controller Pump Management
 Superpos.: Switch on/off Superposition System
 Actuating variable: Actual current proportional valve pumps
 Controller: Controller on/off
 Ramp: Hand lever controlling on/off

poses
3721506en - (01) Page 9.6.5 - 59

9.6 BCS SOFTWARE
20.2.1 Diagram
5 7
8
4 9
3
10
2
11
643009
Fig. 46 Diagram - 643009
riod of time. When opened from the “Engine Controller Settings” menu, the following signal sources are pre-
selected:
 Speed
 Prop. Current
 Prop. Pressure
 Main pump pressure
Page 9.6.5 - 60 3721506en - (01)

9.6 BCS SOFTWARE

displayed.

 Actual value
in other programs such as excel.

sources.

ent colors.
 Scroll up
 Scale up
 Scale down

 Scroll down
9 Scroll through the time scale
10 Logfile sample time: Select 50 or 100 ms
20.2.2 Log file
Not applicable.
3721506en - (01) Page 9.6.5 - 61

9.6 BCS SOFTWARE
20.3 RH Drive Controller Fan Regulation
Fig. 47 20.3 RH Engine Fan regulation - 643193
Page 9.6.5 - 62 3721506en - (01)

9.6 BCS SOFTWARE

1 Engine cooling
 Monitored parameters are the temperature of the engine coolant and
the Intake Manifold Temperature (IMT). The parameter that has the
higher value triggers the speed level of the fan.
erage value.
erage value.

poses
3721506en - (01) Page 9.6.5 - 63

9.6 BCS SOFTWARE
20.4 RH Engine Shutdown
Fig. 48 20.4 RH Engine Shutdown - 643194
Page 9.6.5 - 64 3721506en - (01)

9.6 BCS SOFTWARE

1 Condition for shutting down the engine:
 Only if both engines are running: An engine can only be shut down if the
other engine is still running. This mode allows the driver to leave the
danger zone with the machine.
 Always: Shut down the engine as soon as the trigger conditions are
reached.
 After x seconds: The engine shuts down a specified time after the trig-
ger conditions for shutting down the engine are fulfilled. This mode al-
lows the driver to leave the danger zone with the engine.
2 Cold area warm up mode:
 The engine speed goes to 1300rpm and the pumps go to maximum
deflection (if lowering speed automatic is active)
 Specify thresholds for the water temperature and the hydraulic tempera-
ture to start cold area warm up mode.
This mode is only active if the engine is running. Trigger conditions are:
 The coolant temperature is below 70 °C
 The hydraulic oil temperature is below 20 °C
As soon as the excavator starts to work, the mode is switched off.

poses
3721506en - (01) Page 9.6.5 - 65

9.6 BCS SOFTWARE
20.5 RH Engine History
Fig. 49 20.5 RH Engine History - 643195

 Serial No.: Serial number of the CPU according to the manu-
facturer of the CPU hardware
 Firmware Version: Version of the basic controller software
provided by the software supplier
2 Last update of the RH engine controller parameters
3 Current software version of the servo controller and the change
history for all previous versions.

6 In the test mode, the signal of a running engine is generated for
testing purposes
 Use this mode to test sensors which only work, if they re-
ceive an ‘Engine Running’-signal.
Page 9.6.5 - 66 3721506en - (01)

9.6 BCS SOFTWARE
3721506en - (01) Page 9.6.5 - 67

9.6 BCS SOFTWARE
Page 9.6.5 - 68 3721506en - (01)

9.7 TROUBLESHOOTING
9.7 Troubleshooting Dismantling components

This section describes how to react in the event of
an error/alarm in terms of: Never do dismantling while the machine is at oper-
 Identifying the reason for the failure/alarm ating temperature.
 Solving the problem Oils, greases, or coolants may have a high tem-
 Bringing the machine back to normal operation perature and result in burning or scalding.
Leave time for the machine to cool down.
For information on replacing faulty hardware com- Before starting work, depressurize piping and
ponents see section “Control And Monitoring Plat- hoses, cylinders, radiator, hydraulic tank and other
form (CAMP)”. systems or units.
Replace defective components in good time to
prevent major damage.
Clean the defective component carefully before
9.7.1 Safety instructions dismantling it.
Mark the dismantled parts in the correct sequence
to facilitate re-assembly.
Reading the technical documentation When dismantling the component, close off ex-
posed hose and piping connections, exposed drill
Never carry out repair work without having read holes and housings carefully to prevent any dirt
and understood the operating instructions. from penetrating.
Pay special attention to: "Fundamental Safety In-
structions", "Inspection and servicing – safety in- Never remove lead seals
structions" and all warnings and safety instructions
attached to the machine. Never change rated pressure of pressure relief
The descriptions of job sequences provide only valves without the explicit authorization of Bucyrus
experienced personnel with the necessary instruc- HEX.
tions. Never remove lead seals from pressure relief
The operating manual must be kept with the ma- valves and accumulators.
chine at all times.
After the repair work
Repair personnel
To prevent corrosion, coat all bright metal machine
Repair personnel must have know-how and ex- parts with a grease film.
perience relevant to repairing this or comparable On completing the work, re-assemble all protective
machines. devices, covers and noise- and vibration insulation
In the absence of such know-how, meticulous material.
training must be given by experienced repair per- Never start up the drive engines while work is be-
sonnel, e.g. from Bucyrus HEX. ing done on the machine.
Check the repaired components and all machine
Working in greater heights functions in a trial run.
Never release the machine for recommissioning
Always wear safety harnesses when working at until it is fully functioning.
greater heights.
Wear an approved safety harness; it must be
equipped with fall arresters and safety cables.
Prestressed units
Never open defective prestressed units but replace

them as an entirety.
In exceptional cases, open only when the system
and the operating sequence are precisely known
and any special tools required are available.
The operating manual contains no information on
this point.
3721493en - (00) Page 9.7 - 1

9.7 TROUBLESHOOTING
Working functions are produced by: Motors, gen-

9.7.2 General troubleshooting erators, solenoid valves, lamps etc. Switch ele-
ments, e.g. switches, relays, pressure monitors,
control these working functions.
9.7.2.1 General troubleshooting procedure
This section
If an error message becomes active in normal
 Introduces the basic procedure to be followed
operation, follow the step-by-step procedure for
for solving a problem
checking the alarm menu and solving the alarm.
 Illustrates the procedure by an example
 Lists specific information for each error identi-
fied by an error-ID
Preparing the machine for solving the error  Explains how to work on electronical compo-
nents such as terminal strips, hartings, circuit
1. Park the machine on level and stable ground. breakers, relay contacts, diods, sensors,
2. Stand the working equipment on the ground. switches, valves
3. Shut off the engines.
4. Depressurize the hydraulic system.
a. While pressing the “Emergency loads“ Basic procedure
switch, move each lever in all directions
5. Withdraw the key from the key-switch. 1. Recognition/notification of fault.
6. Switch of the battery main switch and secure it
secured with a padlock against unintended re- 2. Determination of the actual working function
start. (using circuit diagram and key) - determination
of the functions carried out.
3. Voltage measurements. Measuring points as

Solving the error stated in the connection tables.
1. Check the alarm menu for the fault message. 4. Evaluation of the measurements. "Yes/No"
2. Look up the error description and correction judgements using the results of the measure-
task in section “9.6.4 Specific troubleshooting ments. Each check requires an answer to ei-
per error-ID”. ther "Fault located?" of "Which measuring
3. Solve the problem according to the procedure point next?".
identified in step 2.
5. Remedying of fault.
Restarting the machine

Example
1. Make sure that all errors are solved and the
machine is ready for normal operation. If there The following example has been chosen to simu-
are still errors indicated by the BCS, start this late the trouble-shooting procedure.
procedure again until all problems are solved.
2. Restart the machine for normal operation as Assumed fault: The engine cold-start system is not
described in the operating manual. working. Mechanical systems have been checked
over and found to be in working order.
9.7.2.2 Using circuit diagram and key

1. Locate the components responsible for working
In the majority of cases when trouble-shooting on functions from the key (Page 7).
the electrical system, a voltage tester or meter
(machine system = 24 Volt) is usually all that is The cold-start system is put into action by a so-
required in addition to the circuit diagrams. lenoid valve. Solenoid valves are coded with
the letter Y. The solenoid valve for the cold-start
A rule of thumb is: Start trouble-shooting at the system is Y 2.
point where the required working function is
needed, respectively is not happening.
Page 9.7 - 2 3721493en - (00)

9.7 TROUBLESHOOTING
Reading across the line Y 2, one finds the ap-

proximate location of the valve and its current
path in the diagram.
Location: engine
Current Path: 1-8/40
In addition, the location of the valve can be de-

termined using the layout illustration Fig.1,
Page 4.
2. The next step is to acquaint oneself with the

function of the system using the circuit diagram
(Fig. 4) and the key (Fig. 3):
The relay 3.1 is energized when button S
21 is pressed (but only at temperatures be-
low 25°C as temperature sensor S 34 is
otherwise open). The contact of relay 3.1
closes the circuit to solenoid valve Y 2.
The valve opens and injects cold-start fluid
into the engine's intake manifold.
3. Carry out voltage checks. The connection ta-

bles for terminal strips and plug/socket con-
nections (e.g. table for terminal strip X 1, Page
12, Fig. 2) indicate the metering points. Fig. 1
shows how to proceed systematically through
the trouble-shooting procedure.
3721493en - (00) Page 9.7 - 3

9.7 TROUBLESHOOTING
643057
Fig. 1 Troubleshooting diagram - 643057
Page 9.7 - 4 3721493en - (00)

9.7 TROUBLESHOOTING
9.7.2.3 Testing electrical components
This section explains techniques to test whether

the electronical components work properly.
Terminal Strips Diodes
In electronics, a diode is a two-terminal electronic

component that conducts electric current in only
one direction. Diodes can be seen as electronic
check valves. Fig. 4 Blockage voltage - 643128
Circuit breakers
If the circuit breaker is deactivated (Pin out), the

contacts should have no continuity.
2 1 643126
Fig. 2 Diodes - 643126
The diode works properly if the blockage voltage of

the diode is around 0.7V.
643130
Fig. 5 Breaker deactivated - 643130
If the circuit breaker is activated (Pin in), the con-

tacts should have continuity.
Fig. 3 Blockage voltage - 643127
643125
Fig. 6 Breakers activated - 643125
3721493en - (00) Page 9.7 - 5

9.7 TROUBLESHOOTING
Relay contacts 9.7.2.4 Actions requiring special tools
If the relay is deactivated, the LED should be off. Removing controller connector pins
Contacts 11 and 14 should have no continuity.
643133
LED off
Fig. 9 Controller connector - 643133
643131
Fig. 7 Relay deactivated - 643131 For removing the pins of a controller connector,
use the removal tool for controller connector pins
(part No. 3739002) as indicated in the figure be-
If the relay is activated, the LED should be on. low.
Contacts 11 and 14 should have continuity.
Valves
Testing of valves (proportional and switching

valves)
Valve Test Adaptor

Bucyrus P/N: 1433919
Resistance
643134
Current Fig. 10 Removal tool for controller connector

pins - 643134
Voltage
643124
Fig. 8 Testing of valves - 643124
Page 9.7 - 6 3721493en - (00)

9.7 TROUBLESHOOTING
Inserting harting pins 3. Insert the cable.
For inserting harting pins proceed as follows:
1. Strip the cable. Use the stripping tool with part

No. 6001883.
643135
643138
Fig. 11 Stripping tool (part No. 6001883) - 643135
Fig. 13 Inserting the cable - 643138
2. Crimp the pin. Use the crimping tool with part

No. 6001880. 4. Remove the pin. Use the pin removal tool with
part No. 3685377.
643136 643137
Fig. 12 Crimping tool (part No. 6001880) - 643136 Fig. 14 Pin removal (part No. 3685377) - 643137
3721493en - (00) Page 9.7 - 7

9.7 TROUBLESHOOTING
9.7.2.5 Individual problems LH RH
Emergency Mode for Engine Run
CAUTION!
Lubrication of engines is not guar-
anteed in Emergency Mode for
Engine Run.
 Use Emergency Mode only in
the event of an emergency, for
example when the machine has
to leave blasting area.
643145
In the event of electronic problems (bus off), the Fig. 15 Jumpers in position “normal operation” – 643145
engines run just at low idle. The hydraulic oil flow
of the pumps is not sufficient to move the machine.
LH RH
Emergency mode enables the engines speed to
get increased for travelling / moving the equip-
ment.
In this mode, the engines rpm are not adjustable
and engines run right from the start with a speed of
1100 rpm. Lubrication of engines in this phase is
not guaranteed.
Emergency mode is activated / deactivated by two

jumpers, one for each engine, located in X1 elec-
trical cabinet.
When using the emergency mode, proceed as

follows: 643146
 Activate emergency mode by plugging the two Fig. 16 Jumpers in position “emergency operation” -
643146
jumpers from right position into left position.
 Travel / move the equipment.
 Deactivate emergency mode by plugging the
two jumpers back into right position. This is the
position for normal operation.
Page 9.7 - 8 3721493en - (00)

08.2018
10. Attachment
6040

10. ATTACHMENT
10. Attachment
For welding repair is referred to the
Service Manual
‘Welding for maintenance and repair’
For further questions please consult your dealer or

the responsible Caterpillar branch office.
3720211en – (00) Page 10 - 1

10. ATTACHMENT
Page 10 - 2 3720211en – (00)

10. ATTACHMENT
10. Attachment
The assembly of the attachment is described in
Chapters 3.3 - 'Assembly'.
The dismantling of the attachment is carried out

analogously in reversed order.
For welding repair is referred to the
Service Manual
‘Welding for maintenance and repair’
For further questions please consult your dealer or

the responsible Caterpillar branch office.
3720211en – (00) Page 10 - 3

08.2018
11. Central lubrication system
6040

CONTENTS - FS
11. CENTRAL LUBRICATION SYSTEM
11.1 Introduction .................................................................................. 11.1 - 1
11.1.1 Preface ............................................................................ 11.1 - 1
11.1.2 Illustration conventions .................................................... 11.1 - 1
11.1.3 Operator's responsibility ................................................... 11.1 - 1
11.1.4 Safety instructions ............................................................ 11.1 - 2
11.1.5 Operation / maintenance .................................................. 11.1 - 3
11.2 Technical data (1,000 kg grease container – supply) .................. 11.2 – 1
11.2 Technical data (280 kg round container / 180 kg grease

drum – supply) ................................................................................ 11.2 - 1
11.3 Design of the central lubrication system ....................................... 11.3 - 1
11.3.1 Functional diagram .......................................................... 11.3 - 1
11.3.2 Component arrangement ................................................. 11.3 - 6
11.3.3 Distributor design and lubrication point

connections .................................................................... 11.3 - 20
11.4 System function .............................................................................. 11.4 - 1
11.4.1 Central lubrication system ................................................ 11.4 - 1
11.4.1.1 Design ............................................................ 11.4 - 1
11.4.1.2 Operation sequence ....................................... 11.4 - 1
11.4.2 Lubricant distributor .......................................................... 11.4 - 2
11.4.3 Control unit .................................................................... 11.4 - 11
11.4.3.1 Upper carriage control panel......................... 11.4 - 11
11.4.3.2 Upper carriage control panel with

under carriage control ................................... 11.4 - 13
11.4.3.3 Operation sequence ..................................... 11.4 - 16

3723246en - (00) Page 11 - 1
CONTENTS - FS
11.4.4 Grease pump ................................................................. 11.4 - 19
11.4.4.1 Start-up ......................................................... 11.4 - 19
11.4.4.2 Operation sequence ..................................... 11.4 - 19
11.4.5 Electrical function ........................................................... 11.4 - 20
11.5 Lubrication system test .................................................................. 11.5 - 1
11.7 Setting of the lubrication and break times .................................... 11.7 - 1
11.7.1 Lubrication time or normal duration – upper

carriage ............................................................................ 11.7 - 1
11.7.2 Lubrication time or normal duration – under

carriage ............................................................................ 11.7 - 2
11.7.3 Function of the reset button .............................................. 11.7 - 2
11.7.4 Lubrication cycle sequence .............................................. 11.7 - 3
11.8 Bleeding of the central lubrication system.................................... 11.8 - 1
11.9 Repairing the lubrication pump ..................................................... 11.9 - 1
11.9.1 Components..................................................................... 11.9 - 1
11.9.2 Disassembly .................................................................... 11.9 - 3
11.9.3 Assembly ......................................................................... 11.9 - 3
11.9.4 Spare parts ...................................................................... 11.9 - 4
11.10 Repair of the lubrication distributors........................................... 11.10 - 1
11.11 Renewal of high pressure hose lines .......................................... 11.11 - 1
11.12 Troubleshooting guideline .......................................................... 11.12 - 1
Page 11 - 2 3723246en - (00)

11.1 CENTRAL GREASE SYSTEM - INTRODUCTION
11.1 Introduction
11.1.1 Foreword 11.1.3 Operator's responsibility
This technical manual refers only to the central To guarantee the safety during operation, the
lubrication system of the excavator with a two operator is responsible for the fact
line/progressive/Centromatic system. It is designed 1. that the pump / the system will only be
for the operators and the installation and used as described later as part of the usage
maintenance personnel and - intended and that it will not be manipulated with
respect to a desing or construction.
2. that the pump / the system will only be
- should make it easier to know the central operated when in a functional condition and in
lubrication system and the applications it is accordance with the requirements for care and
designed for. maintenance.
- it must always be available at the usage site 3. that the operators are familiar with this
of the pump / system. user information and the safety references
it must be read and used by each person who included and that they follow them.
is charged with works at the pump / system,
e.g.: The operator is responsible for the orderly
• operating including set-up, trouble assembly and installation as well as the correct
shooting during work processes, removal connections of the pipes and hose lines, if not
of production waste, maintenance, specified otherwise by Caterpillar. Caterpillar
disposal of operating and auxilliary would be pleased to help you in case you have
materials, question regarding the installation.
• servicing (maintenance, inspection,
repair) and/or transport.
Persons that are not fluent in the local Environmental protection

language must be informed by the operator of
Waste materials (e.g. residual oil, detergents,
the system about the content of the manual,
lubricants) must be disposed in accordance with
especially about all safety information before
the applicable environmental regulations.
they start working.
11.1.2 Illustration conventions Service

All illustration standards, which are used in this Only trained expert personnel is permitted to use
user information, can be found here. The following the pump / the system. When requested,
pictograms are used in this manual. Caterpillar supports you to qualify your employees
in form of consultations, site installations, training,
etc. This way, we offer you the opportunity to meet
- refers to faults or property all your individual requirements.
damage at the machine.
For maintenance, service and spare part inquiries
we will need type specific information to specifically
identify the components of your pump / your
- refers to serious property damage system.
and possible injuries.
- refers to possible life threatening Please provide item, type and serial number in
injuries. case you have questions.
- refers to improvements for the

equipment handling.
- refers to significant disadvantages
with the equipment handling.
3691790en - (04) Page 11.1 - 1

11.1.4 Safety information

Intended usage General safety information
• The hydraulic barrel pump is designed only for • Incorrect operation can result in damages due
the use in central lubrication systems for the to lack or excess of lubrication of bearing
transport of lubricants. points.
• PVC and rubber softeners can also be • Arbitrary design changes or changes at an
transported in accordance with a special installed system can only be performed in
approval list and after consultation. cooperation with the manufacturer or contract
• The limit values listed in the technical data, partner.
especially the maximum operating pressure of • Hot or cold machine parts that present a
350 bar (200 bar for Centromatic) must not be danger must be protected by the operator
exceeded under any circumstances . against contact.
• The pressure of 49 bar for the oil supply of the • Contact protection for moving parts must not
hydraulic barrel pump set during start-up must be removed during operation.
be maintained for the operation. • Work at the machine must only be performed
• Usages that go beyond the use as central if the machine stands still. The procedure for
lubrication system are not intended usages the shut down of the machine described in the
and will result in loss of warranty and liability operating instructions must be followed.
claims. • Re-attach all safety and protection furnishings
immediately after the work has been
Misuse completed
• The operating safety of the delivered product Accident prevention regulations

is only guaranteed for those applications that
are described under "Intended usage". The Please always observe the current regulations for
limit values listed in the documentation and accident prevention in the respective countries
the user information must not be exceeded when operating the described central lubrication
under any circumstances. system.
• The start-up of the products
(pump/valve/distributor) is forbidden in the Eu- Operation, maintenance and repair
ropean Union until it has been determined that
the machine in question, which includes the Please make absolutely sure that the
product, is in accordance with the EU guide- hydraulic system of the carrier
lines. equipment is without pressure before
• Any warranty or liability claims expire if the you start maintenance or repair work.
central lubrication system or its components
are used or operated in deviation from its in-
tended usage. It is strongly forbidden to execute
maintenance or repair work while the
hydraulic equipment is running.
Legal claims cannot be made against

Caterpillar if system component,
Repairs
personal or material damages occur
due to an illegal operation, e.g. by Repairs must only be made by authorized and
disregarding the safety information or trained persons who are familiar with the
through incorrect installation. regulations.
Page 11.1 - 2 3691790en - (04)

11.1.5 Operation / maintenance

The central lubrication system works automatically.
Regardless, a frequent check (daily) must be made Assembly / disassembly
to verify that the pump is actually feeding lubricants
(observation). Please make absolutely sure that the
hydraulic system of the carrier
equipment is without pressure before
The technical data and limit values for the main you start assembly or disassembly
components of the central lubrication system can work at the central lubrication system.
be found in the category TECHNICAL DATA of
this documentation.
The information in the user information for the
individual components must be observed during
If you need more information than provided in this the work to be performed. This is especially
documentation, please refer to: applicable for the information about the items
maintenance / repair and start-up.
Caterpillar Global Mining HMS GmbH

Technical Publications
D-44149 Dortmund
Karl – Funke - Str. 36
Assembly and maintenance of the hydraulic
Phone: ++49 / 231 / 922-4340
hoses
Fax: ++49 / 231 / 922-5340
The operational safety of the central
lubrication system is only guaranteed
if the hydraulic hose lines are
correctly assembled and maintained.
Liability disclaimer The following information must be
observed under any circumstances!
The manufacturer of the central lubrication system
assumes no liability for
• late filling of the grease container or Hydraulic hose lines
grease barrel change (lubricant shortage).
• contaminated lubricants. • must never be subjected to torsion.
• use of lubricants that are not suitable or of • must be assembled without twisting.
limited suitability for the hydraulic • must not rub on metal parts or edges.
equipment or which are not transportable. • must frequently be subject to visual checks
• environmentally unsuitable disposal of and must be exchanged when wear is
used or contaminated lubricants or parts identified.
that have been in contact with them.
• arbitrary changes of system parts. Please provide bending radii as large as possible
• use of unauthorized spare parts. for curved installations. Sharp bends should be
avoided. Use pipe bends when little space is
available to prevent the danger of sharp bends.
3691790en - (04) Page 11.1 - 3

Page 11.1 - 4 3691790en - (04)

11.2 CENTRAL GREASE SYSTEM – TECHNICAL DATA
11.2 Technical data
 Lubrication pump:  Lubricant container:
Drive Container type Stainless steel container

Hydraulic oil pressure Pmax 120 bar Fill quantity: 1,000 kg
... plant adjusted to 65 bar ± 5% (for app. 1500 cycles)
Hydraulic oil flow rate (ad- Filling: Filling via tank lift
justable) Qmax 14 ltr./min Lubricant Lubricants in acc. with
per 12 double stroke /min appr. 4,5 ltr./min lubricant table in operat-
Viscosity min. 13 mm²/s ing instructions
max. 380 mm²/s Lubricant filled at the High pressure grease
plant: type KP-F 2K or in acc.
Filter unit hydraulic oil 10 μm
with customer specifica-
Pump tube tions
Pressure intensification 6,6 : 1
Feed pressure,
theoretical at 55 bar 363 bar
Feed quantity per double  Lubricant filter (filling – pressure line):
stroke:
30 cm³
Threaded connection G 1 1/4“
Feed quantity, controllable 12-15 DH / min
Volume flow Qmax 200 l/min
Max. operating overpressure 420 bar
Note:
The maximum operating pressure (output pres- Max. perm. delta p at element 315 bar
sure) of the pump depends on the hydraulic pres- Filter area: 1565 cm³
sure, the lubricant, the outside temperature and
the internal friction losses. Filter mesh 200 µm
The theoretical maximum operating pressure is 55
bar x 6.6 = 363 bar. This pressure will be limited Operating temperature range -10°C - +100°C
by a pressure switch to a maximum of 250 bar to
ensure the safety of all components. The feed
flow listed is based on grease, N LG I - class 2,
 Hydraulic oil filter:
measured at +20° C and 100 bar back pressure.
Deviating pressures or temperatures result in Threaded connection G 1“
changes of the feed rate. Volume flow Qmax 50 l/min
Max. operating overpressure 160 bar
Filter mesh 6 µm
Operating temperature range -10°C - +100°C
3723051en - (02) Page 11.2 - 1

11.2 CENTRAL GREASE SYSTEM – TECHNICAL DATA
 Electrical equipment...
…at the lubricant container:  Lubricant distributor type VSG - KD:
1 fill level control, min. capacitive With control shaft and dosing screw
1 fill level control, max. capacitive at the shaft outrigger the control shaft is pro-
... at the change-over control panel: tected by a screwed on brass sleeve (-MS)
3 solenoid valves 24V DC
1 pressure switch 0-600 bar Feed volume per stroke
1 manometer 0-400 bar and per outlet pair in accordance
... at the shaft: with dosing screw used: 1,1 / 1,65 / 2,2 cm³
2 proximity initiators possible number of outlets: 1-8
... Under carriage equipment max. operating pressure: 400 bar
1 pressure switch 0-600 bar min. operating pressure: 35 bar
main line connection: G 3/8
lubricant point connection: G 1/4
 Electronic control:
The central lubrication system is controlled by the

SPS (see chapter 9.3)  Lubricant distributor type VSL - KR:
The lubrication and brake times are adjustable. with control shaft and continuous control
at the shaft outrigger the control shaft is pro-
 Response times: tected by a screwed on brass sleeve (-MS)
controllable feed volume
The sequence of the lubrication cycles is not di- per stroke and per outlet pair: 0 – 5,0 cm³
rectly controlled through fixed operating and break possible number of outlets: 1-8
time information, but runs within a timeframe de- max. operating pressure: 400 bar
pending on the position of the control pistons at min. operating pressure: 35 bar
the last shaft distributor (positioned furthest away Main line connection: G 3/8
from the pump). The specified timeframe can be Lubricant point connection: G 1/4
changed in the second BCS level under "PLC
Options" (see SPS control, chapter 9.3).
 Lubricant distributor type SL-1:
CentroMatic system
 Lubricant distributor type VSG - KR:
Feed volume per distributor: 0,131 to 1,31 cm³
with control shaft and continuous control
manifolds used: 3-times / 4-times
at the shaft outrigger the control shaft is pro-
max. operating pressure: 240 bar
tected by a screwed on brass sleeve (-MS)
recom. operating pressure: 173 bar
min. operating pressure: 128 bar
controllable feed volume
pressure relief for: < 41 bar
per stroke and per outlet pair: 0 - 2,25 cm³
main line connection: 3/8“ NPTF
possible number of outlets: 1-8
outlet thread: 1/8“ NPTF
Main line connection: G 3/8
Lubricant point connection: G 1/4  Lubricant distributor type SSV D:
Progressive - system
Feed volume adjustable in 10 steps:

Per stroke and outlet pair [cm³] :
A = 0,08 / B = 0,14 / C = 0,2 / D = 0,3 / E = 0,4
F = 0,6 / G = 0,8 / H = 1,0 / I = 1,4 / J = 1,8
possible number of outlets: 1-22
max. pressure differential between
two outlets: 100 bar
main line connection: G 1/8
Lubricant point connection: M 10 x 1
Page 11.2 - 2 3723051en - (02)

11.3 DESIGN OF CENTRAL GREASE SYSTEM – BH
11.3 Design of the central lubrication system – backhoe equipment

11.3.1 Functional diagram
Components for the backhoe equipment (Fig. 1 to Fig. 68)
Assembly Item Component Connected lubrications points
1 Hydr. control unit (see chapter 11.4)
2.1 Lubrication pump upper carriage
2.2 Lubrication pump under carriage
3.1 Manometer upper carriage
3.2 Manometer under carriage
4 Hydraulic oil fine filter
5.1 Lubricant filter pressure filter
5.2 Lubricant filter pressure filter
6 Lubricant container
Lubricant filter, filling
7 (optional with round container)
8 Ventilation filter
Fill level sensor, max.
9 (optional with round container)
Upper car- 10 Fill level sensor, min.
Expansion control unit for under carriage
riage 11 CentroMatic system (see chapter 11.4)
12 ---------------------
13 ---------------------
14 VSG 4-KD / 4-fold distributor (1,65 cm³) Swing rack
15 VSL 2-KR / 2-fold distributor (5 cm³) Item 16
SSV D 8 - AFFF / 8-fold distributor
16 Swing gear / Engine mounting
(2 x 0,08 cm³ / 6 x 1,0 cm³)
19 VSL 2-KR / 2-fold distributor (5 cm³) Toothed rim
20 VSL 2-KR / 2-fold distributor (5 cm³) Support block / foot shaft
22 VSG 8-KD / 8-fold distributor (1,1 cm³) Boom cylinder
23 VSL 2-KR / 2-fold distributor (5 cm³) Mono / Support block
24 VSG 8-KD / 8-fold distributor (1,1 cm³) Shaft cylinder / shaft cylinder fork
Mono boom VSG 8-KD / 8-fold distributor (1,1 cm³) Mono cylinder / Mono cylinder fork
25
26 VSL 2-KR / 2-fold distributor (5 cm³) Mono / shaft
27 VSL 2-KR-MS / 2-fold distributor (5 cm³) Mono / shaft
28 VSG 8-KD-MS / 8-fold distributor (1,1 cm³) Shaft cylinder / fork
29 VSG 8-KD-MS / 8-fold distributor (1,1 cm³) Backhoe cylinder / fork
BH-Shaft VSL 8-KR –2xNP / 8-fold distributor (5 cm³)
30 Backhoe bearing
with two sensors
VSL 8-KR-MS / 8-fold distributor (5 cm³)
34 optional: Backhoe bearing
enlarged system only
Tab. 1 f.
3723275en - (00) Page 11.3 - 1

Assembly Item Component Connected lubrications points

31 VSL 2-KR-MS / 2-fold distributor (5 cm³) Toggle link
32 VSL 8-KR-MS / 8-fold distributor (5 cm³) Toggle link / toggle lever
Toggle link 33 VSL 8-KR-MS / 8-fold distributor (5 cm³) Backhoe

VSL 6-KR-MS / 6-fold distributor (5 cm³)
35 optional: Backhoe
enlarged system only
36 SL 1-4 / 4-fold distributor (0,131 – 1,31 cm³) Chassis – rollers left
37 SL 1-4 / 4-fold distributor (0,131 – 1,31 cm³) Chassis – rollers right

38 SL 1-3 / 3-fold distributor (0,131 – 1,31 cm³) Chassis – rollers left
Under car- 39 SL 1-3 / 3-fold distributor (0,131 – 1,31 cm³) Chassis – rollers right
SL 1-4 / 4-fold distributor (0,131 – 1,31 cm³)
riage 40 Chassis – rollers left
both sides lubrication
CentroMatic SL 1-4 / 4-fold distributor (0,131 – 1,31 cm³)
41 Chassis – rollers right
42 Chassis – rollers left
43 Chassis – rollers right
Swinging
44 SSV 12 / 12-fold distributor (0,2 cm³) Swinging ladder bearing
ladder
Folding lad. 45 SSV 12 / 12-fold distributor (0,2 cm³) Folding ladder bearing
Tab. 1
The lubricant storage on the RH 170 equipment is provided by …

.... a 1,000 kg grease container (Fig. 5 and Fig. 6).
.... a 280 kg – round container with 180 kg grease drum intake (Fig. 8 to Fig.10)
The CentroMatic – undercarriage lubrication consists of ....

.... an expansion for the grease container (Fig. 6).
.... an expansion with 2. round container (Fig. 9).
Identification of the wire connections in Fig. 1 to Fig. 12

Identification Designation
PS Pressure connection pump (lubricant)
RS Return flow connection to the grease container (lubricant)
PH Pressure connection pre-control pressure (hydraulics)
RH Return flow connection to hydraulics container
AS Main line A (lubricant)
BS Main line B (lubricant)
P Hydraulics connection pump (pressure line)
T Hydraulics connection pump (tank line)
CS Main line C (lubricant) for under carriage lubrication
Tab. 2
Page 11.3 - 2 3723275en - (00) - 01.11

The functional sequence will be described in chapter 11.4
Fig. 1 Schematic diagram of the pump station with a 1,ooo kg grease container 6413
11
3723275en - (00) Page 11.3 - 3

The functional sequence will be described in chapter 11.4
Fig. 2 Schematic diagram of the pump station with a 1,ooo kg grease container and under carriage – CentroMatic lubrication 6413
12
Page 11.3 - 4 3723275en - (00) - 01.11

Component arrangement for BH equipment
Fig. 3 Functional diagram for backhoe equipment with under carriage – CentroMatic lubrication 641313
3723275en - (00) Page 11.3 - 5

Component arrangement for BH equipment enlargement
Fig. 4 Functional diagram with under carriage–CentroMatic lubrication–system enlargement 641314
Page 11.3 - 6 3723275en - (00) - 01.11

11.3.2 Component arrangement
Fig. 5 Lubricant pump with 1,000kg grease container and upper carriage – control unit 3723276a
Fig. 6 Lubricant pump with 1,000kg grease container and upper and under carriage – control unit (CentroMatic) 3723276b
3723275en - (00) Page 11.3 - 7

Fig. 7 Grease container - filling 3723276c
Fig. 8 Pumping station round container OW 3723276d
Page 11.3 - 8 3723275en - (00) - 01.11

Fig. 9 Pumping station round container OW with UW - RC 3723276e
Fig. 10 Pumping station round container OW with stand-by RC 3723276f
3723275en - (00) Page 11.3 - 9

Fig. 11 Round container - filling 3723276g
Fig. 12 Main lines of upper carriage to outrigger and to the under carriage lubrication 3691795f
Page 11.3 - 10 3723275en - (00) - 01.11

Fig. 13 Swing rack and drip lubrication in the toothed rim cover 3691590e
Fig. 14 Swing rack and toothed rim lubrication with two greasing pinions 3691590f
3723275en - (00) Page 11.3 - 11

Fig. 15 Upper carriage – support block and swing rack ( front) 3691590h
Fig. 16 Swing gear 3691590m
Page 11.3 - 12 3723275en - (00) - 01.11

Fig. 17 Under carriage, longitudinal girder left – CentroMatic system 3691590n
Fig. 18 Under carriage, longitudinal girder right – CentroMatic system 3691590o
3723275en - (00) Page 11.3 - 13

Fig. 19 Under carriage, longitudinal girder left - both sides lubrication 3723252c
Fig. 20 Under carriage, longitudinal girder right – both sides lubrication 3723252d
Page 11.3 - 14 3723275en - (00) - 01.11

Fig. 21 Under carriage, longitudinal girder left – without central grease system 3691590r
Fig. 22 Under carriage, longitudinal girder right – without central grease system 3691590s
3723275en - (00) Page 11.3 - 15

Fig. 23 Mono boom 3691594a
Fig. 24 Mono boom 3691594b
Page 11.3 - 16 3723275en - (00) - 01.11

Fig. 25 Mono boom 3691594c
Fig. 26 BH - shaft 3723205a
3723275en - (00) Page 11.3 - 17

Fig. 27 BH - shaft 3723205b
Fig. 28 BH – shaft – system enlargement 3723158b
Page 11.3 - 18 3723275en - (00) - 01.11

Fig. 29 Toggle link – toggle lever – backhoe 3723206a
Fig. 30 Toggle link – toggle lever – backhoe – system enlargement 3723206b
3723275en - (00) Page 11.3 - 19

Fig.31 Swinging ladder 3723215c
Fig. 32 Folding ladder 3723215d
Page 11.3 - 20 3723275en - (00) - 01.11

11.3.3 Distributor design

The terminal assignment and the adjustment of the Distributor installation
rotary valves for the individual BH equipment dis-
tributors will be described in the following chapter.
The distributor type, the installa-

tion position, the terminal assign-
ment and the adjustment of the
rotary valves must
not
be changed, because lubricant
shortage may result at the affected
bearing points, which in turn may
result in damages (bearing jam-
ming)!
When exchanging a distributor, the

same
distributor type must be used! Fig. 33 641114
The position of the rotary valve A: Main line connection
must be checked and, if required, B: Motion display with brass sleeve
must be changed accordingly! C: Rotary valve
Adjustment of the rotary valves

The following pictures (Fig. 35 to Fig. 58) show the
individual distributors in such a way that the motion
displays are positioned on top and the adjustment
screws for the rotary valve are visible. The distribu-
tors are installed in the equipment in such a way
that the rotary valve adjustment always points to
the mounting plate and therefore it is not visible
(Fig. 33.
The distributors of the under carriage lubrication,

items 36 to 43 (Fig. 59 to 66), will be installed as
described.
Fig. 34 640105
Lock screw 1 can be loosened and the rotary valve
can be rotated by 90° if the system is without pres-
sure. In position A of the rotary valve, the connec-
tion channel between the two outlets is blocked
and the feed is supplied through the two outlets. In
position B, the connection channel is open. One of
the two outlets must now be closed by using a lock
screw and the double feed is performed through
the open outlet.
The position information of the distributors used in
the following text refer to Fig. 3 and Fig. 4.
3723275en - (00) Page 11.3 - 21

Item 14: VSG 4-KD / 4-fold distributor (1,65 cm³) Item 16: SSV D 8 (2 x 0,08 / 6 x 1,0 cm³)
Fig. 35 640223 Fig. 37 640225

Output 1: Swing rack Output 1: Swing gear
Output 3: locked Output 3: Swing gear
Output 5: Swing gear
Output 6: Swing gear
Output 7: Engine mounting
Output 8: Engine mounting
Item 15: VSL 2-KR / 2-fold distributor
Fig. 36 640224
Output 1: locked
Output 2: Item 16
Page 11.3 - 22 3723275en - (00)

Item 17: VSG 4-KD / 4-fold distributor (1,65 cm³) Item 19: VSL 2-KR / 2-fold distributor
Fig. 38 640226 Fig. 40 640228

Output 1: Swing rack Output 1: Toothed rim (drip point / pinion)
Output 2: Swing rack Output 2: Toothed rim (drip point / pinion)
Output 3: Swing rack
Output 4: locked
Fig. 39 640227 Fig. 41 640229

Output 1: Swing rack Output 1: Support block / foot shaft
Output 2: Swing rack Output 2: Support block / foot shaft
Output 3: locked
3723275en - (00) Page 11.3 - 23

Fig. 42 640230 Fig. 44 640256

Output 1: Swing rack Output 1: Mono / support block
Output 2: Swing rack Output 2: Mono / support block
Item 22: VSG 8-KD / 8-fold distributor (1,1 cm³) Item 24: VSG 8-KD / 8-fold distributor (1,1 cm³)
Fig. 43 640231 Fig. 45 640257

Output 1: OW - frame outside Output 1: Shaft cylinder fork
Output 2: OW - frame outside Output 2: Shaft cylinder fork
Output 3: Boom cylinder outside Output 3: locked
Output 4: Boom cylinder outside Output 4: Shaft cylinder bearing in boom
Output 5: Boom cylinder inside Output 5: Shaft cylinder bearing in boom
Output 6: Boom cylinder inside Output 6: locked
Output 7: OW – frame inside Output 7: Shaft cylinder fork
Output 8: OW – frame inside Output 8: Shaft cylinder fork
Page 11.3 - 24 3723275en - (00)
Item 25: VSG 8-KD / 8-fold distributor (1,1 cm³) Item 27: VSL 2-KR -MS / 2-fold distributor
Fig. 46 640258 Fig. 48 641123

Output 1: Mono cylinder fork Output 1: Mono / shaft
Output 2: Mono cylinder fork Output 2: Mono / shaft
Output 3: Mono cylinder
Output 5: Mono cylinder Item 28: VSG 8-KD -MS / 8-fold distributor (1,1 cm³)
Output 7: Mono cylinder fork
Output 8: Mono cylinder fork
Item 26: VSL 2-KR / 2-fold distributor
Fig. 49 641320
Output 1: Shaft cylinder fork
Output 2: Shaft cylinder fork
Output 3: locked
Output 4: Shaft cylinder
Output 5: Shaft cylinder
Fig. 47 640259 Output 6: locked
Output 1: Mono / support block Output 7: Shaft cylinder fork
Output 2: Mono / support block Output 8: Shaft cylinder fork
3723275en - (00) Page 11.3 - 25

Item 29: VSG 8-KD -MS / 8-fold distributor (1,1 cm³) Item 30a: VSL 8-KR-2xNP / 8-fold distributor (5 cm³)
with two sensors
Attention:
Distributor fittings for standard equipment with
2 x 15 cm³ und 2 x 5 cm³.
50 641321
Output 1: Backhoe cylinder fork
Output 2: Backhoe cylinder fork
Output 3: locked Fig. 51 641322
Output 4: Backhoe cylinder Output 1: Toggle link
Output 5: Backhoe cylinder Output 2: Connected to Output 4
Output 6: locked Output 3: Toggle link
Output 7: Backhoe cylinder fork Output 4: Connected to Output 2
Output 8: Backhoe cylinder fork Output 5: Connected to Output 7
Output 6: Toggle link
Output 7: Connected to Output 5
Page 11.3 - 26 3723275en - (00)

Item 30b: VSL 8-KR -MS / 8-fold distributor (5 cm³) Item 31: VSL2-KR -MS / 2-fold distributor (5 cm³)
With two sensors
Attention:
Distributor fittings for enlarged greasing sys-
tem with 1 x 30 cm³ und 1 x 10 cm³.
Fig. 53 641127
Fig. 52 641267
Output 1: locked
Output 2: Intake from Output 4
Output 3: Intake from Output 5
Output 7: locked
3723275en - (00) Page 11.3 - 27

Item 32: VSL 8-KR -MS / 8-fold distributor (5 cm³) Item 33a: VSL 8-KR -MS / 8-fold distributor (5cm³)
Attention:
Distributor fittings for standard equipment with
2 x 10 cm³ und 4 x 5 cm³.
Fig. 54 641323
Output 1: Toggle lever
Output 2: Toggle lever
Output 3: Toggle lever Fig. 55 641324
Output 4: Toggle lever Output 1: Backhoe
Output 5: Toggle link Output 2: Backhoe
Output 6: Toggle link Output 3: Backhoe
Output 7: Toggle link Output 4: locked
Output 8: Toggle link Output 5: locked
Output 6: Backhoe
Output 7: Backhoe
Output 8: Backhoe
Page 11.3 - 28 3723275en - (00)

Item 33b: VSL 8-KR -MS / 8-fold distributor ( 5cm³) Item 34: VSL 8-KR -MS / 8-fold distributor (5 cm³)
optional: enlarged system only
Attention: Attention:
Distributor fittings for enlarged greasing sys- Distributor installed only in enlarged greasing
tem with 2 x 20 cm³. system.
Fig. 56 641133 Fig. 57 641130

Output 1: Intake from Output 3 Output 1: locked
Output 2: locked Output 2: Toggle link
Output 3: Connected to Output 1 Output 3: Intake from Output 5
Output 4: Backhoe Output 4: Toggle link
Output 5: Backhoe Output 5: Connected to Output 3
Output 6: Intake from Output 8 Output 6: Intake from Output 8
Output 7: locked Output 7: locked
Output 8: Connected to Output 6 Output 8: Connected to Output 6
3723275en - (00) Page 11.3 - 29

Item 35: VSL 6-KR -MS / 6-fold distributor (5 cm³)

optional: enlarged system only
Attention:
Distributor installed only in enlarged greasing
system.
Fig. 58 641131
Output 1: Backhoe
Output 2: Backhoe
Output 3: locked
Output 4: Backhoe
Output 5: Backhoe
Output 6: locked
Page 11.3 - 30 3723275en - (00)

Item 36: SL 1-4 / 4-fold distributor (1,31 cm³) Item 38: SL 1-3 / 3-fold distributor (1,31 cm³)
Fig. 59 640235 Fig. 61 640237

Output 1: Roller Output 1: Roller
Output 4: Roller
Fig. 60 640236 Fig. 62 640238

Output 4: Roller
3723275en - (00) Page 11.3 - 31

Fig. 63 641285 Fig. 65 641287

Output 4: Roller
Fig. 64 641286 Fig. 66 641288

Output 4: Roller
Page 11.3 - 32 3723275en - (00)

Item 44: SSV 12 / 12-fold distributor (0,2 cm³) Item 45: SSV 12 / 12-fold distributor (0,2 cm³)
Fig. 68 641309 Fig. 69 641310
Output 1-9: Swinging ladder Output 1-10: Folding ladder

Output 10: locked Output 11: locked
Output 11-12: Swinging ladder Output 12: Folding ladder
3723275en - (00) Page 11.3 - 33

Page 11.3 - 34 3723275en - (00)

11.4 CENTRAL GREASE SYSTEM – SYSTEM FUNCTION
11.4 System function
11.4.1 Central lubrication system
11.4.1.1 Design
The system consists mainly of the grease feed An electrical pressure switch with digital display on
system with a rerouting unit on the upper carriage the rerouting panel monitors the preset min. – max.
(near the driver's cabin) and is therefore accessi- operating pressure.
ble for service work. The central lubrication pump The control valve on the rerouting panel will be
is actuated by the control valve on the rerouting switched by a control system on the vehicle and
unit, which is connected to the hydraulic oil circula- the lubrication pump transports the lubricant in line
tion of the excavator. Additional control valves on B of the two line system. Line A is at this time not
the rerouting unit control the pressure and relief under pressure. The pressure in main line B in-
phases of the two line system of the excavator. creases until the feed resistance, the actuation
The main lines are routed from the control panel pressure of the distributor and the input resistance
via the upper carriage as a two line system via the at the lubrication points have been overcome. Only
outrigger assemblies to the shovel back panel or now, the control and operating pistons of the VSL /
the bucket equipment. The central lubrication sys- VSG distributors are actuated, which in turn pro-
tem is controlled by a control system on the vehi- vides a dosed lubricant feed to the lubrication
cle. points (Fig. 1).
11.4.1.2 Operation sequence

An initiator sends an electrical signal to the SPS
To actuate the lubricant pumps, a continuously control unit once all pistons reach the end position.
circulating oil flow from the hydraulic oil circulation The pump continues to run for another 22 seconds
of the excavator )through a fine filter) is routed (pressure increase in main line B) and switches off
through the control valves by using a viscosity for 4 seconds. The rerouting process will be initiat-
independent flow rate restrictor to enable a start-up ed during this time and the pressure line will be
of the pumps at low temperature connected to main line A, which was not yet used.
Main line B is at this time not under pressure.
Fig. 1 Operating sequence of the two line system – 1st half-pulse 640131
██ Relief line 3 Lubricant distributor

██ Pressure line 4 Main lines
1 Central lubrication pump 5 To the friction points
2 Rerouting unit
Tab. 1
3723250en - (00) Page 11.4 - 1

Fig. 2 Operating sequence of the two line system – 2nd half-pulse 640132
██ Relief line 3 Lubricant distributor

██ Pressure line 4 Main lines
1 Central lubrication pump 5 To the friction points
2 Rerouting unit
Tab. 1
The distributor piston is actuated in the same

manner by the pressure increase in main line A
until the other half of the connected lubrication
lines have been supplied with the specified quanti-
ty of lubricant (Fig. 2). The second initiator at the
shaft distributor sends an electrical signal to the
SPS control unit. The pump continues to run for
another 22 seconds (pressure increase in main
line A) and will be switched off afterwards.. This
completes one lubrication cycle. Function:
Stage 1 (Fig. 3)
11.4.2 Lubricant distributor The lubricant will be provided under pressure
through the main line to the distributor. The control
piston (1) moves in the direction of the arrow (a)
11.4.2.1 Functional sequence and moves the lubricant, which is found in front of
distributor type VSL / VSG the control piston, back through the relieved main
line II.
The grease distributor supplies the lubrication
points (two line distributor). They work like piston
pumps and will be operated through the change of
the grease pressure in both main lines I and II of
the two line system. The lubricant will be dosed
and will be transported to the storage point inde-
pendent of the counter pressure of the individual
lubrication connection.
██ Without pressure
██ Under pressure
Tab. 2 Fig. 3 Two line distributor – stage 140
33
Page 11.4 - 2 3723250en - (00)

Stage 2 (Fig. 4) Stage 4 (Fig. 6)
The lubricant gets in front of the right front side of The lubricant gets in front of the left front side of
the feed piston (3) and moves it to the left in the the feed piston (3) and moves it to the right in the
direction of the arrow (A) after the control piston (1) direction of the arrow (B) after the control piston (1)
releases channel (2). The lubricant in front of the releases the channel (5). The lubricant in front of
feed piston will now be transported through chan- the feed piston (3) will now be transported through
nel (4) to the lubrication point. The pressure in channel (6) to the lubrication point. The pressure in
main line I increases up to the preset switch-over main line II increases up to the preset switch-over
pressure of the two line system if the feed piston pressure of the two line system if the feed piston
reaches its end position. The rerouting unit of the (3) reaches its end position. A pressure change
two line system connects main line I, which is now occurs now in main lines I and II and the process is
under pressure, with the lubricant container of the repeated as described under stage 1.
pump, which reliefs the lubricant in the line and the
pressure is reduced.
Fig. 6 Two line distributor – stage 4 640136

Stage 3 (Fig. 5) ██ Without pressure
The rerouting unit connects main line II at the ██ Under pressure

same time with the pump and the pressure in- Tab. 2
creases in this line. The control piston (1) moves in
the direction of the arrow (B) and moves the lubri-
cant, which is found in front of the control piston, to
the relieved main line.
3723250en - (00) Page 11.4 - 3

Combining outlets Adjustment of the rotary valves
This ensures that the grease amount through one

outlet is doubled. The second outlet is in this case
closed with a lock screw.
Rotary valves are used to combine outlets (item 2,

Fig. 9).
Fig. 7 shows stage 2 and Fig. 8 shows stage 4

while feeding only through the left outlet..
Fig. 9 640105
1 Lock screw
2 Rotary valve
A Adjusted to both outlets
B Adjusted to only one outlet
Lock screw 1 can be loosened and the rotary valve

can be rotated by 90° if the system is without pres-
sure. In position A of the rotary valve, the connec-
tion channel between the two outlets is blocked
and the feed is performed through the two outlets.
Fig. 7 640137
In position B, the connection channel is open. One
of the two outlets must now be closed by using a
lock screw and the double feed is performed
through the open outlet.
Fig. 8 640138
██ Without pressure
██ Under pressure
Tab. 2
Page 11.4 - 4 3723250en - (00)

Motion display Dosage volume
The function of two outlets is displayed through the Distribution types with different feed quantities per
control shaft (10.1, Fig. 10). It is connected to the piston stroke will be installed to adjust the grease
feed piston. This is how its motion and therefore amount to meet the demand of the individual lubri-
the grease feed is made visible. The control shaft cation points.
is protected by a screwed on brass sleeve (10.4, Two different characteristics will be used in the
Fig. 10). distributors for this purpose, which are –KR for a
The outlets behind the motion displays have dis- continuous adjustment and –KD for a fixed lubri-
tance adapters (10.2, Fig. 10), which permit easy cant quantity.
assembly or disassembly. Each of the open outlets Option –KD:
must receive a check valve (10.3, Fig. 10). These feed quantities are fixed values and cannot
be changed. The distributor receives the additional
characteristic –KD with the information of the dos-
age volume in cm³ (e.g. VSG –KD 1.65).
Option –KR:
These feed quantities are adjusted at the factory to
the maximum lubricant quantity and can be
changed.
A change at the control screws

results in a reduction of the deliv-
ered grease quantity and can
therefore result in bearing damage.
Return valve
Fig. 10 641115
The grease distributors are equipped with return
A 8-fold distributor is equipped in addition with two valves at the outputs (10.3, Fig. 10). The valves
sensors, which report the motion of the feed pis- prevent an impact on the piston motion through
tons to the SPS. This distributor is mounted on the vacuum pressures in the lubrication lines.
shaft outrigger.
Installation of a new distributor:
These are the basics: The same type must be installed

when distributors are exchanged
Main line A is always connected to the side of because a reduction of the grease
the distributor with even coding of the outlets quantity can result in bearing dam-
(2; 4; 6; 8); the control shafts are also arranged age.
on this side (Fig. 10). Main line B is connected
The position of the rotary valve (2,
to the distributor side with odd coding (1; 3; 5;
Fig. 9) must be checked and, if
7).
required, must be changed accord-
ingly!
The control shafts must be retracted for the
distributors after the lubricant pressure in main
line A has been established and they must be
extracted when the pressure has been estab-
lished in main line B.
3723250en - (00) Page 11.4 - 5

11.4.2.2 Functional sequence with

progressive distributor type SSVD
For reasons of clarity, only the
grease flow to outlets 6, 4 and 2is
For greasing of the swing gear shown. The remaining grease
and the engine bearing an ad- supplies are delivered in the
justable distributor type SSV D 8 same logic sequence for the out-
– AFFF is used. lets 5, 3 and 1.
The lubricant distributor SSVD is a progressive

distributor with a variable setting of grease volume
for each pair of outlets.
Grease flow in the distributor

On the following 7 figures is shown the transport of
the grease is demonstrated
When the grease supply is interrupted:
● the pistons stop moving. Fig. 11 Layout of distributor - SSVD 640267
● no grease is transported to the grease
points. DS Metering screw
When the grease supply is continued the greasing SK Control piston
cycle continues also from that point where it was
DK Metering piston
stopped.
V1, V2 Volume
1-8 No. of outlets
Tab. 3
Stage 1 (Fig. 12)

The grease pressure is built up from the top (red
arrow) in the distributor and the grease flows to the
right side of the control piston A.
Control piston A has completed the grease supply
to outlet on and the metering piston B is supplying
grease to outlet 6.
██ Grease with pump pressure

██ Grease with delivery pressure of the piston
██ Grease without pressure
Tab. 4
Fig. 12 Distributor SSVD – stage 1 640268
Page 11.4 - 6 3723250en - (00)

Stage 2 (Fig. 13)
Metering piston B has completed the grease

transport. Control piston B is transporting the en-
closed grease (volume 1) on the left side of piston
B to outlet 6.
Stage 3 (Fig. 14)
When the metering piston B has reached its piston

the control piston B has completed the transport of
the enclose volume V 2. The total output at outlet 4
is the output of metering piston B and control pis-
ton B (V 1 + V 2).
Metering piston C is ready for transport
Stage 4 (Fig. 15)
Metering piston C has completed the grease

transport (black arrow) and the enclosed grease
(volume V 1) is transported to outlet 4.
Control piston C is now ready for transport.

Tab. 4
3723250en - (00) Page 11.4 - 7

Stage 5 (Fig. 16)
When the metering piston C has reached its posi-

tion the control piston C has completed the
transport of the enclosed volume V 2. The total
output at outlet 4 is the output of metering piston B
and control piston B (V 1 + V 2).
Metering piston A ready for transport.
Stage 6 (Fig. 17)
Metering piston A has completed the grease

transport (black arrow) and the enclosed grease
(volume V 1) is transported to outlet 2.
Control piston A is now ready for transport
Stage 7 (Fig. 18)
When the metering piston A has reached its posi-

tion the control piston A has completed the
transport of the enclosed volume V 2. the total
output at outlet 2 is the output of metering piston A
and control piston A (V 1 + V 2).
Metering piston B is ready for transport

Tab. 5 Fig. 18 Distributor SSVD – stage 7 640274
Page 11.4 - 8 3723250en - (00)

11.4.2.3 Functional sequence for

CentroMatic – distributor SL 1
Distributor design
The distributor is used for the dosage of lubricants
to a lubrication point. The distributors for the under
carriage lubrication are combined to an assembly
on 3-fold and 4-fold distributor rails. The identifica-
tion SL1-3 describes a distributor assembly with
three SL 1 distributors. SL 1-4 describes a distribu-
tor group with four SL 1 distributors.
Function:
Lubrication break phase (Fig. 19)

The distributor is without pressure and the pres-
sure spring (5) is released. The dosage chamber
(a) of the previous cycle is filled with lubricant.
Holes in the valve piston (6) connect the chambers
(a) and (b) through a connection channel.
1 Adjustment screw
2 Control shaft (optical function dis-
play)
3 Lock screw
4 Piston with gasket
5 Pressure spring
6 Valve piston
7 Second outlet, closed Control out-
let; also used to fill the lubrication
point line as well as for the connec-
tion to combine distributors to one
outlet.
P1 Inlet; grease pressure line from the
pump.
P2 Outlet; grease pressure line to
the lubrication point. Fig. 19 Lubrication break phase 640211
Pressure generation and lubrication phase

(Fig. 20)
The central lubrication pump generates a lubrica-
tion pressure in the main line and in the distributor
inlet (P1). The valve piston (6) will be pushed for-
ward by the pressure and subsequently opens the
feed-through hole from the valve body to the dos-
age chamber. Lubricant flows through the connec-
tion channel into the chamber (b); the piston (4) is
now under pressure and is actuated and the con-
trol shaft (2) will be retracted at the same time.
While the chamber (b) gets filled on one side, the
piston (4) displaces under pressure a dosed lubri-
cation quantity on the other side out of the cham-
ber (a) to the outlet (P2).
Connection of the lubrication

point line selectively at P2 or at
the outlet positioned on top (with
lock screw).
Fig. 20 Pressure generation and lubrication 640212
phase
3723250en - (00) Page 11.4 - 9
Conclusion of the lubrication phase (Fig. 21)

The piston (4) has displaced the dosed lubrication
quantity completely from the chamber (a) to the
outlet and actuated the valve piston (6). Once the
pressure equalization point was reached, the valve
piston (6) has moved into a position, which closes
the inlet to the connection channel. The distributor
remains in this position until the pump pressure
relief valve is actuated.
Fig. 21 Conclusion of the lubrication phase 640213
Lubrication relief phase (Fig. 22)

The pressure in the main line (lubricant line be-
tween pump and distributor) must be released after
each lubrication has been completed so that the
distributor can reverse. The pressure at the distrib-
utor inlet (P1) must be below 41 bar. The pressure
spring (5) is released when the remaining pressure
reaches app. 41 bar. It moves the valve piston (6)
initially downwards. The connection between both
chambers (a & b) will be established through the
valve holes. The expanding spring actuates the
piston (4), which displaces a dosed lubrication
quantity from chamber (b) to chamber (a). The
distributor returns to the starting position (Fig. 19)
after this phase has been completed.
Fig. 22 Lubrication relief phase 640214
Page 11.4 - 10 3723250en - (00)

11.4.3 Control unit

11.4.3.1 Arrangement of the components for
upper carriage lubrication
The central lubrication system is controlled by

means of solenoid and hydraulic valves mounted
on a control panel. Fig. 23 shows the arrangement
of the components. The operating mode can be
found in the circuit diagram (Fig. 24) and the fol-
lowing functional description.
Fig. 23 Upper carriage control panel 3691794a
3723250en - (00) Page 11.4 - 11

Circuit diagram of the pump control with relief and switch-over valve
Fig. 24 Control panel with lubricant container and pump 641311
Page 11.4 - 12 3723250en - (00)

11.4.3.2 Arrangement of the components for

under carriage lubrication-CentroMatic
The under carriage – CentroMatic – lubrication

system is controlled by the components (11.1 to
11.4), which are installed on the upper carriage
control panel and which actuate a separate
grease lubrication pump. Fig. 25 shows the ar-
rangement of the components. The operating
mode can be found in the circuit diagram (Fig. 26)
and the following functional description.
Fig. 25 Upper carriage control panel with under carriage control – lubrication system 3691794b
3723250en - (00) Page 11.4 - 13

Circuit diagram of the pump station with upper carriage and under carriage control panel
Fig. 26 Control panel for upper and under carriage CentroMatic with lubricant container and pumps 641312
Page 11.4 - 14 3723250en - (00)

Identification of the wire connections in Fig. 23 to Fig. 26

Identification Designation
PS Pressure connection pump (lubricant)
RS Return flow connection to the grease container (lubricant)
PH Pressure connection pre-control pressure (hydraulics)
RH Return flow connection to hydraulics container
AS Main line A (lubricant), upper carriage
BS Main line B (lubricant), upper carriage
CS Main line C (lubricant), under carriage
P Hydraulics connection pump (pressure line)
T Hydraulics connection pump (tank line)
Tab. 5
Identification of the components in Fig. 23 to Fig. 26

Item Designation
1 Control panel upper carriage
1.1 Pressure transmitter
1.2 Manometer 0 - 400 bar
1.3 2/2-way solenoid valve
1.4 Hydraulically actuated rerouting unit
1.7 3/2-way solenoid valve (shut-off valve hydraulic)
2.1 / 2.2 Lubricant pumps
3.1 / 3.2 Manometer for hydraulic operating pressure of the lubricant pump
4 Hydraulic oil fine filter
5.1 / 5.2 Lubricant filter pressure filter
6 Lubricant container
7 Lubricant filter, filling (optional with round container)
8 Ventilation filter
9 Fill level sensor max. (optional with round container)
10 Fill level sensor min.
11 Upper carriage control panel with under carriage control – lubrication system
11.1 Pressure transmitter
11.3 3/2-way solenoid valve (shut-off valve hydraulic)
Tab. 6
3723250en - (00) Page 11.4 - 15

11.4.3.3 Operating sequence  The relief valve (on the lubricant pump – chap-
ter 11.9, Fig. 2, item 2) limits the hydraulic
This chapter describes the operating sequence pressure to the operating pressure of 49 bar
during a lubrication cycle. specified for the lubricant pump (manometer
3.1).
All electrical signals are controlled by the SPS
(chapter 9.3).  The valve (1.3) closes, the return bypass (lubri-
cant) is closed.
The preset total break time is running when the
lubrication cycle starts (see chapter 11.7.3).  Lubricating via main line B
The next lubrication cycle only starts (as de-
scribed in the following) after this total break  The pump transports the lubricant through the
time is completed. In connection with the sig- filter (5.1) and rerouting unit 1.4) into mainline
nals from the end of line initiators at the shaft, B.
the required pump operating time for the lubri-
cation pulses will repeatedly be adjusted to the The manometer (1.2) displays the current operat-
existing temperature and viscosity effects. ing pressure. The operating pressure is ac-
quired by the pressure transmitter (1.1) and will
The total break time will only be counted down if be analyzed in the SPS control unit. The pump
the equipment is actually operating, which means (2.1) will be switched off by the valve (1.7) if the
that outrigger, shaft or bucket are actuated (pres- operating pressure reaches 250 bar within the
sure switch "Load"/DSL is present). operating/lag time.
Excavator travel times are not included, lubrica-
tions will not be performed during breaks.  Control and operating piston in the two line
This adjusts the grease feed to the grease demand distributors will be moved from one end position
and prevents an unnecessary lubrication during to the other and the first half of the connected
the production breaks. In addition it guarantees lubrication points will be lubricated.
that the lubrication cycles are executed at constant
intervals independent of the time required to gen-  The end of line initiators at the shaft report at
erate the pressure in the system. Another ad- this time the completion of the control piston
vantage is the automatic change from summer to motion to the SPS.
winter operations. The increased viscosity of the
lubricant in winter requires that grease is automati-  An additional lubrication time of 22 sec will now
cally pumped for a longer time. be executed in the system. This time is used to
ensure that possibly slower pistons have
enough time to safely reach end position A.
A new cycle will be started with
each engine start. 2) Rerouting
 The solenoid valve (1.7) will be switched after

the lag time has been expired. This means that
Function of the upper carriage lubrication the incoming hydraulic oil flows directly back in-
If not indicated otherwise, all item numbers listed in to the hydraulic circuit. The pump (2.1) is there-
this chapter refer to Fig. 23, Fig. 24 and Tab. 6. fore switched-off.
1) Lubrication
 The valve (1.5) will be actuated and as a con-
After the start of an engine or after the con-
sequence the rerouting valve (1.4) will be
clusion of a break time:
switched.
 The solenoid valve (1.7) opens and supplies
 Main line B will be connected to the return line
the grease lubrication pump (2.1) with hydraulic
Rs and the lubrication pressure will be reduced.
oil from the 60 bar servo-system. The hydraulic
The pressure line will be relieved. At the same
pressure is displayed on the manometer (1.6).
time, main line A will be connected with the lu-
brication pump (2.1).
 SPS specifies a time frame of 4 seconds for this

process.
Page 11.4 - 16 3723250en - (00)
Lubricating via main line A 4) Restart after EMERGENCY OFF:
The solenoid valve (1.7) opens again and feeds  Hydraulic pressure is present, see manometer
the grease lubrication pump (2.1) with hydraulic (1.6).
oil from the servo-system. The pump (2.1)
transports the lubricant through the filter (5.1)  The valve (1.7) opens.
and rerouting unit (1.4) into main line B.
 The valve (1.3) closes, the return bypass
 The manometer (1.2) displays the current (lubricant) is closed.
operating pressure. The operating pressure is
acquired by the pressure transmitter (1.1) and  Rerouting unit (1.4) switches to main line B.
will be analyzed in the SPS control unit. The
pump (2.1) will be switched off by the valve  Continues as described under item 1).
(1.7) if the operating pressure reaches 250 bar
within the operating/lag time.
 Control and operating piston in the two line

distributors will be moved from one end position
11.4.3.4 Display and adjustments in BCS
to the other and the second half of the
connected lubrication points will be lubricated.
The progress of the lubrication cycle will be
 The end of line initiators at the shaft report at displayed in the BSC by a red band in the control
this time the completion of the control piston field of the lubrication system.
motion to the SPS.
The band changes color slowly to green from left
to right if the load pressure switch will be actuated.
 An additional lubrication time of 22 sec will now The time has expired once the band is completely
be executed in the system. This time is used to green and the lubrication as well as a new cycle
ensure that possibly slower pistons have get started.
enough time to safely reach end position B.
During the lubrication, the background of the
 The pump, the rerouting valve and (5 seconds pictogram is shown in green!
later) the relief valve will be switched-off after
the lag time has expired. The lubrication pressure will be shown on an
analog display in the BCS.
 A new lubrication cycle starts after the total
break time (adjusted via SPS) has been The cycle time can be changed on the BCS and it
reached. should be preset to a time between 20 and 30
minutes, ergo 1200 to 1800 seconds. The minium
value is app. 5 minutes (300 sec) and the
maximum time is 40 minutes (2400 sec). The
3) EMERGENCY OFF, switch-off during the adjustment is made in the second BCS access
lubrication cycle: level under "PLC options".
 All electrical valve switch-off.
 The hydraulic part of the rerouting unit is

without pressure, see manometer (1.6).
 Rerouting unit (1.4) does not switch!
 The valve (1.3) opens, the lubrication pressure

is released.
3723250en - (00) Page 11.4 - 17

Function of the under carriage lubrication with

the CentroMatic system, (Fig. 26)
All item numbers listed in this chapter refer to Fig.
25, Fig. 26 and Tab. 6.
1) Lubrication
After the start of an engine or after the

conclusion of a break time:
 The solenoid valve (11.3) opens and supplies

the grease lubrication pump (2.2) with hydraulic
oil from the 60 bar servo-system. The hydraulic
pressure is displayed on the manometer (1.6).
 The relief valve (on the lubricant pump –

chapter 11.9, Fig. 2, item 2) limits the hydraulic
pressure to the operating pressure of 49 bar
specified for the lubricant pump (manometer
3.2).
 The valve (11.4) closes, the return bypass

(lubricant) is closed.
 Lubricating via main line C
 The pump transports the lubricant through the

filter (5.2) into mainline C.
 The manometer (11.2) displays the current

operating pressure.
 The dosed lubrication quantity in the SL 1

distributors will be transported to the lubrication
points. The operating pressure increases again
after all distributors complete this cycle.
2) Relief for main line C
 When reaching the operating pressure of 180

bar, the pressure switch (11.2) reroutes the
solenoid valve (11.3) and therefore switches
the pump off.
 The solenoid valve (11.4) opens and the

lubrication pressure in main line C is released
into the lubricant container.
 Main line C will be relieved and the lubricant

distributors SL1 store the lubricant in the
dosage chamber for the next lubrication cycle.
Page 11.4 - 18 3723250en - (00)

after it reaches its end position. The cylinder also

11.4.4 Grease pump retracts if the motion stops while moving out, e.g.
when the oil flow stops or if the counter pressure is
too high. The cylinder actuates the flange-
11.4.4.1 Start-up mounted pump pipe. Grease will be transported
into the central lubrication system via the pump
The feed lines and hoses must be cleaned with an pipe and the connection 'Px'.
appropriate medium, must be blow-out with air and
must be filled with grease before they can be
connected to the system. This removes possible
contamination and moisture, which could damage
the pump and other system parts.
The pump was tested in light machine oil, which

was not removed to protect the pump against
corrosion.
It must be ensured that all lubricant and hydraulic

connections are tight before the pump is used.
All connections must be checked

for tightness before the pump is
started-up!
Fig. 27 640140
The maximum operating pressure depends on the

application conditions and the internal friction
The pump can only be started-up losses. The theoretical maximum operating
for operation after it is placed in a pressure is 55 bar (input pressure) x 6.6
filled lubricant container. (intensification) = 363 bar. This pressure will be
When changing the container, it limited by a pressure switch to a maximum of 250
must be ensured that no bar to ensure the safety of all components.
contamination or other foreign
particles are in the container.
The pressure controller for the
hydraulic drive of the lubrication
pump must not be changed.
11.4.4.2 Operating sequence
The oscillation cylinder is a self-switching

operating cylinder with an automatic direction
rerouting unit. A terminal block with current
regulation valve and pressure reducer is mounted
at the cylinder head.
The cylinder starts after pressure is applied by the

hydraulic system to connection P. The cylinder
always retracts at the start, independent of the
direction it was going during switch-off. The
cylinder reverses the stroke direction automatically
3723250en - (00) Page 11.4 - 19
11.4.5 Electrical function
The central lubrication system is controlled by the

SPS and is described in chapter 9.3.
Page 11.4 - 20 3723250en - (00)

11.5 CENTRAL GREASE SYSTEM – LUBRICATION SYSTEM TEST
11.5 Lubrication system test
11.5.1 Start of the lubrication in test mode at

Check whether the lubrication
the SPS
system works flawlessly before
the start of work and once per
The following conditions must be present for
work shift.
normal as well as for test mode:
 Engine must run
 Grease container must not be empty
Before start of work:  No malfunction message must be present
1. Visual check of the hydraulic system or the

lubrication system for leakages. Test mode 1 cycle:
By pressing the reset button for 2 seconds, an
2. Visual check of the lubrication lines for damage individual cycle will be started and processed
3. Visual check of the cables on the control unit. Test mode 3 cycles:
The test mode will be started by pressing the reset
4. Check grease quantity in the lubricant button five times within 5 seconds. 3 complete
container. lubrication cycles will be processed.
5. The control display lights up for the duration of The test mode can be stopped by pressing the
the lubrication cycle after a drive engine is reset button for 1 second during test mode,
started. however, the current cycle will be completed. (The
number of cycles to be completed during test
6. The control pins at all distributors must be mode is preset in the SPS).
retracted after the pressure has been build-up
in main line A.
7. The control pins at all distributors must be

extended after the pressure has been build-up
in main line B.
3691580en - (02) Page 11.5 - 1

11.5 CENTRAL GREASE SYSTEM – LUBRICATION SYSTEM TEST
Page 11.5 - 2 3691580en - (02)

11.7 CENTRAL GREASE SYSTEM – TIME SETTINGS
11.7 Setting of the lubrication and

break times
A complete grease cycle (time for greasing and a
The control of the installation depend on the actual
pause) is always started after the time set in the
position of the control piston in the grease distribu-
PLC has expired. At the beginning of a greasing
tor and the pressure at the pump. Supply of grease
period the greasing cycle begins again. Time can
is guaranteed due to monitoring at the stick and
be changed by the BCS and should be pre-set to
monitoring the pump pressure. The control pistons
20 and 30 min, i.e. 1200-1800 sec, the minimum
are monitored via a grease distributor at the stick
value being 5 min (300 sec), the maximum time 40
rear wall. It is to be assumed that it has the most
min (2400 sec). Settings are made on the 2nd BCS
unfavourable position in this system because of
level of access “PLC options”.
the largest distance to the grease pump.
At the beginning of a grease cycle, voltage is ap-

plied to the hydraulic valve of the pump by means A change of the settings is
of the PLC, and the hydraulic pump starts pumping normally not required and can
into line 1 until the proximity switch 1 (Diesel Pin result in lubrication deficiencies
20, Electro Pin 15) switches over (light 1 Ini on, and therefore create significant
light 2 Ini off) and the pressure at the pump damages.
reaches 250 bar. After a 4 sec time of changing
over (pump switches off for 4 s) the pump starts
pumping into line 2 until the proximity switch no. 2
Time is counted only when the machine is in op-
(Diesel Pin 19, Electro Pin 16) switches over (light
eration, i.e. when boom, stick or bucket are oper-
Ini 2 on, light Ini 1 off) and the pressure reaches
ated (pressure switch „load“ /DSL is enabled). The
250 bar once again. The hydraulic valve and thus
travel times of the excavator are not counted, there
the pump are switched off after that. During a
is no greasing during breaks. Thus the supply of
greasing cycle the lights of the proximity switches
grease is adapted to demand and any unneces-
have to switch on at least once (first proximity
sary greasing during production breaks is avoided.
switch no.1!).
Moreover it is guaranteed that grease breaks are
made at regular intervals. The automatic change
from summer to winter operation is a further ad-
11.7.1 Duration of a lubrication cycle for the vantage. Upon higher lubricant viscosity in winter,
upper carriage in normal operation: grease is automatically pumped for a longer time.
Upon any start of the engine, a new cycle is
In the beginning the „greasing time“ depends on started.
the pump adjustments made by Lincoln; the prox-
imity switches switch over at approx. 40bar (dura-
tion approx. 7-10 sec). In order to guarantee The lubrication and break times are
supply of all grease distributors the pump pressure set at the SPS of the excavator
is monitored and has to reach 250 bar until (see chapter 9.3).
greasing is deviated or switched off. During a
switch over of 4 sec. the pump is switched off.
Fig. 1 Example lubrication time 641316

T1 Lubrication time
T2 Operating time excavator
Tab. 1
3723204en - (01) Seite 11.7 - 1

The conditions of greasing in the normal and in 11.7.2 Duration of a lubrication cycle for the
the test mode: under carriage in normal operation:
As well in the normal mode as in the test mode the
following conditions must be given: The under carriage lubrication is activated if the
 The engine must be in operation. equipment is continuously driven for at least 5
 The grease drum may not be empty. seconds, i.e. the pressure switch "driving" is
 There may not be any fault message. actuated! The pump will now be started and a
"lubrication cycle" will be processed, independent
of whether or not the equipment is driven after the
start of the pump.
BCS fault messages and switch-off of the The pump switches off when the pressure reaches
grease pump: 180 bar.
The fault messages are suppressed 8 min after
Afterwards, the pressure must be lowered to 50
starting the engine (i.e. during the first greasing) in
bar for 5 seconds before (again after the 5 second
order to prevent possible faults (e.g. a longer
actuation of the pressure switch driving) a new
greasing because of cold oil or grease)!
"lubrication cycle" can be started.
 When pressure exceeding 350bar is built up.
 After 2 min each if one of the two proximity The lubrication will last app. 10 seconds (until it
switches does not switch over reaches 180 bar).
 After 4 min each if 250 bar will note be
reached in one of the two lines
11.7.3 The functions of the reset button:
If any fault is coming up in line A Press button: Function:

a switch over to line B will be 1 sec resets PLC values and
done nevertheless after deletes fault messages
monitoring time!
2 sec + starts one single
greasing cycle (also done
upon engine start!)
BCS fault messages without grease pump 5 times shortly starts the test mode
being switched off superstructure: (within 5 sec) (3 ongoing greasing
 When a cable of the pressure sensor is broken cycles)
 When a cable of the grease level sensor is
broken 1 sec stops the test mode
(ongoing greasing cycle
continues)
Cut-off shovel/bucket cylinders:

After a fault message persisting during 15 min in
the superstructure the shovel/bucket cylinders Test mode 1 cycle:
switch off. One separate cycle is started and operated by
pressing the re-set button for 2 sec.
If the grease system restarts (ei-

ther by pushing the reset button Test mode 3 cycles:
for 2 seconds or by starting the The test mode is initiated by pressing five times
engine) the cylinder-cut-off (and within 5 sec the re-set button. 3 complete grease
the fault message on the BCS) will cycles are run.
remain until a complete grease The test mode can be stopped by pressing the re-
set button for 1 sec during the test mode. The
cycle will be finished without any
current cycle, however, is finished. (The number of
failure.
the cycles to be run during the test mode is pre-set
in the PLC.)
Seite 11.7 - 2 3723204en - (01)

11.7.4 Greasing cycle: Greasing of the

superstructure
Fig. 2 Lubrication cycle sequence 641317
██ Grease interval 3 End of line switch (Line A)

██ Break interval 4 End of line switch (Line B)
1 Pump status 5 Relief valve
2 Pressure at the pump
Tab. 2
- A new grease cycle starts as soon as pause time - At (t4) the „End of Line“ proximity switches at the
(t0) has elapsed. stick indicate that the movement of the control
- Pump is switched on and pumps grease to line A. piston towards direction B is finished.
- At (t1) the „End of Line“ proximity switches at the - Now the system is pumping until a pressure of
stick indicate that the movement of the control 250 bar is reached.
piston towards direction A is finished. The pump is switched off after reaching 250 bar
- Now the system is pumping until a pressure of (t5), the switch valve is operated and 5sec later
250 bar is reached. the relief valve is switched off.
- The pump is switched off after reaching 250 bar - When (t6) is reached a new greasing cycle
(t2) and the switch valve is operated. starts.
- After a 4s break the pump is re-activated (t3) and
pumps grease into line B.
3723204en - (01) Seite 11.7 - 3

Display and settings in the BCS
In the BCS, the sequence of a grease cycle is

indicated by means of a red bar in the control field
of the greasing system. In case the pressure
switch „charge“ is activated, the bar turns green
from the left to the right. When the bar has
completely changed to green time has elapsed and
greasing and a grease cycle start anew.
During greasing the background of the pictogram
is displayed in yellow. In the BCS, the grease
pressure is indicated by means of an analogue
signal.
Time can be changed via the BCS and should be
pre-set to 20 to 30 min, i.e. 1200-1800 sec, the
minimum value being 5 min (300 sec), the maxi-
mum time 40 min (2400 sec). Settings are made
on the BCS level of access.
It must also be set if the machine is equipped with
a grease drum and/or a greasing system for the
undercarriage.
A change of the settings is

normally not required and can
result in lubrication deficiencies
and therefore create significant
damages.
The lubrication and break times are

set at the SPS of the excavator
(see chapter 9.3).
Seite 11.7 - 4 3723204en - (01)

11.8 CENTRAL GREASE SYSTEM - BLEEDING
11.8 Bleeding of the central

lubrication system
The system must be carefully bleeded if air
entered the system, e.g. when lines are
replaced or if a lubricant container is empty.
Bleeding the pump Bleeding the system
1. Exchange empty lubricant container or fill 1. Release both main lines A and B at the last
container. (see operating instructions, part 3: distributor
Maintenance).
2. Release knurled screw (A, Fig. 1). Let pump 2. Switch-on lubrication pump until grease exits
run. Re-tighten knurled screw if grease exits one of the main line.
without bubbles.
3. Switch-off lubrication pump and reconnect this
line back to the distributor.
4. Switch-on lubrication pump again until grease

exits the 2nd main line.
5. Switch-off lubrication pump and reconnect this

line back to the distributor.
Hose lines must be filled with

lubricant before installation when
they are exchanged.
Fig. 1 Bleeding screw at the pump 641254
It is possible that the intake hole

of the pump is blocked if no
lubricant exits after a longer
period. The pump must be
disassembled in this case and
the intake hole must be cleaned.
The pump element must be

exchanged if it still does not
deliver any grease.
3723132en - (02) Page 11.8 - 1

11.8 CENTRAL GREASE SYSTEM - BLEEDING
Page 11.8 - 2 3723132en - (02)

11.9 CENTRAL GREASE SYSTEM – LUBRICATION PUMP
11.9 Repairing the lubrication pump

11.9.1 Components of the barrel pump
Switch-off the pump and secure
against unintended switch-ons The items refer to Fig. 1
before any maintenance or repair
work is started. Item Qty Identification
Release the pressure in the system 1 1 SCREW
by opening the couplings. 2 1 CONNECTION ADAPTER
Repairs can only be performed by 3 1 PISTON ROD
qualified personnel using only 3.1 1 SCRAPER RING
original spare parts. 4 1 PACKING
Do not touch the lower part of the 5 1 O-RING, polyurethane
pump (suction intake) during start- 6 1 GROOVE RING, polyurethane
up/test run.
7 1 SUPPORT WASHER
8 1 RETAINING RING
Do not flush or clean pump / pump 9 1 OUTLET CASE
pipe with flammable fluids.
10 1 LOCK SCREW
11 1 ADAPTER
12 2 GASKET, copper
The pump must be tested frequently. Worn or 13 1 VALVE SEAT
damaged parts must be repaired or replaced
immediately. 14 1 BALL VALVE
15 1 BACKSTOP
Special tools and special know-how is required for 16 1 OUTLET ADAPTER
the repair of this pump. Please contact the nearest
repair service if the repair requires more 17 1 O-RING, nitrile
maintenance instructions than listed in this manual. 18 1 PIPE
It is recommended to perform annual maintenance 19 1 ADAPTER
for the pump. 20 2 SPLINT
21 1 CONNECTING ROD
Repair 22 1 ADAPTER
23 1 BALL
Repairs are limited to the exchange of the listed
24 1 BALL
spare parts. Repairs that exceed the listed
exchange parts require special know-how and 25 1 PIN
special tools. 26 1 FIT PISTON SET
27 1 O-RING, nitrile
Please list the item number, identification, type
number and serial letter when ordering spare parts 28 1 CYLINDER LINER
(see spare parts list). 29 1 RETAINING RING
30 1 VALVE GUIDE
31 1 PISTON ROD SET
32 1 SPLINT
33 1 VALVE RETAINING RING
34 1 VALVE
35 1 VALVE SEAT
36 1 SCOOPING PISTON NUT
37 1 END PIPE
Components of the barrel pump:

3723251en - (00) Page 11.9 - 1
Fig. 1 Parts of the barrel pump 641342
Page 11.9 - 2 3723251en - (00)

11.9.2 Disassembly of the pump
The hydraulics and lubricant lines must be 18. Remove fit piston (26) from adapter (22).
completely de-pressurized before the pump can be 19. Remove ball valve (23) from the adapter (22).
disassembled. 20. Remove pin (25) and ball valve from the fit
piston (26).
21. Remove splints (20) from connection shaft
Disassembly instructions (21).
22. Remove adapter (22) and piston rod (3) from
Note: The following information in bold brackets ( connection shaft (21).
) refers to the item information in the spare parts
drawing and spare parts list as shown in Fig. 1.
1. Remove cylinder liner (28) from pipe (18). Repair

2. Grab cylinder liner (28) and pull until the
connection between fit piston set (26) and 1. Check fit piston set (26) and exchange if worn
scooping piston rod (part of 31) is open. out or damaged.
Unhook the scooping piston rod and remove 2. Check valve & scooping piston shaft of piston
completely with lower segment (27-37). rod set (31) and exchange completely if worn-
3. Remove cylinder liner (28) from end pipe (37). out or damaged.
4. Remove the piston rod set including the 3. Check fit piston rod (3) and exchange if worn
scooping piston nut and the complete foot out or damaged.
valve (29 to 36) form the cylinder liner. 4. Check the other parts and exchange if
5. Remove splint (32) from the scooping piston required.
rod (part of 31). 5. Exchange all sealings.
6. Remove scooping piston nut (36) from the
scooping piston rod..
7. Remove retainer ring (29) and valve guide
(30) from piston rod set (31).. 11.9.3 Assembly of the pump
8. Remove O-ring (27) from the pipe (18).
9. Remove screw (1) from piston rod (3).
The pump pipe is assembled as described in
10. Grab fit piston (26) and pull piston rod (3)
disassembly but in reverse.
including valve stem (21), adapter (22) and
bushing of the fit piston set from the pipe (18).
11. Remove pipe (28) from the outlet housing For the assembly, tighten the
(18). screw identified as item 1 with a
12. Remove O-ring (17) from the outlet housing
torque of 88 Nm.
(9).
13. Remove packing (4) from outlet housing (9).
14. Remove adapter (11) with lock screw (10)
from outlet housing (9). The piston rod must be oiled
15. Remove outlet adapter (16) from outlet before the installation to protect
housing (9). the packing of the pump against
16. Remove ball valve (14) and gaskets (12) from damage and to prolong its life
the outlet housing (9).
span.
17. Uninstall retainer ring (8) support washer (7)
and groove ring (6) from the packing (4). For the assembly of the pump.
The piston rod will be fed through
the packing.
Initially, assemble all parts
manually to avoid damages to the
threads.
3723251en - (00) Page 11.9 - 3

11.9.4 Spare parts for hydraulic pump (Fig. 2):
Item Qty Designation

1 1 OSCILLATING CYLINDER COUPLING WITH CONTROL BLOCK
2 1 PRESSURE REDUCER 65 ± 5% BAR
3 1 FLOW REGULATION VALVE 11-14 L/MIN
4 1 GASKET SET FOR OSCILLATING CYLINDER
5 1 COVER
6 1 PUMP PIPE (Component parts see Fig. 1)
Tab. 2
Fig. 2 Main Components for hydraulic pump 641255
Page 11.9 - 4 3723251en - (00)

Gasket set for oscillating cylinder (Fig. 3):
Item Quantity Identifcation

1 2 Piston guide ring
2 1 Turcon Glyd-Ring
3 1 O-ring 37.69 x 3.53
4 1 Groove ring 35 x 43 x 7
5 2 Shaft guide ring
6 1 Scraper ring 35 x 43 x 7
7 1 O-ring 55.0 x 3.0
Tab.3
Fig. 3 Components for the hydraulic cylinder of the barrel pump 641256
3723251en - (00) Page 11.9 - 5

Page 11.9 - 6 3723251en - (00)

11.10 CENTRAL GREASE SYSTEM - DISTRIBUTOR
11.10 Repairing the lubrication dis-

tributors
The repair of the lubricant Distributor type VSG-KR

distributors is limited to the
exchange of gaskets and mounted
parts, because all pistons are
individually fit into the distributors
body.
Disassembly of distributor pistons
results in loss of function with
resulting bearing damages.
Repair
Repairs are limited to the exchange of the listed

spare parts. More involved repairs are not
Fig. 2 Spare part drawing VSG-KR 640149
possible.
Please list the item number, identification, type
number and serial letter when ordering spare Item Identification
parts. 1 Lock screw M10 x 1
2 Gasket Cu 5 x 9 x 1
The following lists the exchangeable spare parts
for each distributor type. 3 Lock screw R1/4”
4 Gasket Cu 13.5 x 16 x 1
5 Locking screw M8 x 1
6 Control pin complete
7* Regulation bushing with groove ring AU (std.)
Regulation bushing with groove ring FPM
8 O-ring 12 x 2
9 Brass Sleeve
10 Ring nut M 10 x 1
11 O-ring 6 x 2
12 Lock screw
Tab. 2
Note: * incl. item 8 (O-ring 12 x 2)
3691758en - (02) Page 11.10 - 1

Distributor type VSL-KR Distributor type SL 1
Fig. 3 Spare part drawing VSL-KR 640150
Item Identification
1 Lock screw M10 x 1
2 Gasket Cu 5 x 9 x 1
Fig. 4 Spare part drawing SL-1 640215
3 Lock screw M 16 x 1.5
4 Gasket Cu 16 x 19 x 1 Item Identification
5 Locking screw M8 x 1
1 ADJUSTMENT SCREW
6 Control pin complete
2 LOCK NUT (SW 5/8“)
7* Regulation bushing with groove ring AU (std.)
3 LOCK NUT (SW 5/8“)
Regulation bushing with groove ring FPM
4 GASKET
8 O-ring 12 x 2
5 DISK
9 Brass sleeve
6 O-RING, FKM
Regulation compl. AU
(item 7 + 9) 7 DISTRIBUTOR BODY
Regulation compl. 8 PISTON with control pin
FPM (item 7 + 9)
9 Lock nipple
10 Ring nut M 10 x 1
10 PRESSURE SPRING
11 O-ring 6 x 2
11 SPRING SEAT
12 Lock screw
12 VALVE PISTON
Tab. 3
13 SEALING, FKM
Note: * incl. item 8 (O-ring 12 x 2) 14 VALVE DISK
15 SEALING, FKM
16 DISK
17 GASKET
18 SEALING, FKM
19 HOLLOW SCREW (SW 7/8“)
MANIFOLD
#
3-fold or 4-fold
Tab. 4
Page 11.10 - 2 3691758en - (02)

Distributor type SSVD
Fig. 5 Spare part drawing SSVD 640275
Item Identification
1 No return valve
2 Metering screw A (0,08 cm³)
3 Metering screw F (1,00 cm³)
4 Lock screw
Tab. 5
3691758en - (02) Page 11.10 - 3

Page 11.10 - 4 3691758en - (02)

11.11 CENTRAL GREASE SYSTEM – HOSE LINE
11.11 Renewal of high pressure hose

lines
The specified pressure must be met

High-pressure hoses used
if the high pressure hose lines are
The following high pressure hose types are used in
renewed.
the central lubrication system
Hoses that do not meet the
specified pressure range can burst
and can disable the lubrication Hydraulic line grease lubr. pump
system. Operation pressure = 110 bar
Nominal size = 10 mm
Type of connection = 12 mm DKO-L / DKO-L
The specified hose length must be Temperature range = -40°C to 125°C
met if the high pressure hose lines
are renewed.
Lubricant line grease lubric. pump
Hoses that are too short can tear
and
while in operation; hoses that are
main line on the equipment
too long can kink and/or can be
Operation pressure = 400 bar
damaged.
Nominal size = 16 mm
The lubrication system can in both Temperature range = -40°C to 125°C
cases be disabled. Type of connection = 20 mm, DKO-S / DKO-S
Hose for lubr. point connections

and
branch lines to the VSG-VSL distributors
Burst pressure = 1379 bar
Nominal size = 6 mm
Temperature range = -40°C to 100°C
Type of connection = variable,
see Fig.1 to Fig. 3
Lubrication point connections for SSVD –

distributors
Min. burst pressure = 600 bar at 20°C
Nominal size = 4,1 mm
Min. bending radius = 35 mm at 20°C
Type of connection = connecting piece 6 mm,
see Fig. 4
Lubrication point connections for SL 1

distributors
Nominal size = 8 mm
Type of connection = 10 mm, DKO-L / DKO-L
3691586en - (02) Page 11.11 - 1

11.11 CENTRAL GREASE SYSTEM – HOSE LINE
Possible types of connecting pieces High-pressure plastic hose Ø 8,6 x 2,3 mm

For the high-pressure hose for the lubrication point
connections and branch lines to the VSG-VSL –
distributors.
Fig. 4 Threaded union and connecting piece 640154
Fig. 1 Connecting piece, straight 640151 Fitting (Fig. 4)

Turn threaded union 1 counter-clockwise onto the
high-pressure plastic hose 2 until the dimension
shown of 11 mm is reached. Then, screw hose
connecting piece 3 down into union 1.
Before screwing in, parts 1 and 3

must be properly oiled.
The outer diameter dimensions of
the high-pressure plastic hose may
deviate from the nominal value. In
this case, the high-pressure plastic
hose should be given an elliptic
Fig. 2 Connecting piece, 45° 640152
shape on the screwing side by 1 or
2 mm to prevent the high-pressure
plastic hose from being forced out
of the union when the connecting
piece is screwed into the union.
Fig. 3 Connecting piece, 90°° 640153

The hose connecting pieces shown must be
crimped with a suitable tool (supplied with the ex-
cavator) onto the hoses and checked for leaks.
Page 11.11 - 2 3691586en - (02)

11.12 CENTRAL GREASE SYSTEM – TROUBLESHOOTING INSTR.
11.12 Trouble shooting instructions
Fault Cause Resolution

Hydraulic pressure at Check supply for the hydraulic valve unit with
Pump does not run.
pump too low servo oil
Lubricant container is
Fill lubricant container.
empty
Internal leakage in the
Repair pump, exchange if required
drive part of the pump
Volume control valve for
the oil feed of the
Check valve settings.
lubrication pump is
wrongly set
Solenoid valve defect Exchange solenoid valve
Power supply of
Check power supply for valve unit.
solenoid valves
Check SPS function
interrupted
Lubrication time setting Set lubrication time in accordance with
is set to 0 minutes. operating instructions.
Check feed lines and exchange sensor if
Fill level display defect.
required.
Pump operates but Lubricant container
pressure in empty but no empty Fill lubricant container and bleed system; check
lubrication system is message by the fill level fill level sensor
not generated sensor.
Check pump line to valve unit and the main
Lubricant line leaks lines A and B for open screw connections,
line breakage and torn hoses.
Foreign particles in the
Clean pump and exchange contaminated
inlet valves of the pump
lubricant.
piston.
Pump sealing elements
Exchange sealing elements.
are worn out
Piston rod is worn out. Exchange wear and tear parts and gaskets.
Return valve in pump
element is defect or Exchange pump element.
clogged.
Release additional lubricant. Open outlet
Air pockets in lubricant. screw connections or main lines. The lubricant
must exit without bubbles.
Bypass valve defect. Exchange bypass valve.
3691587en - (02) Page 11.12 - 1

11.12 CENTRAL GREASE SYSTEM – TROUBLESHOOTING INSTR.
Fault Cause Resolution

Pump operates but Lubricant container Fill lubricant container and bleed system;
pressure in empty but no empty check fill level sensor
lubrication system is message by the fill level
not generated sensor.
Used unqualified Exchange lubricant, see lubricant table.
lubricant.
Pressure limit valve for Set valve, exchange if required.
pump set too low in
control table or it is
defect
Pump piston worn out Exchange pump piston
Pressure generation Hydraulic supply Check hydraulic system for the pump.
in lubrication system pressure too low for
is too slow lubricant pump.
Volume control valve is Set volume control valve.
set to volume that is too
small.
Leakage in lubrication Resolve leakage..
system.
Unqualified lubricant Use lubricant in accordance with lubricant
(wrong viscosity). table in operating instructions (observe
permissible temperature range).
System blocked Hydraulic pressure for Check pressure settings.
lubricant pump is too
low.
Electrical or hydraulic Check electrical and hydraulic actuation of the
switching valve defect; switching valve; exchange component if
i.e. only one main line required.
receives pressure.
Lubricant filter is Clean filter.
contaminated.
Blockage in Contamination, Exchange distributor.
distributor mechanical defect.
Outlet at distributor, line Remove cause for blockage.
to lubrication point or
lubrication point
blocked
Tab. 1
Page 11.12 - 2 3691587en - (02)

08.2018
12. Options
6040

12. OPTIONAL EQUIPMENT
12. Optional equipment

Please refer to the printed version of the Service
Manual, search the section ‘Other Documents’ on
the CD/DVD which was supplied with the machine,
or search for the machine serial-no. on the Cater-
pillar Global Mining HMS GmbH homepage in the
internet.
3720212en - (00) Page 12 - 1

12. OPTIONAL EQUIPMENT
Page 12 - 2 3720212en - (00)

3 842 950.00 en
February 2014
Service Manual
for Fundamental
Principles of Electricity
6015 - 6090
3 842 950.00 en
Issued by: Caterpillar Global Mining HMS GmbH

Technical Publications Dept.
D-44149 Dortmund, Karl-Funke-Strasse 36
Tel. +49 (0) 231 922 4340
Fax +49 (0) 231 922 5005
https://mining.cat.com www.bucyrus-hex.de
© Caterpillar Global Mining Hydraulic Mining Shovels GmbH 2014. Unless expressly permitted, the transfer
and reproduction of this manual/file and the sale and disclosure of its content is prohibited. Contraventions
are liable to compensation. All rights reserved in the event of patent, utility model, or registered design
registration.
Printed in Germany
3 842 950.00 en
CONTENTS
FOREWORD__________________________________________________________________________ 1
SAFETY INSTRUCTIONS _______________________________________________________________ 1

Personnel Requirements ............................................................................................................................1
Observe the hazard warnings on the machine...........................................................................................1
Observe the warnings and safety instructions in the instructions ..............................................................1
GENERAL INFORMATION ON ELECTRICITY _______________________________________________ 2

Atoms .............................................................................................................................................2
Atomic Structure.............................................................................................................................2
Free Electron..................................................................................................................................2
Electromagnetic Field.....................................................................................................................3
Alternating Current – Display .........................................................................................................4
Electric Power Generation, Principle..............................................................................................4
Electric Power Generation in Motor Vehicles .................................................................................5
Function of an Alternator ............................................................................................................................5
Rectification – Three-Phase Bridge Circuit ....................................................................................6
Construction of an Alternator......................................................................................................................8
Type Identification.......................................................................................................................................8
Maintenance ...............................................................................................................................................8
Charging Batteries..........................................................................................................................9
Circuit with error indicator when excitation circuit is interrupted.....................................................9
Testing the Charging System .......................................................................................................10
COMPONENTS USED IN VEHICLE ELECTRICAL SYSTEMS__________________________________ 11

Battery ..........................................................................................................................................11
Battery Design..............................................................................................................................12
Maintenance-Free Starter Battery ............................................................................................................12
Low Maintenance Batteries ......................................................................................................................13
Battery Testing..........................................................................................................................................13
Acid values for diluted sulfuric acid ..........................................................................................................13
Mixing Fresh Battery Electrolyte...............................................................................................................14
Mixing Instructions ....................................................................................................................................14
Maintenance .............................................................................................................................................14
Faults ........................................................................................................................................................15
Electric Motors..............................................................................................................................17
Electric Motors..............................................................................................................................17
Electric Motor Operation...............................................................................................................17
Starter motor ................................................................................................................................18
3 842 950.00 en
Starting Engine Operation ........................................................................................................................18

Engaging...................................................................................................................................................18
Engaged ...................................................................................................................................................18
Checking Vehicle Starter System .............................................................................................................19
Starting Engine .........................................................................................................................................19
Maintenance .............................................................................................................................................20
Carbon brushes ........................................................................................................................................20
Commutator ..............................................................................................................................................20
Lubrication ................................................................................................................................................21
BASIC PRINCIPLES OF VEHICLE ELECTRICAL SYSTEMS __________________________________ 21

Current, Voltage, Resistance, and Power ....................................................................................21
Current (I) .................................................................................................................................................21
Voltage (V)................................................................................................................................................21
Resistance (R) ..........................................................................................................................................21
Power (P)..................................................................................................................................................22
MEASUREMENTS USING A MULTIMETER ________________________________________________ 22

Multimeter Settings.......................................................................................................................22
Voltage Measurements ................................................................................................................22
Testing diodes ..............................................................................................................................23
Current Measurements.................................................................................................................23
Ohm Measurements (Resistance)................................................................................................23
Check cable continuity .................................................................................................................23
SERIES AND PARALLEL CONNECTION OF COMPONENTS _________________________________ 24

Batteries .......................................................................................................................................24
Series Connection ....................................................................................................................................24
Parallel Connection ..................................................................................................................................24
Resistors ......................................................................................................................................24
Capacitors ....................................................................................................................................24
Electrolytic Capacitor....................................................................................................................25
VOLTAGE LOSS AND LINES ___________________________________________________________ 26
LINE CALCULATION __________________________________________________________________ 27

Parameters and Units...................................................................................................................27
Calculation: ...............................................................................................................................................27
LINES FOR VEHICLE ELECTRICAL SYSTEMS_____________________________________________ 28

3 842 950.00 en
Calculation Example.....................................................................................................................29
LIGHTING ___________________________________________________________________________ 30
Instructions for Adjusting Headlights ............................................................................................30
Requirements ...........................................................................................................................................30
Working Lights ..........................................................................................................................................30
Incandescent Lamps ................................................................................................................................30
Sources of Error and Reasons for Lighting ..................................................................................30
Transition Resistances in a Line Circuit ...................................................................................................30
SPECIAL CIRCUITS IN VEHICLE ELECTRICAL SYSTEMS ___________________________________ 31

Diode ............................................................................................................................................31
“Recovery Diode” .........................................................................................................................31
Varistor .........................................................................................................................................32
Generator Regulator.....................................................................................................................32
Vehicle Fuses...............................................................................................................................33
MARKING INDIVIDUAL PARTS _________________________________________________________ 34
STANDARD TERMINAL DESIGNATIONS _________________________________________________ 35

Terminal Designations..................................................................................................................35
3 842 950.00 en
3 842 950.00 en
FOREWORD SAFETY INSTRUCTIONS

The purpose of this manual is to share knowledge Personnel Requirements
of the most essential basic principles in the field of
electricity. Knowing these fundamentals will make All work performed on electrical or electronic
it easier for maintenance personnel to understand components and systems of the machine must be
the electrical systems used in Caterpillar Global carried out by trained and qualified professionals
Mining HMS GmbH machines. only, or by personnel undergoing training under the
This manual is also intended to be a reference supervision and guidance of a qualified person.
work for trained electricians working in customer If personnel do not have the required expertise,
service or workshops. then in-depth training must be provided by
experienced personnel, e.g. by Caterpillar Global
It does not describe actual repair or maintenance
Mining HMS GmbH.
work. Descriptions of this work can be found in the
Electrical systems may be installed with varying
operation and maintenance instructions or in the
levels of high voltage in the machines that
technical manual for the machine.
have to be operated. This also calls for different
requirements regarding the qualifications of the
Notice:
personnel who will be responsible for carrying
The article numbers listed here should not be used
out maintenance or repair work.
to order replacement parts. The article numbers
For example, an electrician may not work on
used in this manual are only intended to serve as
systems operating at 6000-7200 V without further
documentation of the parts to which the data listed
training and instruction if he only has experience
below refer.
with 24 V wiring systems.
Please use the replacement parts list associated
with a specific machine when ordering spare parts. Detailed information on personnel requirements can
This replacement parts list is available in hard copy be found in the “Electrics and Electronics” section of
form, as well as in digital format and online. Please the technical manual for a specific machine.
contact your Caterpillar dealer for more information. In all cases, the applicable national legislation
and the accident prevention regulations for your
respective country must be observed. These are
not included in this manual.
Observe the hazard warnings on the

machine
Observe all safety instructions and hazard
warnings on the machine.
Keep all safety instructions and hazard warnings
at and on the machine in place, and make sure
they are complete and in legible condition.
Replace any illegible or missing warning signs
or information immediately.
Observe all national laws, regulations
and guidelines that apply in your country.
Observe the warnings and safety

instructions in the instructions
Descriptive and instructive text contains warnings
and safety information. This information alerts the
operator to potential risks and is thus provided for
your safety. For this reason, always observe all
warnings and safety information.
1
3 842 950.00 en
GENERAL INFORMATION
ON ELECTRICITY
To make the concept of electricity more
understandable, we are going to make a brief
sidestep into the field of electrical engineering.
Atoms
All substances are made up of atoms.
An atom consists of a nucleus, which has a positive
charge, and electrons. These electrons have a
negative charge and orbit the nucleus at great Fig. 2
speed. The nucleus itself is composed of protons,
which are positively charged, and neutrons, which The electron from nucleus A has reached a neutral
have a neutral charge. The number of protons and orbit. Since atom B is electrically neutral and atom
neutrons is based on the given atomic structure. If C is not (it's missing an electron), the electron is
the nucleus has the same number of electrons as attracted by nucleus C and nucleus A is therefore
protons, the atom acts neutrally to the outside, in no longer neutral. Another atom attracts another
terms of electrical charge. All electrons are bonded electron that has reached a neutral orbit. If an
magnetically at their core. If an electron is missing, electron from nucleus C, which is now neutral,
for whatever reason, i.e. there is one more proton reaches a neutral orbit again, it is likewise
in the nucleus than there are electrons orbiting it, attracted by a non-neutral nucleus (and so on).
the atom is positive.
Atomic Structure
The number of protons corresponds to the number
of electrons, e.g. it is electrically neutral
(see Fig. 1).
Fig. 3
Precious metals and nonferrous metals contain

a relatively large number of free electrons. If
Fig. 1 you move a conductor (e.g. a copper wire) into
a magnetic field, free electrons will be pulled
Because substances contain a multitude of atoms, in one direction or another.
it often occurs that an electron exists at an equal
distance to another nucleus as to its own nucleus.
In this case, the magnetic attraction from its own
nucleus increases. Such an electron is no longer
bound to its own nucleus, in other words it is free.
Electrons of this type are called “free electrons.”
Free Electron
If an electron leaves its orbit and is at the same
distance to another nucleus as to its own, it is no
longer bound to its nucleus – it is free (see Fig. 2).
2
3 842 950.00 en
Electromagnetic Field The result is that an electrical potential is built

up alternatingly at the ends of the conductor. This
When current flows through a conductor, potential is called electrical voltage (V), measured
a magnetic field then forms around the in volts (V). If this conductor is now formed as
conductor (see Fig. 4). a closed circuit, the electron current that moves
through the conductor can be measured. This
flow of electrons is called electrical current
(I) and is measured in amperes (A).
Fig. 4
The resistor “R” serves only to prevent a short in

the circuit. If a conductor is formed into a coil with
several windings, a magnetic field will spread
Fig. 6
around the coil (see Fig. 5). The strength of the
magnetic field depends on the current that flows
through the coil and on the number of windings. The formation of a continuously alternating
potential in a conductor is called AC voltage. The
current flowing in this process is called alternating
current, i.e. the current constantly changes its
direction and strength. The alternating current
and AC voltage can be made visible by means
of a display unit. Current and voltage are normally
synchronized. If current is not synchronized with
voltage, this is known as a phase shift.
Fig. 5
An iron core with preferred magnetic orientation

is normally used to support the windings in order
to increase the intensity of the magnetic field.
Consequently, the electromagnetic force is
sufficient to, e.g. pull the core of a solenoid valve.
3
3 842 950.00 en
Alternating Current – Display Electric Power Generation, Prin-

The waveform of the alternating current or AC ciple
voltage is a sine curve. If the current and voltage It then becomes relatively easy to construct a
are in phase, both achieve their peak value at the power generator based on the fact that a magnetic
same time. The oscillations that occur in one field is formed around a conductor when a current
second are known as the frequency (f). The is made to flow through the conductor. This
number of oscillations that occur in one second are principle is described in Fig. 8. Windings (2) are
specified in hertz (Hz). A few important physical mounted on a rotor (1) and are supplied with direct
parameters are listed below (see Fig. 7): current (3). This produces a magnetic field (4). The
rotor magnetic field runs through the windings (6)
mounted to the stators (5) of the generator when
the rotor turns. Electrical voltage is thereby
generated in the stator winding.
Fig. 7
T Duration of a complete oscillation (period)

in s
f Frequency in Hz
(f = 1/T)
î Peak value (amplitude) of current
û Peak value (amplitude) of voltage
ω Angular frequency in 1/s
(ω = 2 * f = 2 π/T)
Fig. 8
φ Phase shift angle between current and
voltage; phase-shifted means: current and
voltage achieve their threshold or their zero
crossing at different points
t Time axis (time in s)
4
3 842 950.00 en
Electric Power Generation in

Motor Vehicles
Function of an Alternator
The purpose of a generator is to cover the energy
needs of electrical consumers. It must also ensure
that the battery itself is charged when permanent
consumers are connected at low engine speeds
(low idle). The generator must supply constant
voltage at all operational and load conditions. A
regulator helps the generator in this process by
regulating voltage between 13 and 14.5 V,
regardless of the load and speed of the generator.
An alternator (also generator, Fig. 9) generates Fig. 10

three alternating currents, each phase-shifted by
120° (Fig. 10). This three-phase current is rectified Current flows when voltage is applied to the field
by the controller electronics by means of diodes and winding mounted to the magnet wheel. This current
converted into direct current. A controller is used produces a magnetic field.
to adjust the DC voltage to the nominal charging AC voltage is generated in each coil when the
voltage. The direct current that is produced as magnet wheel turns. Three equal voltages are
a result is required for recharging the battery, produced in the three coils. However, these
i.e. the battery is recharged as the motor runs. voltages are shifted in time to each other by 1/3 of
a period, i.e. the phase shift amounts to 120°. If the
coils are loaded equally, the phase angle between
currents is also 120°. Three alternating currents that
are each phase-shifted by 120° are called three-
phase alternating current or three-phase current.
Fig. 9
5
3 842 950.00 en
Rectification – Three-Phase
Bridge Circuit
Since three-phase alternating current is
generated in motor vehicles, it must be rectified
in order to recharge the battery. If the three-
phase AC voltage produced by the generator
is made visible, this results in three sine curves
that are each phase-shifted by 120°, based on
the design of the generator.
Consider a curve: It rises to “V+ max (plus)”,
the highest voltage value, then falls through the
“0 point” to “V-max (minus)”, the lowest voltage
value. If AC voltage is now applied to the anode
side of a diode, the negative half-wave is blocked
and the positive one can pass through. Fig. 11
Fig. 12
Only positive (plus) voltage exists at the cathode side (cathode output voltage) and no longer the full anode
input voltage (Fig. 12).
If we examine the direction of the three-phase current, several diodes are connected in parallel to a bridge
(see Fig. 13). The individual diodes of this bridge are known as main diodes.
6
3 842 950.00 en
Fig. 13
Only positive waves still exist at the output of the rectifier bridge, i.e. direct current or DC voltage still exists.
This direct current is used to back up the battery.
7
3 842 950.00 en
Construction of an Alternator Type Identification
Fig. 15
Note:
24 V generators are installed in equipment.
Maintenance
The alternators installed in current CAT machines
are largely maintenance-free. V-belt tension should
Fig. 14 be checked about once a month, depending on
how the machine is used. Carbon brushes should
1 Slip-ring end shield be checked once a year. A visual examination
2 Rectifier – Heat sink of slip rings should also be performed, and, if
necessary, these components should be sanded
3 Power diode
down using a very fine emery cloth.
4 Exciter
5 Transistor regulator using hybrid
technology (= electronic regulator)
6 Stator with three-phase winding
7 Claw-pole rotor
8 Fan
9 Belt pulley
10 Drive end shield with mounting flanges
Note:
The battery should not be disconnected from the
generator while the generator is running; this would
endanger semiconductor components in the
generator and in electronic control units.
8
3 842 950.00 en
Charging Batteries Circuit with error indicator when

Since the generator in motor vehicles is used for excitation circuit is interrupted
backing up (recharging) batteries, the three-phase
current must be transformed into direct current.
This is achieved by means of rectifier diodes
(see Fig. 16).
Fig. 17
1 Generator
2 Generator indicator lamp
3 Resistor R
4 Ignition or driving switch
5 Battery
Fig. 16
The only function of the charge alarm indicator
1 Field diodes is to ensure the generator is premagnetized and
2 Main diodes to monitor the excitation circuit. If the charge alarm
indicator is lit while the generator is running, this
3 Regulator
means there is no excitation current and therefore
no battery charge.
Field diodes are responsible for transforming three-
phase current into direct current. This direct current The functions of the charge controller are based
is then routed to the field winding by means of the on the principle described in Fig. 17. When the
regulator, and this component is responsible for ignition switch (4) is closed, current flows from the
limiting or shutting off field current after charging battery (5) through the indicator lamp (2) over
voltage is reached. The main diodes are a resistor (3) to the ground. The resistor (3) is
interconnected by means of a so-called bridge. calculated so that the indicator lamp is lit. If the
The output (B +) of this diode bridge is permanently diesel engine is then started so the generator is
connected to the battery terminal (+). powered up, a positive voltage is supplied to the
terminal (D +) of the generator. Because a positive
voltage is now being supplied to both sides of the
indicator lamp, the charge alarm indicator goes
out. The resistor must be connected in the
immediate vicinity of the indicator lamp.
9
3 842 950.00 en
Testing the Charging System

Note:
The voltage gauge must be switched to direct
current operation.
The voltage gauge must be connected directly to

the battery for the charging system to be tested.
The engine must then be brought to full speed.
The nominal charging voltage must be
reached after approx. 2 minutes. This voltage
should be between 13-14.5 V in a 12 Volt
system, or 26-29 V in a 24 Volt system.
If the voltage gauge shows an extremely high
value, the regulator is probably defective. On the
other hand, if the voltage value is too low, there
is probably a fault in the charging system.
10
3 842 950.00 en
COMPONENTS USED IN VEHICLE ELECTRICAL SYSTEMS

Battery
The battery is only used for starting the vehicle
and for the lights when the machine is parked.
During operation, the generator takes over the
supply of power to the vehicle and simultaneously
recharges the battery.
The batteries most frequently used in vehicles

are 12 volt batteries. They are constructed from
individual cells (see Fig. 19) (Basic Lead Cell
Construction). A nominal voltage of 12 V is realized
by interconnecting (serial connection) six cells
(2 V cells) (see Fig. 18).
Fig. 19
Fig. 18
The nominal voltage of a battery is based on the

number of cells connected in series.
UB  n  U Z
n Number of cells
UB Nominal voltage of battery
UZ Nominal voltage of cells (= cell voltage)
11
3 842 950.00 en
Battery Design Maintenance-Free Starter Battery

Metallurgical measures ensure that electrolysis of
water during normal operation under wiring system
conditions (V = constant) is reduced sufficiently
so that the electrolyte supply via the plates is
adequate for the full working life of the battery.
If a battery of this type needs to be recharged

outside of the wiring system, make sure the
charging voltage per cell is limited to
a maximum 2.3–2.4 V.
Fig. 20
1 Block cover
2 Terminal cover cap
3 Direct cell connector
4 End terminal
5 Safety valve
6 Plate connector
7 Battery casing
8 Base hold-down
9 Positive plates immersed in foil separators
10 Negative plates
Note:
The description “maintenance-free in accordance

with DIN” only means that a battery must remain
under a prescribed limit in terms of water
consumption. This by no means ensures that
water refilling can be dispensed with over the
entire lifetime of the battery. In addition, the
remaining maintenance aspects are generally
not affected by this definition. For these reasons,
some advertising statements regarding freedom
from maintenance are misleading.
12
3 842 950.00 en
Low Maintenance Batteries Battery Testing

The electrolyte level in low maintenance batteries Acid density is the key characteristic that indicates
should be checked at least once a year. If the the state of charge for a battery. Acid density can
electrolyte level lies below the level line set by the be measured to see how fully a battery is charged.
manufacturer, the battery's chambers should be A hydrometer is used to measure acid density. The
refilled with distilled water. If the battery needs scale of the hydrometer shows the acid density.
to be recharged away from the wiring system,
it should be charged using a tenth of the current Acid values for diluted sulfuric acid
of the nominal capacity of the battery.
Acid Freezing
State of Battery
Battery charging results in the density threshold
charge design
production of highly explosive kg/l °C
oxyhydrogen. Batteries should only
be charged in well-ventilated areas charged normal 1.28 -68
specifically provided for that
for 1.23 -40
purpose. Working with fire and open
tropics
flames, and smoking are prohibited.
Relevant safety regulations must half- normal 1.16/1.20 -17…-27
always be observed. charged
for 1.13/1.16 -13…-17
tropics
discharged normal 1.04/1.12 -3…-11
for 1.03/1.08 -2...-8

tropics
Table 1
The start test involves measuring voltage under

load by means of a battery tester.
Battery testers for 12 V are used for block

cover batteries. The battery tester is used to
simulate a battery charge for approximately
5 seconds with a fixed resistance of 300 A.
The voltage is then measured during this
process and approximates a benchmark of the
battery's ability to start. The permissible limit
voltage is set at 8 V for 6 cells = 1.33 V/cell.
When using a battery tester, you must ensure
that there is good contact between the needle
tips of the tester and battery terminals.
Finally, the measurement is evaluated. If the acid

density is too low but the start test was acceptable,
the battery generally only needs to be recharged.
If both acid density and the start test were

unsatisfactory, the battery is usually no longer
usable. If cell acid densities or battery voltages in
charged batteries deviate significantly in the start
test or are unsatisfactory, the battery should be
taken out of service.
13
3 842 950.00 en
Mixing Fresh Battery Electrolyte Maintenance

This term includes all maintenance measures
When mixing fresh battery required to ensure that the battery functions
electrolyte, make sure that the optimally during its lifetime:
concentrated sulfuric acid is always
poured into distilled water and
 Refilling water
never the other way around! Risk
of splashing acid! Always wear
 Periodic recharging when battery is stored
safety glasses and protective
clothing! Accident prevention
 Immediate recharging after discharge
regulations must always be
observed while working.
 Avoiding overcharging
The following table (Table 2) shows the volume ratio  Avoiding deep discharges
of concentrated sulfuric acid (96%) to distilled water.
Mixing Instructions
Required Volume ratio of concentrated
acid density sulfuric acid (96%) to
kg/l distilled water
1.23 1 : 3.8
1.26 1 : 3.2
1.28 1 : 2.8
1.30 1 : 2.6
1.34 1 : 2.3
Table 2
14
3 842 950.00 en
Faults
Faults Cause Remedy
1. Acid level is too low Overcharging, evaporation Refill with distilled or desalinated water
(especially in summer) (in charged batteries)
2. Acid flows out of Charging voltage is too high Test voltage regulator, then adjust or
sealing plug replace
Acid level is too high Draw off excess acid with hydrometer
3. Acid density is too low Battery is discharged Charge battery
Generator is not working Have generator checked

properly
Short circuit in power network Have electrical system checked
Acid is diluted because Correct acid balance

of a maintenance error
4. Acid density is too high Excessive acid content Correct acid balance
after refilling
5. Effective output is too Battery is discharged Recharge battery

low; voltage is dropping
too quickly Charging voltage is too low Adjust or replace voltage regulator
Connection terminals are loose Clean connection terminals and lightly

or oxidized grease terminals, especially underside,
using anti-corrosion grease “Ft 40 v 1”;
tighten connection screws
Battery capacity is too low Use larger battery; also install larger
(too many consumers) generator if necessary; best to consult
specialist workshop
Battery self-discharge too high Replace battery

because of impurities in battery
electrolyte
Battery may be “sulfated” Charge battery with low current so

(grayish-white film on positive film slowly recedes; replace battery
and negative plates) if effective output is still too low after
repeated charging and discharging
Battery is exhausted, active Replace battery

plate ground has failed
Acid level is below the Refill with distilled or desalinated water

upper edge of the plates up to prescribed height
15
3 842 950.00 en
Faults Cause Remedy
6. Battery lifetime is too Battery was discharged too Use battery with greater capacity;
short frequently and too deeply if necessary, use special
model “S” battery
Battery is becoming too warm Select a better installation location
Vibration stress too high Select a better installation location
Battery may be “sulfated” See item 5.6

(grayish-white film on positive
and negative plates)
Battery electrolyte Replace battery

is contaminated
7. Battery charges are Fault in generator, voltage Increase generator output or

consistently too low regulator or line connections repair/replace generator and voltage
regulator; make sure lines are fastened
correctly
V-belt is loose Tighten or replace V-belt
Too many consumers Install larger battery. Also use larger

are connected generator if necessary; best to consult
specialist workshop
8. Continual overcharging Fault in voltage regulator, Replace or otherwise adjust voltage

possibly also in generator regulator; check generator
9. Switch contacts in Battery is incorrectly connected Connect battery with correct polarity,
voltage regulator (incorrect polarity) Replace voltage regulator
charred (in direct
current generators)
10. Diode rectifier Battery is incorrectly connected Connect battery with correct polarity,
is destroyed (incorrect polarity) replace diode rectifier
(in alternators)
Table 3
16
3 842 950.00 en
Electric Motors The torque is equal to zero when the conductor is

positioned between pole shoes (see Fig. 22).
Normally only direct current motors (starters,
windshield wiper motors, fan motors, etc.) are
used in vehicles. We therefore present a brief
overview on how motors of this type work.
Electric Motor Operation

An electric motor transforms electrical capacity
(product of voltage times current) into mechanical
capacity (product of speed times torque). This
process is based on the fact that a force is exerted
on a current-carrying conductor in a magnetic field.
The size of this force is proportional to the strength
of the magnetic field and the amperage, and is at
its maximum when the magnetic field and current
are aligned perpendicularly to one another. It is Fig. 22
useful to form the conductor as a rotatable loop
(see Fig. 21). If it is ensured that the direction of current is
changed, or turned, after every half turn in the
conductor loop, the torque then has the same
direction of rotation and can cause a constant
spinning of the loop. This reversal of current occurs
in a commutator that consists of two segments,
shaped like half-rings and isolated from one
another, to which the two conductor ends of the
loop are connected. Two current collectors, called
carbon brushes, are connected to the power
source and rub against the segments (Fig. 21 and
Fig. 23). A large number of wire loops are used in
order to achieve a steady torque (see Fig. 23; this
example shows three conductor loops).
Fig. 21
The magnetic lines of force run from pole to pole,

i.e. from pole shoe to pole shoe. If the conductor is
located under the pole shoes (i.e. in the area of the
magnetic field) the torque acting on the conductor
loop is constant and has a specific direction. When
the conductor is given a half turn and is in the area
of the opposing magnetic field, the torque has the
same value, but the reverse direction.
Fig. 23
17
3 842 950.00 en
Fig. 24 shows the separate torques and resulting Starter motor

total torque for three loops arranged symmetrically.
The commutator used here has six individual Starting Engine Operation
segments, also called laminations. In reality the
number of loops is much higher, since torque also When the starter switch is activated, the solenoid
increases along with the number of loops. plunger and the actuating lever cause the bevel
pinion to be inserted into the ring gear through the
action of the helix (Fig. 25, “engaging”). Contacts
for main current are connected to the end of the
pinion travel of the engagement relay (Fig. 26,
“Engaged”). The pull-in winding is de-energized
and the pinion is held by means of the holding
winding. When the motor starts, the bevel pinion
is returned to the rest position by the return spring
after the starter switch is let go.
Engaging
Fig. 24
Fig. 25
Engaged
Fig. 26
18
3 842 950.00 en
Checking Vehicle Starter System

 Test battery.
 Check to make sure battery cable and connections have proper contact.
 Measure voltage drop (0.5 V).
 Measure minimum pull-in voltage at magnetic switch (8.0 V).
Starting Engine
1 Return spring 14 Armature
2 Holding winding 15 Exciter developer
3 Pull-in winding 16 Armature winding
4 Solenoid plunger 17 Guide ring
5 Contact 18 Control stop
6 Connection bolts 19 Roller freewheel
7 Contact bridge 20 Armature shaft
8 Commutator bearing 21 Bevel pinion
9 Brush spring 22 Cam
10 Commutator 23 Brake disc
11 Carbon brush 24 Engaging spring
12 Pole housing 25 Actuating lever
13 Pole shoe
Fig. 27
19
3 842 950.00 en
Maintenance
Note:
The risk of short circuiting exists whenever work is
performed on the electrical components in installed
starting engines.
The ground lead to the battery must be
disconnected before working on the electrical
components of the starting engine.
Tools must not be placed on the battery itself!
Carbon brushes
Carbon brushes should be inspected from time
to time to ensure they are in flawless condition
(see Fig. 28).
 Remove the seal cap.

 Use a hook to lift up the spring that is pressing
the carbon brush onto the commutator. While
doing so, you should always make sure you Fig. 28
don't bend the spring to the side, or lift it more
than necessary.
 Now check to see if the carbon brushes
can move easily as they are fed into the
brush holder.
Commutator
The commutator should have a regularly smooth,
grayish-black surface and must be free of oil
and grease.
 Clean dirty commutators with a clean cloth

moistened with gas (not steel wool), then dry
them well.
 Worn commutators (ridged or out-of-center)
must be skimmed in a workshop equipped
for this purpose.
Note:
Under no circumstances may sandpaper or files
be used to work on commutators.
20
3 842 950.00 en
Lubrication BASIC PRINCIPLES OF

Both of the screw push starter bearings are fitted VEHICLE ELECTRICAL
with self-lubricating bearings (composite bushing)
so that these do not require lubrication. These SYSTEMS
bearings must not be treated with degreasing
cleaning agents. Current, Voltage, Resistance, and
In addition, the following instructions must
always be observed: Power
Carbon brushes and brush holders must be free
Current (I)
of oil and grease. Electrical current is understood to mean the
flow of free electrons in a conductors. Current
Clean dirty brushes and holder using a clean cloth measurements are carried out by means of an
moistened with gas (not with steel wool, since this ammeter, which must be connected in the path
frays easily), then dry them well. of the current. The amount of electrical current is
Always wear gloves in order to avoid injuries specified using “I” and the unit with “A” (ampere).
through skin contact with aggressive substances.
Voltage (V)
Do not use sandpaper, files or knives to work on
bare carbon brush grinding surfaces. Electrical voltage is the difference in potential
between two conductors (using the same reference
Blow out the brush holder well. point). Voltage is measured by means of a voltage
Always wear safety glasses when working in order gauge, which must be connected in the shunt path
to prevent injuries caused by flying dust particles. to the consumer of between potential points. The
amount of voltage is specified using “V” and the
If a carbon brush is broken, unsoldered, or so worn units with “V” (volt).
that the spring or strands soldered in the brush
threaten to contact the brush holder, it should Resistance (R)
be replaced.
Electrical resistance is understood to mean the
When inserting carbon brushes, make sure the resistance that is brought against the electrical
spring does not hit the brush. flow of current and slows it down. The amount
of resistance depends upon the material in use
Always replace carbon brushes each time the as well as its dimensions. The amount of electrical
motor is completely overhauled. resistance is specified using “R” and the unit with
“Ω” (ohm).
Skim the commutator every time carbon brushes
are replaced.
21
3 842 950.00 en
Power (P) MEASUREMENTS USING

Power is understood to mean the current that flows A MULTIMETER
through a consumer at constant voltage. Its amount
is specified using “P” and the unit with “W” (watt).
The relationship between current (I), voltage (V),
Multimeter Settings
resistance (R), and power (P) are summarized in Follow the instructions below before connecting the
Fig. 29. This section also includes conversion multimeter:
formulas you can use to calculate different
quantities.  Set direct current/alternating current
and/or DC/AC voltage.
 Select as large a measuring range as possible.
 Connect the multimeter then reset the
measuring range until it shows the highest
possible reading.
Voltage Measurements
Fig. 29
Fig. 30
Note:
A voltage gauge is always connected in parallel
to the consumer or voltage.
22
3 842 950.00 en
Testing diodes Ohm Measurements (Resistance)

A voltage measurement can also be used to check Ohm meter
diodes. The structure of an diode is always as
shown in the figure below. Here, the “positive side”
is the anode and the “negative side” is the cathode.
The direction of flow is from “positive” to “negative.”
The following values can be measured in the test:

Measured voltage Diode condition
0.637 V Diode is working properly
0 volts Diode is not working properly
Current Measurements Fig. 32
Note:
The component to be measured in an ohm
resistance measurement must always be
voltage-free. Components in a circuit may
be measured only if they are removed.
Check cable continuity
An ohm resistance measurement can also be used
to check cable continuity. The following situations
may arise in this case:
Measured resistance Cable condition

Fig. 31 0 ohms Cable assembly is ok
(has continuity)
Infinite ohms Cable assembly is not ok
Note:
(break in cable)
The current-carrying line must always be
disconnected and the meter connected to the
circuit before measuring current. Current
must flow through the meter.
23
3 842 950.00 en
SERIES AND PARALLEL

CONNECTION OF
COMPONENTS
Batteries
Capacitors
Series Connection
When two or more batteries (C) are connected
Series Connection
in series, the voltages of each battery are When capacitors (C) are connected in series, the
added together. total capacity (Ctot) is less than the smaller
individual capacity.
Parallel Connection
When two or more batteries – these must be of the Parallel Connection
same voltage – are connected in parallel, the
voltage remains the same. When capacitors (C) are connected in parallel, the
capacity value is added up, i.e. total capacity (Ctot)
However, the capacity of each is added together is the sum of all individual capacities.
(i.e. the amount of electrical charge that can
be output).
Note:
Capacitors connected in series and in parallel have
Note: the opposite behavior of resistances.
Proper polarity must always be observed
when batteries are interconnected.
Resistors
Series Connection
When two or more resistors (R) are connected in
series, the resistance value is added up. The sum of
the resistances produces the total resistance (Rtot).
Parallel Connection
When two or more resistances (R) are connected
in parallel, the total resistance value (Rtot) is less
than the smaller individual resistance value. If two
equal resistances (equal resistance value) are
connected in parallel, the total resistance is then
half of each individual resistance.
24
3 842 950.00 en
Electrolytic Capacitor
Electrolytic capacitors behave exactly like the
capacitors described above, but they are installed
polarized. The polarity is imprinted on the
capacitor.
Series connection:
Parallel connection:
Risk of accident!
Electrolytic capacitors must never
be installed the wrong way. Other
components and circuit symbols
can be found in section 12.1.
25
3 842 950.00 en
VOLTAGE LOSS AND LINES
The values specified in Table 4 for voltage loss in a The Vvg values specified are test values and can
line (Vvl) and for total voltage drop (Vvg) are used also include contact resistances of switches, fuses,
to calculate plus wires. The voltage drop from the etc. for line calculation.
ground return remains unconsidered. However, the
forward and return lines are normally used as
a line length in case the ground lead is isolated.
Power type Permissible voltage drop Permissible voltage drop Comments

of positive line in overall power circuit
Vvl Uvg
Light Lines
Terminal 30 from light switch up to lighting 0.1 V 9.6 V Current at nominal voltage
> 15 W up to trailer socket and nominal power
From trailer socket
up to lighting
Terminal 30 from light switch 0.5 V 0.9 V

up to lighting > 15 W
up to trailer socket
Terminal 30 from light switch 0.3 V 0.6 V

up to headlights
Charging line
From alternator
Terminal B 0.1 V at 12 V Current at nominal voltage
and nominal power
up to battery 0.8 V at 24 V
Control Line up to maximum

From alternator 0.1 V at 12 V excitation current (note 1)
up to regulator
(terminal D+, D-, DF) 0.2 V at 24 V
Main Starter Line 0.5 V at 12 V Starter short circuit current

at +20 °C
1.0 V at 24 V (notes 2 and 3)
Starter Control Line

Terminal 50 from starter switch up to 1.4 V at 12 V 1.7 V at 12 V Maximum control current
starting motor (notes 4 and 5)
Solenoid plunger with basic winding 2.0 V at 24 V 2.5 V at 24 V
Solenoid plunger with pull-in and 2.4 V at 12 V 2.8 V at 12 V
holding winding 2.8 V at 24 V 3.5 V at 24 V
Other Control Lines 0.5 V at 12 V 1.5 V at 12 V Current at nominal voltage

From switch to relays, horn etc. 1.0 V at 24 V 2.0 V at 24 V
Table 4
26
3 842 950.00 en
Note: LINE CALCULATION

All three control lines should have equal length and
equal resistance as far as possible. Parameters and Units
If start limit temperature is decreased, the Vvl
value may be exceeded if necessary in special Parameter Unit
cases, using a very long main starter line.
If the return of the main starter line is isolated, the I Amperage A
voltage loss in the return line should not exceed l Line length m
that of the forward line; the permissible value P Power required by W
consumer
is 4% of the nominal voltage, giving 8% altogether. 2
q Conductor cross-section mm
Vvl values apply for solenoid plunger temperatures
of 50-60 °C R Resistance (consumer) Ω
If necessary, include the line in front of the starter S Line current density A/mm
2
switch in calculations. VN Nominal voltage V

Vvl Permissible voltage V
drop of isolated line
Vvg Permissible voltage V
drop around overall
power circuit
ρ Specific electrical Ωmm
resistance
Table 5
Calculation:
Include voltage drop and heating when determining
conductor cross-section.
 Determine amperage I of consumer
I  P / UN
 Calculate conductor cross-section

q with Uvl – value from Table 6
(for copper = 0.0185 Ω mm/m)
q = I * l/Vvl
 Round off q to next-highest conductor cross-

section as per Table 6. Individual lines under 1
mm are not recommended because their
mechanical strength is too low.
 Calculate actual voltage drop Vvl
Vvl = I * l/q
 To avoid excessive heating, check

current density S (during short-term
operation S < 30 A/mm2, for values
during continuous operation see
Table 6).
S = I/q
27
3 842 950.00 en
LINES FOR VEHICLE ELECTRICAL SYSTEMS

One-wire, untinned, PVC-insulated
Nominal Resistance per Conductor Line diameter Permissible continuous current Permissible
cross-section meter diameter (guideline value) current
density
mm at 20 °C Maximum Maximum at +30 °C at +50 °C Continuous

m Ω/m dimension mm dimension mm A A operation
A/mm
0.5 37.1 1 2.3 11 7.8 10

0.75 24.7 1.2 2.5 15 10.6 10
1 18.5 1.4 2.7 19 13.5 10
1.5 12.7 1.6 3 24 17 10
2.5 7.6 2.1 3.7 32 22.7 10
4 4.71 2.7 4.5 42 29.8 10
6 3.14 3.4 5.2 54 38.3 6
10 1.82 4.3 6.6 73 51.8 6
16 1.16 6 8.1 98 69.6 6
25 0.743 7.5 10.2 129 91.6 4
35 0.527 8.8 11.5 158 112 4
50 0.368 10.3 13.2 198 140 4
70 0.259 12 15.5 245 174 3
95 0.196 14.7 18 292 207 3
120 0.153 16.5 19.8 344 244 3
Table 6
28
3 842 950.00 en
Calculation Example
The line cross section must be determined if an According to Table 6, a cable assembly with a
electrical unit is to be added as well. conductor cross section of 0.5 mm2 can be used at
an assumed ambient temperature of 50 °C. This
Example: Adding a work light (two lamps)
temperature value is always used when you cannot
rule out the fact that cable assemblies will be
The following parameters must be known: Vehicle routed through the engine compartment.
operating voltage and power consumption of flood
Note:
light. In our example operating voltage is 24 volts Lay cable assemblies in a protective sleeve so that
(28 volts), power consumption of a work light they cannot become chafed or jammed.
is 70 W.
Be sure to note the cable color when laying cable.
We must first calculate the current of This is especially important when installing units
the incandescent lamp (see Section 4 at a later time. “Brown” is always “ground” or
“Ohmic Range”).
“negative” here.
P 70W All circuits must be protected with
J   2,9 A appropriate fuses.
U 24V
Any switches that are used must be able
to connect the expected current.
A current of approx. 3 A would therefore flow for
one lamp bulb, but since two bulbs are being used,
the doubled amperage must be used (i.e. 6 A).
29
3 842 950.00 en
LIGHTING Sources of Error and Reasons

for Lighting
A crucial factor in vehicle operational safety is
vehicle lighting. Vehicle headlights must be Note:
installed or constructed and divided up in Please remember that lighting is an essential
accordance with German Road Traffic Registration component in vehicle operational safety. The
Ordinance (StVZO). If this is not the case, this can lighting system must be inspected and made ready
lead to a dazzling effect on oncoming traffic. before beginning a trip. The most common sources
of error lie in the fact that headlights shine
“yellowish” and do not radiate “white light”
Instructions for Adjusting Head- as usual. This effect is then caused by an
lights impermissibly high ground transition resistance
when the voltage supply system is functioning
Requirements perfectly. The permissible voltage loss is then
exceeded.
 The vehicle must be on a level surface.
Transition Resistances in a Line
 Tire air pressure must be checked. Circuit
In most cases, transition resistances occur in
Working Lights cable connections, ground connection and
Working lights may only be switched on when defective switches. A transition resistance
work is being carried out. These units are usually results in voltage loss.
installed so as to be movable and can be adjusted
as needed.
Incandescent Lamps
Incandescent lamps are constructed for 2 volt,
12 volt, and 24 volt systems. The socket shape
of each lamp type is different in order to make
confusion impossible. The voltage and power
of incandescent lamps are specified on the lamp
itself. Halogen lamps are designated by means
of symbols H1-H4. Their light output over
conventional incandescent lamps is improved
by 70% on average.
Note:
Incandescent lamps may only be replaced by
those types specified in the wiring diagram.
30
3 842 950.00 en
SPECIAL CIRCUITS IN VEHICLE ELECTRICAL SYSTEMS
Diode “Recovery Diode”

The “Voltage Measurements” section above The term “recovery diode” is only seen in
included some discussion on diodes. Following are connection with a circuit in which coils (inductance)
descriptions of additional information and special are connected. Fig. 34 shows an example of
configurations with diodes. a possible circuit diagram in which a diode
is connected as a “recovery diode.”
Diodes are components that allow current to flow in
only one direction – comparable to the non-return
valves used in hydraulic systems. The two
connections are designated using “anodes”
and “cathodes”.
Fig. 33
If a positive voltage is applied to the cathode of

a diode, the diode blocks the current, i.e. no
current may flow to the anode (blocking direction).
Conversely, if a positive voltage is added to the Fig. 34
anode, the current may flow through to the cathode
(flow direction). If a negative voltage is applied, 1 Solenoid valve
the diode has the opposite behavior as with 2 Recovery diodes
a positive voltage. 3 Switch
Note: 4 Fuse
 Positive voltage at cathode:
Diode blocks. When the solenoid valve is switched off, an
induction voltage is then generated in the coil. The
 Negative voltage at cathode: potential of the induction voltage is directed against
Diode lets current through. the feed voltage. This voltage is so high that when
the switch is opened, an electric arc is produced
 Positive voltage at anode: which is capable of fusing the switch contact. Since
Diode lets current through. the voltage induced when the valve is switched off
is negative and is applied to the cathode of the
 Negative voltage at anode: diode, the diode is connected in the forward
Diode blocks. direction for the voltage. The inductive voltage is
therefore short-circuited to the ground. As a result,
this voltage at the switch contact is no longer so
powerful that it can fuse the contacts of the switch.
31
3 842 950.00 en
Varistor Generator Regulator

A varistor is a voltage-dependent resistor (Fig. 35). The function of a generator regulator is to regulate
In principle, it fulfills the same function as a the field current of the generator so that a constant
recovery diode and is added to a circuit in the voltage, based on the condition of the battery,
same manner. is always available for charging the battery (see
Fig. 36). The regulator ensures the voltage
remains constant no matter what the speed of the
generator is. The field current is generated by the
main windings of the generator (4) and
Fig. 35 transformed into direct current by means of so-
called field diodes. This DC voltage is then applied
to the regulator (1) that controls the generator's
The following is always true of varistors: The
field current.
higher the voltage, the lower the resistance.
Fig. 36
1 Voltage regulator
2 Charge indicator
3 Ignition switch
4 Generator
5 Field diode
The ends of generator windings (4) are designated

using U, V, and W (see Fig. 36).
32
3 842 950.00 en
Vehicle Fuses
Type Nominal current Color
A
Round 5 Yellow
fuses 8 Black
8 White
16 Red
25 White
25 White
Fuse strips 25 White
30, 50, 100 Gray
125, 150, 250
35, 60, 100 Gray
Plug 3 Violet
fuses 4 Pink
5 Beige/clear
7,5 Brown
10 Red
15 Blue
20 Yellow
25 Neutral/white
30 Green
Glass 5 Red
fuse 10 Yellow
15 Blue
20 Green
25 Silver
Radio 2 Clear
Table 7
33
3 842 950.00 en
MARKING INDIVIDUAL PARTS

Extract from DIN EN 81346-2 (replaces DIN 61346-2 and DIN 40719-2)
Letter Name Examples
A Structural component, structural sub-component Amplifier, magnetic amplifier, device combination
B Conversion from non-electrical to electrical Measuring transducers, thermoelectric sensors, thermocells,

quantities (and vice versa) photoelectric cells, dynamometers, quartz crystals, rotating field
sensors, angle transmitters
C Capacitors —
D Delay devices, storage devices, binary elements Combination elements, bistable elements, monostable elements
E Various lighting devices, heating devices
F Protective devices Fuses, surge arresters, locking devices, circuit breakers,

protection relays, trips
G Generators, power supply Rotating generators, rotating frequency converters, battery,

power supply device, oscillators
H Alarm systems Visual and acoustic alarm devices
I DO NOT USE DUE TO RISK OF CONFUSION —

WITH “AMPERAGE”
K Relays, contactors Power contactors, auxiliary contactors, servo relays, turn signal
flashers, timer relays
L Inductances Inductance coils
M Motors —
P Measuring devices, test equipment Display, recording and metering measuring devices, pulse
generators, clocks
Q Power current switching relay Circuit breakers, disconnect switches, safety switches, engine
protection switches, automatic switches, fuse switches
R Resistors Adjustable resistors, potentiometers, regulating resistors
S Switches, selector switches Push buttons, limit switches, control switches, signal generators
T Transformers Voltage converters, current transformers
U Modulators, converters Frequency converters, transducers, inverters, converters,

inverted rectifiers
W Transmission paths, waveguides Jumper wires, cable assemblies, busbars
X Terminals, plugs, sockets Disconnect plugs and disconnect sockets, test plugs, terminal
strips, soldering strips
Y Electrically activated mechanical devices Brakes, clutch, valves
Z Terminator, compensation devices, filters, Cable reproductions

limiters, yoke connections
Table 8
34
3 842 950.00 en
STANDARD TERMINAL DESIGNATIONS

Terminal Designations
(extract from DIN 72552)
Terminal designations are not identical to line designations, since devices with different terminal descriptions
may be connected to both ends of a line. If the terminal designations are no longer adequate (multiple plug
connection), terminals get consecutive number or letter designations that have no standardized functional
assignment.
Terminal Meaning Terminal Meaning
1 Ignition coil, Electric Motors

1)
ignition distributor 32 Return line
1)
Low voltage 33 Main connection
Ignition distributor with two separate power 33 a Self-parking
1a circuits 33 b Shunt field
1b to contact breaker I 33 f for second smaller speed step
to contact breaker II 33 g for third smaller speed step
33 h for fourth smaller speed step
2 Short circuit terminal
33 L Rotation direction left
(magneto ignition)
33 R Rotation direction right
4 Ignition coil, ignition distributor high voltage
45 Starting engine
Separate start relay, output; starting engine,
Ignition distributor with two separate power
input (main current)
4a circuits
from ignition coil I 45 a Two-starter parallel operation
4b terminal 4 45 b Start relay for engagement current
from ignition coil II, Output starting engine I,
terminal 4 Input starting engines I and II
Output starting engine II
15 Switched positive terminal downstream of
battery, (output of ignition [driving] switch) 48 Terminal on the starting engine and on the
repeating start relay
15 a Output at series resistor to ignition coil and
starting engine for monitoring the start procedure
Glow plug and starter switch 49 Turn-signal flasher

17 Start 49 a (pulse generator)
19 Preheat 49 b Input
49 a Output
Battery Output, 2nd turn signal flasher
30 Input from battery positive terminal, direct Output, 3rd turn signal flasher
30 a Battery changeover relay 12/24 V 50 Starting engine
Input from battery II positive terminal Starter control
31 b Return line to battery negative or ground, (direct)
via switch or relay (switched negative)
50 a Battery changeover relay
Battery changeover relay 12/24 V return line Output for starter control
31 a to battery II negative terminal return line
to battery I negative terminal 50 b Starter control
31 c
for parallel operation of two starters with
sequential control
50 a Start relay for sequential control of the
50 d engagement current for parallel operation
of two starting engines
Input at start relay for starting engine I
Input at start relay for starting engine II
Note:
1) Polarity change possible in terminal 32–33
35
3 842 950.00 en
Terminal Meaning Terminal Meaning
Start-locking relay AC generator

50 e Input (Magneto generator)
50 h Output 59 AC voltage, output, rectifier, input
59 a Charging armature, output
AC generator
59 b Taillight armature, output
51 DC voltage at rectifier
59 c Brake light armature, output
51 e DC voltage at rectifier with choke
coil for daytime driving 61 Generator indicator lamp
Trailer signals Tone sequence control

52 Additional signals from trailer 71 Input
to traction vehicle 71 a Output to horn 1 + 2 low
71 b Output to horn 1 + 2 high
53 Wiper motor,
input (+) 72 Alarm switch
53 a (rotating beacon)
Wiper (+), self-parking
53 b Wiper (shunt winding) 75 Radio, cigarette lighter
53 c Electric windshield washer pump 76 Loudspeakers
53 e Wiper
(brake winding) 77 Door valve control
53 i Wiper motor with permanent magnet and third Switches
brush (for higher speed) Normally closed and changeover switches
Brake light 81 Input
54 for lighting combinations and trailer plug 81 a Output 1, normally closed switch side
connections 81 b Output 2, normally closed switch side
Trailer signal Normally open switch
54 g Pneumatic valve for brakesaver, solenoid 82 Input
operated 82 a Output 1
55 Fog lamp 82 b Output 2
82 z Input 1
56 Headlamp 82 y Input 2
56 a High bean and high-beam indicator lamp
Multi-position switches
56 b Low beam
83 Input
56 d Headlamp flasher contact
83 a Output, position 1
57 Parking light for motorcycles (abroad also for 83 b Output, position 2
passenger cars, commercial vehicles etc.) 83 L Output, position left
57 a Parking lamp 83 R Output, position right
57 L Parking lamp, left Current relays
57 R Parking lamp, right 84 Input
58 Clearance lamp, taillight, license plate and Actuator and relay contact
instrument panel lamps 84 a Output
58 b Taillight changeover for two-wheel tractors Actuator
84 b Output
58 c Trailer plug fitting for one-wire taillight with Relay contact
fuse in trailer Switching relays
85 Output, actuator
58 d Variable intensity instrument illumination, (end of winding to negative or ground)
taillight and clearance lamp Input, actuator
58 L left 86 start of winding
58 R right, 86 a Start of winding or 1st winding
License plate lamp 86 b Winding tap or 2nd winding
36
3 842 950.00 en
Terminal Meaning
Relay contact for normally closed and

changeover switches,
87 Input
87 a Output 1 (normally closed switch side)
87 b Output 2
87 c Output 3
87 z Input 1
87 y Input 2
87 x Input 3
88 Relay contact for normally open switches,
Input
Relay contact for normally open
and changeover switches
88 a (normally open switch side)
88 b Output 1
88 c Output 2
Output 3
Relay contact for normally open switch
88 z Input 1
88 y Input 2
88 x Input 3
Generator and generator regulator
B+ Battery positive
B- Battery negative
D+ Dynamo positive
D- Dynamo negative
DF Dynamo field
DF 1 Dynamo field 1
DF 2 Dynamo field 2
Alternator
U, V, W Alternator terminals
Direction indicator lamp (turn-signal flasher)
C First indicator lamp

C0 Main connection for indicator control circuits
separated from the direction indicator
C2 Second indicator lamp
C3 Third indicator lamp (e.g. when towing
two trailers)
L Turn-signal lamps, left
R Turn-signal lamps, right
37
© Copyright The reproduction, distribution and utilization of this manual / file as well as the
Caterpillar Global communication of its content to others without express authorization is prohibited.
Mining HMS GmbH Offenders will be held liable for the payment of damages. All rights reserved in the event of
2014 the grant of a patent, utility model or design.
Printed in Germany
3 842 951.00 en
February 2014
Service Manual
for the Handling of
Circuit Diagrams
6015 - 6090
3 842 951.00 en

Tel. +49 (0) 231 922 4340
Fax +49 (0) 231 922 5005
are liable to compensation. All rights reserved in the event of the grant of a patent, utility model or design
registration.
Printed in Germany
3 842 951.00 en
CONTENTS
FOREWORD__________________________________________________________________________ 1

Personnel Requirements ............................................................................................................................1
Observe the hazard warnings on the machine...........................................................................................1
Observe the warnings and safety instructions in the instructions ..............................................................1
SCOPE OF THE DOCUMENTATION FOR THE ELECTRICAL SYSTEM __________________________ 2
ELECTRICAL CIRCUIT DIAGRAM________________________________________________________ 2

Names of the electrical/ electronic components.............................................................................2
Excerpt from DIN EN 81346-2 (replaces DIN 40719) ................................................................................3
Circuit diagram – sample page.......................................................................................................4
Circuit diagram ...............................................................................................................................4
Legend to the circuit diagram – sample page ................................................................................5
Circuit Diagram – description .........................................................................................................7
The circuit diagram (current flow diagram) is a representation of the electrical circuits of the machine in
all their details.............................................................................................................................................7
Connection tables – terminal strips ..............................................................................................10
Connection tables – plug connections..........................................................................................13
Troubleshooting............................................................................................................................14
Summary ......................................................................................................................................14
Schematic symbols ......................................................................................................................15
Identification of direction of movement .....................................................................................................42
3 842 951.00 en
3 842 951.00 en

This manual describes the creation and handling of Personnel Requirements
the electrical circuit diagrams which are used at
Caterpillar Global Mining HMS GmbH. It also All work performed on electrical or electronic
explains the symbols shown and gives information components and systems of the machine must be
on troubleshooting. carried out by trained and qualified professionals
This manual is a reference work for trained only, or by instructed individuals under the
electricians working in customer services or supervision and management of a qualified person.
workshops. If personnel do not have the required expertise,
It does not describe actual repair or maintenance then in-depth training must be provided by
work. Descriptions of this work can be found in the experienced personnel, e.g. by Caterpillar Global
operation and maintenance instructions or in the Mining HMS GmbH.
technical manual for the machine. In the machines which are operated, electrical
systems may be installed at varying levels of high
Notice: voltage. This also calls for different requirements of
The part numbers listed should not be used to the qualifications of the personnel who will be
order spare parts. These article numbers in this responsible for carrying out maintenance or repair
manual are only intended to serve as work.
documentation of the parts to which the data For example, an electrician may not work on
below refer. systems operating at 6000-7200 V without further
Please use the replacement parts list associated training and instruction if he only has experience
with a given machine when ordering spare parts. with 24 V wiring systems.
This replacement parts list is available in hard copy
Detailed information on the requirements of
form, as well as in digital format and online.
personnel can be found in the "Electrics and
Please contact your Caterpillar dealer for more
Electronics" section of the technical manual for the
information.
machine.
In all cases, the applicable national legislation and
the accident prevention regulations for your
respective country must be observed. These are
not included in this manual.
Observe the hazard warnings on the

machine
Observe all safety information and hazard
warnings on the machine.
Keep all safety instructions and hazard warnings at
and on the machine, and make sure they are
complete and in legible condition.
Replace any illegible or missing information and
warnings immediately.
Observe the lawful rules, regulations and
guidelines of your respective country.
Observe the warnings and safety

instructions in the instructions
Descriptive and instructive text contains warnings
your safety. For this reason, always observe all
warnings and safety information.
1
3 842 951.00 en
SCOPE OF THE ELECTRICAL CIRCUIT

DOCUMENTATION FOR THE DIAGRAM
ELECTRICAL SYSTEM
Names of the electrical/
The documentation for the electrical system is electronic components
enclosed with the spare parts list. It consists of the
following documents: Electrical and electronic components are identified
in the circuit diagram by their part name.
Identification is carried out in accordance with DIN
 Circuit diagram with
EN 81346-2 (replaces DIN 40719) using letters.
The components of the machine are grouped as
 associated legend (electrical parts for circuit follows:
diagram) and
Group number 1: Parts not connected to any
 Connection tables – terminal strips and controller. These are parts like the key switch,
battery, main switches and working lights.
 Connection tables – plug connections.
Group number 2: Components connected to the
 Overview of the wire harnesses.
Servo controller/ICN-V.
 Catalog of electrical/electronic components.
drive controller LH.
Detailed functional descriptions are included in
Section 9 of the Technical Manual: Group number 4: Components connected to the
"Electrical/Electronic Systems". drive controller RH.

auxiliary controller.
Group number 6: Parts related to the BCS tower.

These are parts like the BCS screen and the FM
Radio.
Based on these groups, the electrical components
are coded in the electrical documentation and in
the spare parts list. This code consists of:
 Group number
 Letter according to DIN 40 719
 Identifying number
Example: -2 K 1:
2: Component connected to the Servo
controller/ICN-V
K: Relays, cabinets
1: Identifier
The following table shows an excerpt from the DIN

EN 81 346-2 (former DIN 40 719) standard.
2
3 842 951.00 en
Excerpt from DIN EN 81346-2 (replaces DIN 40719)

Letter Designation Examples
A Assembly group, parts of groups Amplifiers, magnetic amplifiers, combinations of
devices
B Transformation from non-electrical into Metering transformers, thermo sensors, thermo
electrical magnitudes (and vice versa) cells, photoelectric cells, dynamometers, quartz
crystals, magnetic field sensors, inclinometers
C Capacitors ----
D Time-lags, accumulators, binary elements Coupling links, bi-stable elements,
monostable elements
E Miscellaneous Lights, heaters
F Safety devices Fuses, overload guards, interlocks, circuit
breakers, safety relays, releases
G Generators, electrical supplies Rotary generators, rotary frequency converters,
batteries, power supplies, oscillators
H Monitors Optical and acoustic monitors
I ---- ----
K Relays, contactors Power contactors, auxiliary contactors,
auxiliary relays, blinker relays, time-lag
relays
L Inductive devices Throttle coils
M Motors ----
P Meters, testers Indicating, recording and metering instruments,
impulse initiators, clocks
Q High-voltage switch relays Circuit breakers, main switches, isolators,
motor isolators (thermistors), automatic
cut-outs, fused circuit breakers
R Resistance Adjustable resistances, potentiometers,
shunts
S Switches, selectors Buttons, limit switches, control switches,
signal emitters
T Transformers Transformers, converters
U Modulators, converters Frequency converters, converters, inverters,
transverters, demodulators, reversing
converters
V Diodes Canceling diodes for solenoid valves
W Conductive paths, hollow conductors Switch lines, cables, busbars
X Terminals, plugs, sockets Isolating plugs/sockets, test sockets, terminal
strips, solder strips
Y Electrically actuated mechanical devices Brakes, couplings, valves
Z End points, compensating devices, filters, Cable duplications
limiters, Y-terminals
Table 1
3
3 842 951.00 en
Circuit diagram – sample page
Fig. 1
Circuit diagram
The circuit diagram (current flow diagram) is the
symbolic representation of a circuit showing the
details of the component. It shows how the
electrical components are connected and the
operation of an electrical setup. The circuit diagram
consists of several single A4 sheets which are
compiled by functional group.
All components are shown in de-energized states
and without the effect of an actuating or operating
force.
Symbols from the German standards series DIN
EN 60617 "Elektrische Schaltzeichen und
Symbole" (English "Electrical Circuit Diagrams and
Schematic Symbols") (also IEC 60617; replaces
standards series DIN 40700 and 40900) are used
for the illustration.
All components drawn in the diagrams are
identified in uppercase letters.
4
3 842 951.00 en
Legend to the circuit diagram – sample page
Fig. 2
1 Device designation
The key to electrical components in the circuit
diagram is a systematically arranged list that The unique identifier of the electrical component,
accompanies the circuit diagram. Its purpose is to which is the schematic symbol according to DIN
locate components both in the circuit diagrams and standard, see section “Naming electrical
on the machine itself. It also contains the components.”
components' part numbers (Part No.). Example
The key includes the columns (see Fig. 2): Relay -2K1, see the line highlighted in bold in Fig. 2.
Item Description
1 Device designation 2 Amount
2 Amount
The number of particular component parts on the
3 Function/Description
machine.
4 Description
Example
5 Schematics -2K1 is included once in the machine.
6 Location
7 Group
3 Function/description
8 S/N No.
Function of the component.
The line highlighted in bold indicates the Example
information on relay -2K1, one of the examples for  -2K1: “RELAY”
entries in the list of electrical components that is  -2B10: “SENSOR – HYD. OIL MIN.”
explained below.
5
3 842 951.00 en
4 Description
Additional information on the component. 8 S/No. or Part No.
Example This is the Part No. for ordering spare parts. If no
 “RELAY” for the relay Part No. is given, the part in question is associated
 “FLOAT SWITCH” and “PLUG” for the sensor with the electrical system but is part of another
“HYD. OIL MIN.” assembly group.
The Part No. must then be determined using the
5 Schematics relevant spare parts sheets. For example, the part
numbers for solenoid valves are to be found in the
Current path number that appears at the bottom hydraulic systems.
edge of each circuit diagram sheet, see section Example
“Circuit diagram”. The current path number helps to -2Y1 PROPORTIONAL VALVE
locate electrical components in the circuit diagrams.
Example
-2K1 is located on sheet 50, column 5 in the circuit
diagram matching the list of electrical components
shown in the figure above.
6 Location
The location is the approximate position on the
machine in which the electrical component is
installed.
Example
The relay -2K1 is located in the switch cabinet.
7 Group
Fig. 3
The group number of the component might be
used as cross-reference to the spare parts list if
the part in question is associated with the electrical
system but is part of another assembly group.
Example
For the valve -2Y1, the group number is 23.217 in
the figure below.
Fig. 4
6
3 842 951.00 en
Circuit Diagram – description

If electric connections are separated on two
The circuit diagram (current flow different pages, references will be used.
diagram) is a representation of the The reference is indicated by the arrow in the
figure.
electrical circuits of the machine in
all their details. IMPORTANT: The arrow indicates a reference to a
The diagram shows the following for all electrical different page of the circuit diagram. Physically on
supplies and components: the machine, the connection shown by the
reference might be a cable 5 cm in length.
 The function
 The way they are connected
The circuit diagram comprises several DIN A4

sheets arranged in function groups.
All components are shown in the de-energized state
(i.e. no current flowing) and without any actuating
elements acting.
The electrical supplies and components are

identified by the spare parts number and indicated
by symbols according to the DIN standards 40 700,
40 703, 40 708 and 40 711 to 40 716.
Each page is divided into 0-9 columns or current

paths with a description below each current path (2).
Each page has a page number or “Blatt Sheet”

located in the bottom-right corner (3). In the
bottom-left corner is the machine model to which Fig. 6
the electrical drawing applies (1).
The information included in the reference is:
Fig. 8
Fig. 5
7
3 842 951.00 en
Current path
The current paths run from positive to negative.
The numbers given at the right-hand side,
alongside the main horizontal paths, stand for:
Fig. 9
The location of the contact is stated below the coil

at the bottom of the page.
Fig. 7 Current path – 642653
1 30: Positive (unswitched)

2 15: Positive (key switched)
3 VIQ: Positive (de-energized by use of
Emergency stop) Fig. 10
4 31: Negative (unswitched)
Relays The location of the coil is indicated directly below

the relay contact.
Basically, the two relay types (1) and (2) are used.
Fig. 11
Numbers on the contact points of relays or switch

contacts are exactly as found on the actual
Fig. 8 component.
Relays that have closer, opener or changer
contacts in other current paths have an indication
In general, the coil and the contact of the relay are (under the current path for the energizing coil) as
placed on different pages of the circuit diagram. to the current path in which the contacts are to be
found.
8
3 842 951.00 en
Collector terminal points Cable cross-section

Collector terminal points (open circles) are coded Figures alongside current paths indicate the cable
with the identification of the relevant terminal strip cross-section.
or plug connection. See section "Connection table
terminal strips" and section "Connection table -
Example
plug connections."
Cable cross-section =
10 mm²
Example
The line has a

disconnecting point on
terminal strip -X1, Cable color coding
terminal No.6
Combinations of letters alongside the current path
indicate the cable color coding according to DIN
or ISO.
Example
bl or BL = blue
br or BN = brown
ge or YE = yellow
gn or GN = green
gr or GY = gray
rt or RD = red sw
sw or BK = black
vi or VT = violet
ws or WH = white
9
3 842 951.00 en
Connection tables – terminal

strips
The "Connection tables – terminal strips" show the
connections between electrical components. They
are exact illustrations of the terminal strips as fitted
in the machine. The key to the circuit diagram
gives the exact location of the various terminal
strips.
The connection tables make it possible to locate
the cable connections of a particular component
without checking the continuity.
The following figures show:

 a part of the X1 terminal strip in the X1 switch Fig. 12
cabinet
 the related excerpt of the X1 switch cabinet
layout
 the related connection table
Fig. 13
10
3 842 951.00 en
Fig. 15
Example
In the connection table shown in the figure, end

point No. 3 of terminal No. 61 indicates that this
line from terminal No. 61 is related to the coupling
relay -4K4.
Fig. 14 The cables have tagged sleeves with the

appropriate end point number.
The table includes the following items:
 End points (targets)
 Bridges (jumpers)
 Terminal No.
 Type of terminal
 Cable cross-section
 Potential
Fig. 16
 End points (targets)
This makes reconnection easy (and accurate) if

several cables have been disconnected at the
End point
same time (e.g. during troubleshooting).
The end point numbers are used to locate the
contact point of a specific terminal. They state the Two types of terminal strips with red indicator
receiver and actual connection point. LEDs are used.
End point 1 is always located at the bottom or
where the locking bracket is (see arrow).
11
3 842 951.00 en
Type 1: The LED lights up if the signal is +24 V.

Terminal No.
All terminals on a particular strip are listed here.
The numbers can also be found on the strip
(in switch box).
Type of terminal
This column contains the terminal coding as used
by the manufacturer.
Fig. 17 Cable cross-section

This column indicates the cross-section of the
Type 2: The LED lights up if the signal is 0 V. incoming/outgoing cable.
Potential
This column indicates the voltage potential of the
relevant terminal point. No entry means that the
potential is 24 V.
Fig. 18
Bridges
If terminal points need to be extended, the relevant
terminals are interconnected with bridges
(jumpers). Bridges are indicated by a yellow
jumper bar.
Fig. 19
12
3 842 951.00 en
Connection tables – plug

connections Code
The "Connection table – plug connections" gives The code indicates the specific position in the plug
the pin and sleeve connections of multi-pole plug connection.
connections.
The table includes the following items: Cable cross-section (mm²)
 End point – sleeve connections Here, the cross-section of the incoming/outgoing

cable is indicated in mm².
 Cable cross-section (mm²)
 No. of pin or sleeve No.
 End point – pin connections This number is that of the relevant pin or sleeve
connection. The numbers are stamped into the
plug housing.
 Code
End point
End point no. of the plug (pin connections).
Fig. 20
End point (target)

This is the end point number of the sockets
(sleeve connections).
13
3 842 951.00 en
Troubleshooting Summary
For troubleshooting in the electrical system, To obtain a better understanding of the
alongside the documentation, in most cases, only a troubleshooting, a "schedule" will help with further
voltage tester and analyzer will be required (on- clarification of how to proceed with troubleshooting.
board voltage = 24 V). As a rule of thumb, the
following applies: Start the diagnosis at the point of 1 Fault information
the effect or missing effect. The effect is produced
2 Determine the effect generated by the
by motors, generators, solenoid valves and lights,
etc. Circuit elements, for example switches, relays, component using the legend and circuit
pressure controllers, etc., introduce this effect. diagram and familiarize yourself with the
function.
3 Take readings. Refer to the connection
tables for the measuring points.
4 Evaluate the readings. Each reading leads to
a decision on how to proceed further. The
new information may help to determine the
fault or a new measuring point may need to
be determined.
5 Troubleshooting.
14
3 842 951.00 en
Schematic symbols
Extract from the DIN EN 60617 series of standards "Schematic Symbols for Use in Electrotechnical
Diagrams" (also IEC 60617; replaces the DIN 40700 and 40900 series of standards):
Schematic symbols Description
Direct current
Alternating current
Three-phase alternating current
Ground, general
Positive, unswitched
Positive, switched
Negative
Protective earth, PE
Structural component
Moveable, loose lead end (freehand sketch)
Summary of wires for simplified representation in the circuit diagrams.

Arbitrary sequence; wires must be identified.
Crossover of wires without connection
Branching and crossover with a conducting connection
Non-detachable connection (soldered point)
Detachable connection, general (terminal or connector)
Table 2
15
3 842 951.00 en
Line filter
Radio/receiver
Normally open switch, thermal overload relay
Normally closed switch, thermal overload relay
Switch, mechanically normally open switch
Switch, mechanically normally closed switch
Pressure controller, normally open switch
Temperature sensor
Pressure controller, normally closed switch
Photoelectric sensor
Temperature switch, normally open switch
Temperature switch, normally closed switch
Float switch, normally open switch
Float switch, normally closed switch
Flow monitor, normally open switch
Flow monitor, normally closed switch
Photoelectric sensor, transmitter
Table 2 – (cont.)
16
3 842 951.00 en
Photoelectric sensor, receiver
Initiator, general, 2-wire
Photoelectric reflex sensor
Limit switch, 3-wire, normally closed switch
Limit switch, 3-wire, normally open switch
Limit switch, 2-wire, normally open switch
Limit switch, 2-wire, normally closed switch
Capacitor, vertical
Capacitor for rectifier
Surge arrester
Heating resistor
Slip ring transmitter
Slip ring transmitter
Control cabinet light with connector receptacle
Table 2 – (cont.)
17
3 842 951.00 en
Cigarette lighter
Fuse
Fuses, 3-pole
Fuses, 2-pole
3-pole thermal fuse + contact
Fuse isolator, 3-pole
Fuse isolator, 1-pole
Electrothermal overcurrent device, trips manually
Single pole circuit-breaker, normally open switch
Two pole circuit-breaker, normally open switch
Three pole circuit-breaker, normally open switch
Fuse (auxiliary contact)
Table 2 – (cont.)
18
3 842 951.00 en
Overvoltage release
Overvoltage release
Residual current release
Three pole circuit-breaker (auxiliary contact)
Residual current protection switch
DC alternator, general
Pulse encoder
Power source
Power supply unit with phase monitoring
Three-phase alternator
Battery
AC electric generator with rectifier
Light
Table 2 – (cont.)
19
3 842 951.00 en
Horn
Glow lamp
Buzzer/warning bell/bell
Clock, general
Buzzer
Transformer light
Flashing indicator light
Rotating beacon
Pressure light with lamp test
Triple-pole primary contacts
Normally open switch
Normally closed switch
Normally open switch, delayed closing
Normally closed switch, delayed opening
Normally open switch, delayed opening
Normally closed switch, delayed closing
Normally open switch, leading
Table 2 – (cont.)
20
3 842 951.00 en
Normally closed switch, delayed
Normally open switch, wiping contact closure to the right
Wiping contact right/left
Normally open switch, wiping contact closure to the left
Changeover contact for normally closed switch
Normally open switch, turned 180°
Changeover contact for normally closed switch, right contact
Bottom changeover contact
Changeover contact for normally closed switch, left contact
Relay coil/contactor coil
Electromagnetic drive with pick-up delay
Electromagnetic drive with release delay
Master clock generator
AC relay
Electrical drive with pick-up and release delay
Remanence relay
Remanence relay with latching protection
Multifunction relay
Electrical drive with drop-out delay
Counter
Saver switch, right
Field winding for DC motor
Table 2 – (cont.)
21
3 842 951.00 en
Iron-core choke
Current transformer
Three-phase line choke/transformer
Field for DC motor
Three-phase current motor, pole-changing, 6 terminals
Starter for diesel engine
Three-phase current motor, one speed
Motor, slip ring rotor
Two star delta motor
Motor for ventilator/fan
Motor with PTC
Table 2 – (cont.)
22
3 842 951.00 en
Three-phase drive, 9 terminals in center
Ventilator
PE connection for motor
DC motor with pump
Window wiper motor
DC motor, general
Counter
Voltmeter
Ammeter
Elapsed time meter
Vehicle indicating instrument, general
Three-pole load interrupter switch
Single pole load interrupter switch
Table 2 – (cont.)
23
3 842 951.00 en
Engine protection switch with switch lock
Circuit-breaker
On/Off switch for transformer 380/220 V
Three-pole load interrupter switch
Single-pole load interrupter switch
Resistor
Potentiometer
Voltage-dependent resistor
Bridge circuit
Variable resistor
Potentiometer
Measuring resistor
RC circuit (resistor + capacitor)
Table 2 – (cont.)
24
3 842 951.00 en
Potentiometer
Variable resistor
Measuring resistor
Switch with pressure-actuated normally open switch
Switch with pressure-actuated normally closed switch
Switch with rotation-actuated normally open switch latch position
Switch with rotation-actuated normally closed switch position
Switch with pressure-actuated normally open switch latch position
Switch with pressure-actuated normally closed switch position
Key switch with normally open switch
Key switch with normally closed switch
Foot switch with normally open switch
Foot switch with normally closed switch
Cam switch with normally open switch
Cam switch with normally closed switch
Three-pole main switch
EMERGENCY OFF palm-type push-button
Table 2 - (cont.)
25
3 842 951.00 en
General latching switch (normally closed switch)
General latching switch (normally open switch)
General pushbutton (normally open switch)
General pushbutton (normally closed switch)
Palm-type pushbutton with normally open switch
Palm-type pushbutton with normally closed switch
Single-phase transformer
Three-phase transformer with star connection
Two-phase transformer
Three-phase transformer
Transformer with center tap
Single-phase transformer with two secondary windings
Three-phase autotransformer
Table 2 - (cont.)
26
3 842 951.00 en
Star voltage converter
Delta-star transformer
Star-delta transformer
Open delta voltage converter
Single-phase autotransformer
Transformer primary winding
Transformer secondary winding
LED, cathode below
Diode
Two-phase rectifier bridge
Three-phase bridge
Diode, cathode below
Thyristor
Table 2 - (cont.)
27
3 842 951.00 en
Zener diode
Thyristor
LED, cathode above
LED, cathode on right
Rectifier
Three-phase bridge circuit
Terminal
Jack with male connector
Male connector with jack
Power outlet
Male connector
Coaxial plug
Coaxial plug
Isolating terminal
Single-pole vehicle connector
Solenoid valve
Magnetic brake
Magnetic clutch
General valve coil
Table 2 - (cont.)
28
3 842 951.00 en
Direct current
Alternating current
Three-phase alternating current
Ground, general
Wire, varying line thicknesses for parts to be highlighted
Grounding, N, previously Mp
Protective earth, PE, previously SL
Structural component
Moveable, loose lead end (freehand sketch)
Summary of wires for simplified representation of circuit

diagrams; arbitrary sequence, wires must be identified
Crossover of wires without connection
Branching and crossover with a conducting connection
Non-detachable connection (soldered point)
Detachable connection, general (terminal or connector)
Male connector,
female jack
Table 2 - (cont.)
29
3 842 951.00 en
Connector assembly with male connector and female jack
Make contact, two-way normally open switch with three

switching positions
Mechanical active connection
Manually operated drive, manual drive, general
Latch
Latch with information on latch position
Example: Manually actuated normally open switch with latch

position
Identification of the circuit positions using numbering. The

normal position can be identified by a 0.
For application, see "Switches"
Manual operation by pressure or pulling
Manual operation by turning or tilting
Foot-operated drive
Removable manual drive, e.g. using socket wrench
Drive operated by pressure
Drive operated by temperature
Indirect drive, e.g. via limit switch
Table 2 - (cont.)
30
3 842 951.00 en
Multipole connector assembly (multiway connectors)
Terminal blocks (terminal strip, luster terminal)
Sliding contact
Primary element. Battery, general; battery with multiple cells

(as required)
Fuse, general
Surge protection conductor

(lightning protection)
Make contact element, normally open switch
Break contact element, normally closed switch
Changeover contact element, changeover contact
Fuse with thermally-actuated trip (miniature circuit-breaker)
Table 2 - (cont.)
31
3 842 951.00 en
Example: Ignition lock, latch position in items 0 and 1
Electromechanical drive, e.g. with information on an

effective winding
Example: Relay with normally open switch and normally

closed switch
Resistor, general, also glow plug schematic symbols and

heating resistor
Adjustable resistor, e.g. potentiometer
Capacitor, capacity, general
Electrolytic capacitor
Incandescent lamp
Incandescent lamp with two luminaries, e.g. Bilux
V = Voltmeter, A = Ammeter, Ω = Ohmmeter,

W = Wattmeter, etc.
Circuit letter symbols/abbreviations
AC alternator, general
Table 2 - (cont.)
32
3 842 951.00 en
Alternator with rectifier assembly (turning machine)
Circuit abbreviation, motor, starting motor (vehicle)
Window wiper with motor drive
Three-phase AC motor
Solenoid valve
Horn
Electric fan
Buzzer
Elapsed time meter
Electric clock
Spark gap, e.g. spark plug
Table 2 - (cont.)
33
3 842 951.00 en
Ground, general
Winding, inductivity, general (e.g. throttle)
Winding with core in magnetic material (throttle with core)
Transformer, transducer, converter, general
Circuit abbreviation, three-phase current motor with

squirrel-cage
Shielded by ground connection
Diode rectifier, forward current for positive flow towards

delta peak (equilateral delta)
Zener diode (suitable for operation in the breakdown region)
Thyristor
LED
PNP – Transistor
E = Emitter
} Contact gap and control gap
C = Collector
B = Base (basis; control port)

Table 2 - (cont.)
34
3 842 951.00 en
NPN – Transistor
Phototransistor
Temperature-dependent resistor
Voltage-dependent resistor, e.g. NTH
Electrical amplifier
Operational amplifier (amplifies the voltage between

E1 and E2)
DC converter
Voltage converter (24 V to 15 V)
Initiator
Optocoupler
Table 2 - (cont.)
35
3 842 951.00 en
Battery
Buzzer
Shield
Light
Light
Particle detector
Pressure switch
Thermostatic switch
Fill lever sender
Temperature sensor
644280
Table 2 - (cont.)
36
3 842 951.00 en
Pressure sensor
Tank sensor
Limit switch
Service meter
Indicator light
Heating resistor
Resistor
Voltage converter
644281
Table 2 - (cont.)
37
3 842 951.00 en
Radio
Power outlet
Speaker
Connection for charging unit
Variable resistor
Potentiometer
Overheating protection switch
Magnetic clutch
Residual current protective switch
644282
Table 2 - (cont.)
38
3 842 951.00 en
Normally open switch
Normally closed switch
Changeover contact
Latching palm-type pushbutton
Switch
Switch
Key switch
Rocker switch
Contactor contacts
Circuit-breaker
644283
Table 2 - (cont.)
39
3 842 951.00 en
Fuse
Male contact pin
Female contact jack
Terminal
Ground
LED
Diode
Zener diode
LED – Terminal +
LED – Terminal –
644284
Table 2 - (cont.)
40
3 842 951.00 en
Relay
Timer relay
Starter for diesel engine
Alternator
Fan motor
Window wiper motor
DC motor
Proportioning valve
Solenoid valve
644285
Table 2 - (cont.)
41
3 842 951.00 en
Identification of direction of movement

The direction of movement is identified according to the following agreements:
42
3 842 951.00 en
INDEX
C N
Circuit diagram......................................................4 Names of the electrical/electronic components... 2
Circuit Diagram – description ...............................7
Circuit diagram – sample page.............................4 S
Connection tables – plug connections................13 SAFETY INSTRUCTIONS................................... 1
Connection tables – terminal strips ....................10 Schematic symbols............................................ 15
SCOPE OF THE DOCUMENTATION FOR THE
E ELECTRICAL SYSTEM....................................... 2
ELECTRICAL CIRCUIT DIAGRAM ......................2 Summary............................................................ 14
F T
Foreword...............................................................1 Troubleshooting ................................................. 14
L
Legend to the circuit diagram – sample page ......5
Printed in Germany
Service Manual
for General Information,
Conversion Calculations
and Tightening Torques
6015 - 6090
Tel. +49 (0) 231 922 4340
Fax +49 (0) 231 922 5005
© Caterpillar Global Mining Hydraulic Mining Shovels GmbH 2014. Unless expressly permitted, the
transfer and reproduction of this manual/file and the sale and disclosure of its content is prohibited.
Contraventions are liable to compensation. All rights reserved in the event of patent, utility model,
or registered design registration.
Printed in Germany
GENERAL DATA
FOREWORD ......................................................................................................................................... 1
SI - AND ADDITIONAL UNITS

Quantities of space and mass ........................................................................................................... 3
Time-related quantities...................................................................................................................... 4
Quantities of force, energy and power .............................................................................................. 5
CONVERSIONS TABLES
Conversion for units of length ............................................................................................................ 6
Conversion for units of area............................................................................................................... 7
Conversion from foot and inch to metric measures ............................................................................ 8
Conversion from Newtonmeter "Nm" into foot pounds "ft.lb.".............................................................. 9
Conversion table for units of pressure in gases, steam and fluids ..................................................... 17
Conversion table for units of power, energy and heat quantity .......................................................... 18
Conversion table for units of mechanical stress (strength) ................................................................ 19
Practically equivalent units for pressure and mechanical stress (strength)......................................... 20
Units of temperature and conversion formulas .................................................................................. 21
Power, energy and heat flow ............................................................................................................22
Speed .............................................................................................................................................. 23
Units of mass (weight)......................................................................................................................24
Units of volume, flow rates................................................................................................................25
Fuel consumption.............................................................................................................................26
CALCULATION EXAMPLES
Angles of slope ................................................................................................................................ 27
Travel speeds .................................................................................................................................. 27
Hydraulic outputs (pumps/motors) ....................................................................................................28
Stroking times of cylinders................................................................................................................28
Speeds of hydraulic motors ..............................................................................................................28
TIGHTENING TORQUES
General information..........................................................................................................................29
Bolts with standard thread DIN 13 – 13.............................................................................................30
Bolts with metric fine thread DIN 13 – 13 ..........................................................................................31
O&K Double - hex. Bolts...................................................................................................................32
O&K Double - hex. necked - down bolts ...........................................................................................33
Tightening torques for SAE flange-system ........................................................................................ 34
Tightening angles.............................................................................................................................34
INDEX........................................................................................................................................................
2 804 198 en - (01)

GENERAL DATA
FOREWORD
The Technical Handbook "Service Data" contains de-

The Part Nos. given in the sections are
tails which are important to the service staff. Data
included in other parts of the general documentation not to be used when ordering spare
have been left aside. The set of documents for an parts. They are only intended to identi-
O&K Mining excavator includes: fy the component being referred to.
When ordering spare parts, use only
the Part Nos. given in the spare parts
lists or the O&K internal microfilms.
• Operating Instructions
• Spare Parts List
• Dimension Table or Dimension Sheet
Anyone involved with commissioning,
"Techn. Data" for O&K Mining excavators.
operating, inspecting and servicing the
O&K Mining excavator must read
Technical Handbooks (THB) and "Service Informa- through and acquaint himself with the
tion" bulletins (si) are, furthermore, to be considered Operating Instructions - and especially
as supplements to the general documentation. the Section SAFETY - before starting
work.
Data regarding auxiliary units for operating ancillary
or special systems, as well as data on machines
produced only in small numbers, have not been inclu-
ded.
Filling quantities are only approximate figures inten-

ded to help in stockholding the various fluids and
agents. Each unit has appropriate checking systems,
e.g. dipstick or checking screws, with which the exact
filling level can be checked.
2 802 804 198 en - (01) 1

1
GENERAL DATA
2 2 804 198 en - (01)

GENERAL DATA
SI - AND ADDITIONAL UNITS

Quantities of space and mass
Quantity Symbol Unit Conversion Explanations

and
Remarks
old new for exact for rough

calculation calculation
SI-Unit Selection of appr. 2 %

additional inexact
units
Length I m, mm, cm m m, mm, km

dm, m, km
Area A mm2, cm2, dm2, m2 mm2, cm2

m2
Volume V, Vn mm3, cm3, dm3, m3 mm3, cm3, dm3,

m3, l l
Mass m g, mg, g, kg, kg g, mg, g

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

kg/m3,
(kp s2/m4)
Inertia moment J kp m2, kg m2 Mg m2 1 kp m s2 = 1 kp m s2 =

(kp m s2) 9,81 kg m2 10 kg m2
Specific volume v m3/kg, m3/t m3/kg m3/Mg
22 804 198 en - (01) 33

GENERAL DATA
Time-related quantities

and
Remarks

calculation calculation and
SI-Units Selection of appr. 2 %

additional inexact
units
Time t s, min, h, s ms, min, h, d

d = day
Frequency f Hz Hz 1 Hz 1/s
Rate of revolutions n U/min 1/s 1/min s = min/60
Speed v m/s, km/h m/s km/h
Acceleration a m/s2 m/s2
Volume flow V m3/s, m3/min, m3/s m3/min,

m3/h l/h
Mass flow m kg/s, kg/min, kg/s

kg/h
Heat flow (kcal/h) W kW, MW 1 kcal/h = 1 kcal/h = 1 W = 1 J/s =

1,163 W 1,2 W 1 Nm/s
Specific fuel and b, bs kg/PSh kg/J g/(kW h) 1 g/(PS h) = 1 g/(PS h) =

oil consumption g/PSh 1,359 g/(kW h) 1,36 g/(kW h)
4 2 804 198 en00

- (01)
GENERAL DATA
Quantities of force, energy and power

and
Remarks

calculation calculation
SI-units Selection of appr. 2 %

SI-Units additional inexact
units
Force F (dyn, p) N (Newton) MN, kN, 1 kp = 1 kg x 1 kp = 10 N 1 N = 1 kg x

(njuten) mN 9,81m/s2 = 1 m/s2 =
9,81 N 1 kg m/s2
Pressure (of fluids) P, Pi, (kp/cm2,at,atm,) N/m2, bar, mbar 1 kp/cm2 = 1 kp/cm2=1 bar 1 N/m2=1 Pa
0,981 bar
Pe, (mWS, Torr,) Pa (Pascal) 1 atm = 1 mWS = 1Pa = 10-5 bar
1,013 bar 0,1 bar
Pü, Pu (mmHg) 1 mWS = 1 bar =
0,098 bar 105 N/m2
Mechanical stress (kp/cm2, N/m2, pa N/mm2 1 kp/mm 2 = 1 kp/mm2 = 1 N/m2 = 1 Pa

kp/mm2) 9,81 N/mm2 10 N/mm2
1 kp/cm2 = 1 kp/cm2 =
9,81 N/mm2 10 N/cm2
Energy W (kpm) J (Joule) MJ, kJ, 1 kpm = 9,81 J 1 kpm = 10 J 3,6 MJ =

(dschul) kW h 1 kWh
1 J = 1 NM = 1
Ws
Heat capacity Q (cal, erg) J (Joule) MJ, kJ, 1 kcal = 3,6 MJ =

(dschul) kW h 4,19 kJ 1 kW h
1 J = 1 Nm = 1
Ws
Power P (PS), W W kW, MW 1 PS = 1 PS = 1 W =1 J/s =

Power 0,735499 kW 0,74 kW 1 Nm/s
1 kW = 1 kW = 1,36 PS
1,359622 PS
Torque, bending moment M (kp m) Nm N cm 1 kp m = 1 kp m =

9,81 N m 10 N m
22 804 198 en - (01) 55

GENERAL DATA
CONVERSIONS TABLES
Conversion for units of length
Länge in ft yd mile UK cm m
Length n mile
1 inch 1 0,0833 0,0278 2,54 0,0254
1 foot 12 1 0,3333 0,00019 0,00016 30,48 0,3048
1 yard 36 3 1 0,00057 0,00049 91,44 0,9144
1 statute mile 63 360 5 280 1 760 1 0,86842 1609,3
1 UK nautical mile 72 960 6 080 2 026,7 1,15151 1 1 853,2
1 cm 0,3937 0,0328 0,0109 1 0,01
1m 39,370 3,2808 1,0936 0,00062 0,00054 100 1
6 2 804 198 en00

- (01)en01
GENERAL DATA
Conversion for units of area
Area in2 ft2 yd2 sqmile acre cm2 m2
1 square inch 1 0,0069 6,4516
1 square foot 144 1 0,111 929,03 0,0929
1 square yard 1 296 9 1 0,00021 8361,3 0,8361
1 square mile 1 640
1 acre 43 560 4 840 0,00156 1 4 046,9
1 cm2 0,1550 1 0,0001
1 m2 1 550,0 10,764 1,1960 10 000 1
22 804 198 en - (01) 77

GENERAL DATA
Conversion from foot and inch to metric measures

1 in (inch) = 25,4 mm (exact) 1 ft (foot) = 12 in = 304,8 mm Example: 4 ft 2 in = 1,27 m
ft in
+0 +1 +2 +3 +4 +5 +6 +7 +8 +9 +10 +11
m m m m m m m m m m m m
0 0,0254 0,0508 0,0762 0,1016 0,1270 0,1524 0,1778 0, 2032 0,2286 0,2540 0,2794
1 0,3048 0,3302 0,3556 0,3810 0,4064 0,4318 0,4572 0,4826 0,5080 0,5334 0,5588 0,5842
2 0,6096 0,6350 0,6604 0,6858 0,7112 0,7366 0,7620 0,7874 0,8128 0,8382 0,8636 0,8890
3 0,9144 0,9398 0,9652 0,9906 1,0160 1,0414 1,0668 1,0922 1,1176 1,1430 1,1684 1,1938
4 1,2192 1,2446 1,2700 1,2954 1,3208 1,3462 1,3716 1,3970 1,4224 1,4478 1,4732 1,4986
5 1,5240 1,5494 1,5748 1,6002 1,6256 1,6510 1,6764 1,7018 1,7272 1,7526 1,7780 1,8034
6 1,8288 1,8542 1,8796 1,9050 1,9304 1,9558 1,9812 2,0066 2,0320 2,0574 2,0828 2,1082
7 2,1336 2,1590 2,1844 2,2098 2,2352 2,2606 2,2860 2,3114 2,3368 2,3622 2,3876 2,4130
8 2,4384 2,4638 2,4892 2,5146 2,5400 2,5654 2,5908 2,6162 2,6416 2,6670 2,6924 2,7178
9 2,7432 2,7686 2,7940 2,8194 2,8448 2,8702 2,8956 2,9210 2,9464 2,9718 2,9972 3,0226
10 3,0480 3,0734 3,0988 3,1242 3,1496 3,1750 3,2004 3,2258 3,2512 3,2766 3,3020 3,3274
11 3,3528 3,3782 3,4036 3,4290 3,4544 3,4798 3,5052 3,5306 3,5560 3,5814 3,6068 3,6322
12 3,6576 3,6830 3,70 3,7338 3,7592 3,7846 3,8100 3,8354 3,8608 3,8862 3,9116 3,9370
8 2 804 198en-0(01)en
GENERAL DATA
Conversion from newtonmeter "Nm" into foot pounds "ft.lb."
Nm 0 1 2 3 4 5 6 7 8 9
10 7.376 8.113 8.851 9.588 10.326 11.063 11.801 12.539 13.276 14.014
20 14.751 15.489 16.226 16.964 17.701 18.439 19.177 19.914 20.652 21.389
30 22.127 22.864 23.602 24.339 25.077 25.815 26.552 27.290 28.027 28.765
40 29.502 30.240 30.978 31.715 32.453 33.190 33.928 34.665 35.403 36.140
50 36.878 37.616 38.353 39.091 39.828 40.566 41.303 42.041 42.778 43.516
60 44.254 44.991 45.729 46.466 47.204 47.941 48.679 49.417 50.154 50.892
70 51.629 52.367 53.104 53.842 54.579 55.317 56.055 56.792 57.530 58.267
80 59.005 59.742 60.480 61.217 61.955 62.693 63.430 64.168 64.905 65.643
90 66.380 67.118 67.856 68.593 69.331 70.068 70.806 71.543 72.281 73.018
100 73.756 74.494 75.231 75.969 76.706 77.444 78.181 78.919 79.656 80.394
110 81.132 81.869 82.607 83.344 84.082 84.819 85.557 86.295 87.032 87.770
120 88.507 89.245 89.982 90.720 91.457 92.195 92.933 93.670 94.408 95.145
130 95.883 96.620 97.358 98.095 98.833 99.571 100.308 101.046 101.783 102.521
140 103.258 103.996 104.734 105.471 106.209 106.946 107.684 108.421 109.159 109.896
150 110.634 111.372 112.109 112.847 113.584 114.322 115.059 115.797 116.534 117.272
160 118.010 118.747 119.485 120.222 120.960 121.697 122.435 123.173 123.910 124.648
170 125.385 126.123 126.860 127.598 128.335 129.073 129.811 130.548 131.286 132.023
180 132.761 133.498 134.236 134.973 135.711 136.449 137.186 137.924 138.661 139.399
190 140.136 140.874 141.612 142.349 143.087 143.824 144.562 145.299 146.037 146.774
200 147.512 148.250 148.987 149.725 150.462 151.200 151.937 152.675 153.412 154.150
210 154.888 155.625 156.363 157.100 157.838 158.575 159.313 160.051 160.788 161.526
220 162.263 163.001 163.738 164.476 165.213 165.951 166.689 167.426 168.164 168.901
230 169.639 170.376 171.114 171.851 172.589 173.327 174.064 174.802 175.539 176.277
240 177.014 177.752 178.490 179.227 179.965 180.702 181.440 182.177 182.915 183.652
250 184.390 185.128 185.865 186.603 187.340 188.078 188.815 189.553 190.290 191.028
260 191.766 192.503 193.241 193.978 194.716 195.453 196.191 196.929 197.666 198.404
270 199.141 199.879 200.616 201.354 202.091 202.829 203.567 204.304 205.042 205.779
280 206.517 207.254 207.992 208.729 209.467 210.205 210.942 211.680 212.417 213.155
290 213.892 214.630 215.368 216.105 216.843 217.580 218.318 219.055 219.793 220.530
300 221.268 222.006 222.743 223.481 224.218 224.956 225.693 226.431 227.168 227.906
310 228.644 229.381 230.119 230.856 231.594 232.331 233.069 233.807 234.544 235.282
320 236.019 236.757 237.494 238.232 238.969 239.707 240.445 241.182 241.920 242.657
330 243.395 244.132 244.870 245.607 246.345 247.083 247.820 248.558 249.295 250.033
340 250.770 251.508 252.245 252.983 253.721 254.458 255.196 255.933 256.671 257.408
350 258.146 258.884 259.621 260.359 261.096 261.834 262.571 263.309 264.046 264.784
360 265.521 266.259 266.997 267.734 268.472 269.209 269.947 270.684 271.422 272.159
370 272.897 273.635 274.372 275.110 275.847 276.585 277.323 278.060 278.798 279.535
380 280.273 281.010 281.748 282.485 283.223 283.960 284.698 285.436 286.173 286.911
390 287.648 288.386 289.123 289.861 290.598 291.336 292.074 292.811 293.549 294.286
400 295.024 295.761 296.499 297.237 297.974 298.712 299.449 300.187 300.924 301.662
410 302.399 303.137 303.875 304.612 305.350 306.087 306.825 307.562 308.300 309.038
420 309.775 310.513 311.250 311.988 312.725 313.463 314.200 314.938 315.676 316.413
430 317.151 317.888 318.626 319.363 320.101 320.838 321.576 322.313 323.051 323.789
440 324.526 325.264 326.001 326.739 327.477 328.214 328.952 329.689 330.427 331.164
450 331.902 332.639 333.377 334.115 334.852 335.590 336.327 337.065 337.802 338.540
460 339.278 340.015 340.753 341.490 342.228 342.965 343.703 344.440 345.178 345.916
470 346.653 347.391 348.128 348.866 349.603 350.341 351.078 351.816 352.553 353.291
480 354.029 354.766 355.504 356.241 356.979 357.717 358.454 359.192 359.929 360.667
490 361.404 362.142 362.879 363.617 364.354 365.092 365.830 366.567 367.305 368.042
500 368.780 369.517 370.255 370.992 371.730 372.468 373.205 373.943 374.680 375.418
510 376.156 376.893 377.631 378.368 379.106 379.843 380.581 381.318 382.056 382.793
520 383.531 384.269 385.006 385.744 386.481 387.219 387.957 388.694 389.432 390.169
530 390.907 391.644 392.382 393.119 393.857 394.594 395.332 396.070 396.807 397.545
540 398.282 399.020 399.757 400.495 401.232 401.970 402.708 403.445 404.183 404.920
550 405.658 406.396 407.133 407.871 408.608 409.346 410.083 410.821 411.558 412.296
560 413.033 413.771 414.509 415.246 415.984 416.721 417.459 418.196 418.934 419.671
570 420.409 421.147 421.884 422.622 423.359 424.097 424.834 425.572 426.310 427.047
580 427.785 428.522 429.260 429.997 430.735 431.472 432.210 432.948 433.685 434.423
590 435.160 435.898 436.635 437.373 438.111 438.848 439.586 440.323 441.061 441.798
600 442.536 443.273 444.011 444.749 445.486 446.224 446.961 447.699 448.436 449.174
610 449.911 450.649 451.386 452.124 452.862 453.599 454.337 455.074 455.812 456.550
620 457.287 458.025 458.762 459.500 460.237 460.975 461.712 462.450 463.187 463.925
630 464.663 465.400 466.138 466.875 467.613 468.350 469.088 469.826 470.563 471.301
640 472.038 472.776 473.513 474.251 474.989 475.726 476.464 477.201 477.939 478.676
650 479.414 480.151 480.889 481.626 482.364 483.102 483.839 484.577 485.314 486.052
660 486.790 487.527 488.265 489.002 489.740 490.477 491.215 491.952 492.690 493.427
670 494.165 494.903 495.640 496.378 497.115 497.853 498.590 499.328 500.065 500.803
680 501.541 502.278 503.016 503.753 504.491 505.229 505.966 506.704 507.441 508.179
690 508.916 509.654 510.391 511.129 511.866 512.604 513.342 514.079 514.817 515.554
700 516.292 517.030 517.767 518.505 519.242 519.980 520.717 521.455 522.192 522.930
22 804 198 en - (01) 99

GENERAL DATA
Nm 0 1 2 3 4 5 6 7 8 9
710 523.667 524.405 525.143 525.880 526.618 527.355 528.093 528.830 529.568 530.305
720 531.043 531.781 532.518 533.256 533.993 534.731 535.469 536.206 536.944 537.681
730 538.419 539.156 539.894 540.631 541.369 542.106 542.844 543.582 544.319 545.057
740 545.794 546.532 547.269 548.007 548.744 549.482 550.220 550.957 551.695 552.432
750 553.170 553.907 554.645 555.383 556.120 556.858 557.595 558.333 559.070 559.808
760 560.545 561.283 562.021 562.758 563.496 564.233 564.971 565.708 566.446 567.184
770 567.921 568.659 569.396 570.134 570.871 571.609 572.346 573.084 573.822 574.559
780 575.297 576.034 576.772 577.509 578.247 578.984 579.722 580.459 581.197 581.935
790 582.672 583.410 584.147 584.885 585.623 586.360 587.098 587.835 588.573 589.310
800 590.048 590.785 591.523 592.260 592.998 593.736 594.473 595.211 595.948 596.686
810 597.423 598.161 598.899 599.636 600.374 601.111 601.849 602.586 603.324 604.062
820 604.799 605.537 606.274 607.012 607.749 608.487 609.224 609.962 610.699 611.437
830 612.175 612.912 613.650 614.387 615.125 615.863 616.600 617.338 618.075 618.813
840 619.550 620.288 621.025 621.763 622.500 623.238 623.976 624.713 625.451 626.188
850 626.926 627.663 628.401 629.138 629.876 630.614 631.351 632.089 632.826 633.564
860 634.302 635.039 635.777 636.514 637.252 637.989 638.727 639.464 640.202 640.939
870 641.677 642.415 643.152 643.890 644.627 645.365 646.102 646.840 647.578 648.315
880 649.053 649.790 650.528 651.265 652.003 652.740 653.478 654.216 654.953 655.691
890 656.428 657.166 657.903 658.641 659.378 660.116 660.854 661.591 662.329 663.066
900 663.804 664.542 665.279 666.017 666.754 667.492 668.229 668.967 669.704 670.442
910 671.179 671.917 672.655 673.392 674.130 674.867 675.605 676.342 677.080 677.817
920 678.555 679.293 680.030 680.768 681.505 682.243 682.980 683.718 684.456 685.193
930 685.931 686.668 687.406 688.143 688.881 689.618 690.356 691.094 691.831 692.569
940 693.306 694.044 694.781 695.519 696.257 696.994 697.732 698.469 699.207 699.944
950 700.682 701.419 702.157 702.895 703.632 704.370 705.107 705.845 706.582 707.320
960 708.057 708.795 709.532 710.270 711.008 711.745 712.483 713.220 713.958 714.696
970 715.433 716.171 716.908 717.646 718.383 719.121 719.858 720.596 721.333 722.071
980 722.809 723.546 724.284 725.021 725.759 726.496 727.234 727.972 728.709 729.447
990 730.184 730.922 731.659 732.397 733.135 733.872 734.610 735.347 736.085 736.822
1000 737.560 738.297 739.035 739.772 740.510 741.248 741.985 742.723 743.460 744.198
1010 744.936 745.673 746.411 747.148 747.886 748.623 749.361 750.098 750.836 751.573
1020 752.311 753.049 753.786 754.524 755.261 755.999 756.736 757.474 758.211 758.949
1030 759.687 760.424 761.162 761.899 762.637 763.375 764.112 764.850 765.587 766.325
1040 767.062 767.800 768.537 769.275 770.012 770.750 771.488 772.225 772.963 773.700
1050 774.438 775.175 775.913 776.651 777.388 778.126 778.863 779.601 780.338 781.076
1060 781.813 782.551 783.289 784.026 784.764 785.501 786.239 786.976 787.714 788.451
1070 789.189 789.927 790.664 791.402 792.139 792.877 793.615 794.352 795.090 795.827
1080 796.565 797.302 798.040 798.777 799.515 800.252 800.990 801.728 802.465 803.203
1090 803.940 804.678 805.415 806.153 806.890 807.628 808.366 809.103 809.841 810.578
1100 811.316 812.053 812.791 813.529 814.266 815.004 815.741 816.479 817.216 817.954
1110 818.691 819.429 820.167 820.904 821.642 822.379 823.117 823.854 824.592 825.330
1120 826.067 826.805 827.542 828.280 829.017 829.755 830.492 831.230 831.968 832.705
1130 833.443 834.180 834.918 835.655 836.393 837.130 837.868 838.605 839.343 840.081
1140 840.818 841.556 842.293 843.031 843.769 844.506 845.244 845.981 846.719 847.456
1150 848.194 848.931 849.669 850.406 851.144 851.882 852.619 853.357 854.094 854.832
1160 855.569 856.307 857.045 857.782 858.520 859.257 859.995 860.732 861.470 862.208
1170 862.945 863.683 864.420 865.158 865.895 866.633 867.370 868.108 868.845 869.583
1180 870.321 871.058 871.796 872.533 873.271 874.009 874.746 875.484 876.221 876.959
1190 877.696 878.434 879.171 879.909 880.646 881.384 882.122 882.859 883.597 884.334
1200 885.072 885.809 886.547 887.284 888.022 888.760 889.497 890.235 890.972 891.710
1210 892.448 893.185 893.923 894.660 895.398 896.135 896.873 897.610 898.348 899.085
1220 899.823 900.561 901.298 902.036 902.773 903.511 904.248 904.986 905.724 906.461
1230 907.199 907.936 908.674 909.411 910.149 910.886 911.624 912.362 913.099 913.837
1240 914.574 915.312 916.049 916.787 917.524 918.262 919.000 919.737 920.475 921.212
1250 921.950 922.687 923.425 924.163 924.900 925.638 926.375 927.113 927.850 928.588
1260 929.325 930.063 930.801 931.538 932.276 933.013 933.751 934.488 935.226 935.963
1270 936.701 937.439 938.176 938.914 939.651 940.389 941.126 941.864 942.602 943.339
1280 944.077 944.814 945.552 946.289 947.027 947.764 948.502 949.240 949.977 950.715
1290 951.452 952.190 952.927 953.665 954.403 955.140 955.878 956.615 957.353 958.090
1300 958.828 959.565 960.303 961.041 961.778 962.516 963.253 963.991 964.728 965.466
1310 966.203 966.941 967.678 968.416 969.154 969.891 970.629 971.366 972.104 972.842
1320 973.579 974.317 975.054 975.792 976.529 977.267 978.004 978.742 979.479 980.217
1330 980.955 981.692 982.430 983.167 983.905 984.642 985.380 986.118 986.855 987.593
1340 988.330 989.068 989.805 990.543 991.281 992.018 992.756 993.493 994.231 994.968
1350 995.706 996.443 997.181 997.918 998.656 999.394 1000.131 1000.869 1001.606 1002.344
1360 1003.082 1003.819 1004.557 1005.294 1006.032 1006.769 1007.507 1008.244 1008.982 1009.719
1370 1010.457 1011.195 1011.932 1012.670 1013.407 1014.145 1014.882 1015.620 1016.357 1017.095
1380 1017.833 1018.570 1019.308 1020.045 1020.783 1021.521 1022.258 1022.996 1023.733 1024.471
1390 1025.208 1025.946 1026.683 1027.421 1028.158 1028.896 1029.634 1030.371 1031.109 1031.846
1400 1032.584 1033.321 1034.059 1034.797 1035.534 1036.272 1037.009 1037.747 1038.484 1039.222
10 22 804 198 en - (01)e1

GENERAL DATA
Nm 0 1 2 3 4 5 6 7 8 9
1410 1039.959 1040.697 1041.435 1042.172 1042.910 1043.647 1044.385 1045.122 1045.860 1046.597
1420 1047.335 1048.073 1048.810 1049.548 1050.285 1051.023 1051.760 1052.498 1053.236 1053.973
1430 1054.711 1055.448 1056.186 1056.923 1057.661 1058.398 1059.136 1059.874 1060.611 1061.349
1440 1062.086 1062.824 1063.561 1064.299 1065.036 1065.774 1066.512 1067.249 1067.987 1068.724
1450 1069.462 1070.199 1070.937 1071.675 1072.412 1073.150 1073.887 1074.625 1075.362 1076.100
1460 1076.837 1077.575 1078.312 1079.050 1079.788 1080.525 1081.263 1082.000 1082.738 1083.476
1470 1084.213 1084.951 1085.688 1086.426 1087.163 1087.901 1088.638 1089.376 1090.114 1090.851
1480 1091.589 1092.326 1093.064 1093.801 1094.539 1095.276 1096.014 1096.751 1097.489 1098.227
1490 1098.964 1099.702 1100.439 1101.177 1101.915 1102.652 1103.390 1104.127 1104.865 1105.602
1500 1106.340 1107.077 1107.815 1108.552 1109.290 1110.028 1110.765 1111.503 1112.240 1112.978
1510 1113.715 1114.453 1115.191 1115.928 1116.666 1117.403 1118.141 1118.878 1119.616 1120.354
1520 1121.091 1121.829 1122.566 1123.304 1124.041 1124.779 1125.516 1126.254 1126.991 1127.729
1530 1128.467 1129.204 1129.942 1130.679 1131.417 1132.155 1132.892 1133.630 1134.367 1135.105
1540 1135.842 1136.580 1137.317 1138.055 1138.792 1139.530 1140.268 1141.005 1141.743 1142.480
1550 1143.218 1143.955 1144.693 1145.430 1146.168 1146.906 1147.643 1148.381 1149.118 1149.856
1560 1150.594 1151.331 1152.069 1152.806 1153.544 1154.281 1155.019 1155.756 1156.494 1157.231
1570 1157.969 1158.707 1159.444 1160.182 1160.919 1161.657 1162.394 1163.132 1163.870 1164.607
1580 1165.345 1166.082 1166.820 1167.557 1168.295 1169.032 1169.770 1170.508 1171.245 1171.983
1590 1172.720 1173.458 1174.195 1174.933 1175.670 1176.408 1177.146 1177.883 1178.621 1179.358
1600 1180.096 1180.833 1181.571 1182.309 1183.046 1183.784 1184.521 1185.259 1185.996 1186.734
1610 1187.471 1188.209 1188.947 1189.684 1190.422 1191.159 1191.897 1192.634 1193.372 1194.109
1620 1194.847 1195.585 1196.322 1197.060 1197.797 1198.535 1199.272 1200.010 1200.748 1201.485
1630 1202.223 1202.960 1203.698 1204.435 1205.173 1205.910 1206.648 1207.385 1208.123 1208.861
1640 1209.598 1210.336 1211.073 1211.811 1212.549 1213.286 1214.024 1214.761 1215.499 1216.236
1650 1216.974 1217.711 1218.449 1219.187 1219.924 1220.662 1221.399 1222.137 1222.874 1223.612
1660 1224.349 1225.087 1225.824 1226.562 1227.300 1228.037 1228.775 1229.512 1230.250 1230.988
1670 1231.725 1232.463 1233.200 1233.938 1234.675 1235.413 1236.150 1236.888 1237.625 1238.363
1680 1239.101 1239.838 1240.576 1241.313 1242.051 1242.788 1243.526 1244.264 1245.001 1245.739
1690 1246.476 1247.214 1247.951 1248.689 1249.427 1250.164 1250.902 1251.639 1252.377 1253.114
1700 1253.852 1254.589 1255.327 1256.064 1256.802 1257.540 1258.277 1259.015 1259.752 1260.490
1710 1261.228 1261.965 1262.703 1263.440 1264.178 1264.915 1265.653 1266.390 1267.128 1267.865
1720 1268.603 1269.341 1270.078 1270.816 1271.553 1272.291 1273.028 1273.766 1274.503 1275.241
1730 1275.979 1276.716 1277.454 1278.191 1278.929 1279.667 1280.404 1281.142 1281.879 1282.617
1740 1283.354 1284.092 1284.829 1285.567 1286.304 1287.042 1287.780 1288.517 1289.255 1289.992
1750 1290.730 1291.467 1292.205 1292.943 1293.680 1294.418 1295.155 1295.893 1296.630 1297.368
1760 1298.105 1298.843 1299.581 1300.318 1301.056 1301.793 1302.531 1303.268 1304.006 1304.743
1770 1305.481 1306.219 1306.956 1307.694 1308.431 1309.169 1309.906 1310.644 1311.382 1312.199
1780 1312.857 1313.594 1314.332 1315.069 1315.807 1316.544 1317.282 1318.020 1318.757 1319.495
1790 1320.232 1320.970 1321.707 1322.445 1323.182 1323.920 1324.657 1325.395 1326.133 1326.870
1800 1327.608 1328.345 1329.083 1329.821 1330.558 1331.296 1332.033 1332.771 1333.508 1334.246
1810 1334.983 1335.721 1336.458 1337.196 1337.934 1338.671 1339.409 1340.146 1340.884 1341.622
1820 1342.359 1343.097 1343.834 1344.572 1345.309 1346.047 1346.784 1347.522 1348.260 1348.997
1830 1349.735 1350.472 1351.210 1351.947 1352.685 1353.422 1354.160 1354.897 1355.635 1356.373
1840 1357.110 1357.848 1358.585 1359.323 1360.061 1360.798 1361.536 1362.273 1363.011 1363.748
1850 1364.486 1365.223 1365.961 1366.698 1367.436 1368.174 1368.911 1369.649 1370.386 1371.124
1860 1371.861 1372.599 1373.337 1374.074 1374.812 1375.549 1376.287 1377.024 1377.762 1378.500
1870 1379.237 1379.975 1380.712 1381.450 1382.187 1382.925 1383.662 1384.400 1385.137 1385.875
1880 1386.613 1387.350 1388.088 1388.825 1389.563 1390.301 1391.038 1391.776 1392.513 1393.251
1890 1393.988 1394.726 1395.463 1396.201 1396.938 1397.676 1398.414 1399.151 1399.889 1400.626
1900 1401.364 1402.101 1402.839 1403.576 1404.314 1405.052 1405.789 1406.527 1407.264 1408.002
1910 1408.740 1409.477 1410.215 1410.952 1411.690 1412.427 1413.165 1413.902 1414.640 1415.377
1920 1416.115 1416.853 1417.590 1418.328 1419.065 1419.803 1420.540 1421.278 1422.016 1422.753
1930 1423.491 1424.228 1424.966 1425.703 1426.441 1427.178 1427.916 1428.654 1429.391 1430.129
1940 1430.866 1431.604 1432.341 1433.079 1433.816 1434.554 1435.292 1436.029 1436.767 1437.504
1950 1438.242 1438.979 1439.717 1440.455 1441.192 1441.930 1442.667 1443.405 1444.142 1444.880
1960 1445.617 1446.355 1447.093 1447.830 1448.568 1449.305 1450.043 1450.780 1451.518 1452.255
1970 1452.993 1453.730 1454.468 1455.206 1455.943 1456.681 1457.418 1458.156 1458.894 1459.631
1980 1460.369 1461.106 1461.844 1462.581 1463.319 1464.056 1464.794 1465.531 1466.269 1467.007
1990 1467.744 1468.482 1469.219 1469.957 1470.695 1471.432 1472.170 1472.907 1473.645 1474.382
2000 1475.120 1475.857 1476.595 1477.333 1478.070 1478.808 1479.545 1480.283 1481.020 1481.758
2010 1482.495 1483.233 1483.970 1484.708 1485.446 1486.183 1486.921 1487.658 1488.396 1489.134
2020 1489.871 1490.609 1491.346 1492.084 1492.821 1493.559 1494.296 1495.034 1495.771 1496.509
2030 1497.247 1497.984 1498.722 1499.459 1500.197 1500.934 1501.672 1502.409 1503.147 1503.885
2040 1504.622 1505.360 1506.097 1506.835 1507.573 1508.310 1509.048 1509.785 1510.523 1511.260
2050 1511.998 1512.735 1513.473 1514.210 1514.948 1515.686 1516.423 1517.161 1517.898 1518.636
2060 1519.374 1520.111 1520.849 1521.586 1522.324 1523.061 1523.799 1524.536 1525.274 1526.011
2070 1526.749 1527.487 1528.224 1528.962 1529.699 1530.437 1531.174 1531.912 1532.649 1533.387
2080 1534.125 1534.862 1535.600 1536.337 1537.075 1537.812 1538.550 1539.288 1540.025 1540.763
2090 1541.500 1542.238 1542.975 1543.713 1544.450 1545.188 1545.926 1546.663 1547.401 1548.138
2100 1548.876 1549.613 1550.351 1551.089 1551.826 1552.564 1553.301 1554.039 1554.776 1555.514
22 804 198 en - (01) 11

GENERAL DATA
Nm 0 1 2 3 4 5 6 7 8 9
2110 1556.251 1556.989 1557.727 1558.464 1559.202 1559.939 1560.677 1561.414 1562.152 1562.889
2120 1563.627 1564.365 1565.102 1565.840 1566.577 1567.315 1568.052 1568.790 1569.528 1570.265
2130 1571.003 1571.740 1572.478 1573.215 1573.953 1574.690 1575.428 1576.166 1576.903 1577.641
2140 1578.378 1579.116 1579.853 1580.591 1581.328 1582.066 1582.803 1583.541 1584.279 1585.016
2150 1585.754 1586.491 1587.229 1587.967 1588.704 1589.442 1590.179 1590.917 1591.654 1592.392
2160 1593.129 1593.867 1594.604 1595.342 1596.080 1596.817 1597.555 1598.292 1599.030 1599.768
2170 1600.505 1601.243 1601.980 1602.718 1603.455 1604.193 1604.930 1605.668 1606.406 1607.143
2180 1607.881 1608.618 1609.356 1610.093 1610.831 1611.568 1612.306 1613.043 1613.781 1614.519
2190 1615.256 1615.994 1616.731 1617.469 1618.207 1618.944 1619.682 1620.419 1621.157 1621.894
2200 1622.632 1623.369 1624.107 1624.844 1625.582 1626.320 1627.057 1627.795 1628.532 1629.270
2210 1630.007 1630.745 1631.482 1632.220 1632.958 1633.695 1634.433 1635.170 1635.908 1636.646
2220 1637.383 1638.121 1638.858 1639.596 1640.333 1641.071 1641.808 1642.546 1643.283 1644.021
2230 1644.759 1645.496 1646.234 1646.971 1647.709 1648.447 1649.184 1649.922 1650.659 1651.397
2240 1652.134 1652.872 1653.609 1654.347 1655.084 1655.822 1656.560 1657.297 1658.035 1658.772
2250 1659.510 1660.247 1660.985 1661.722 1662.460 1663.198 1663.935 1664.673 1665.410 1666.148
2260 1666.885 1667.623 1668.361 1669.098 1669.836 1670.573 1671.311 1672.048 1672.786 1673.523
2270 1674.261 1674.999 1675.736 1676.474 1677.211 1677.949 1678.686 1679.424 1680.162 1680.899
2280 1681.637 1682.374 1683.112 1683.849 1684.587 1685.324 1686.062 1686.800 1687.537 1688.275
2290 1689.012 1689.750 1690.487 1691.225 1691.962 1692.700 1693.437 1694.175 1694.913 1695.650
2300 1696.388 1697.125 1697.863 1698.601 1699.338 1700.076 1700.813 1701.551 1702.288 1703.026
2310 1703.763 1704.501 1705.239 1705.976 1706.714 1707.451 1708.189 1708.926 1709.664 1710.401
2320 1711.139 1711.876 1712.614 1713.352 1714.089 1714.827 1715.564 1716.302 1717.040 1717.777
2330 1718.515 1719.252 1719.990 1720.727 1721.465 1722.202 1722.940 1723.677 1724.415 1725.153
2340 1725.890 1726.628 1727.365 1728.103 1728.841 1729.578 1730.316 1731.053 1731.791 1732.528
2350 1733.266 1734.003 1734.741 1735.479 1736.216 1736.954 1737.691 1738.429 1739.166 1739.904
2360 1740.641 1741.379 1742.116 1742.854 1743.592 1744.329 1745.067 1745.804 1746.542 1747.280
2370 1748.017 1748.755 1749.492 1750.230 1750.967 1751.705 1752.442 1753.180 1753.917 1754.655
2380 1755.393 1756.130 1756.868 1757.605 1758.343 1759.080 1759.818 1760.555 1761.293 1762.031
2390 1762.768 1763.506 1764.243 1764.981 1765.719 1766.456 1767.194 1767.931 1768.669 1769.406
2400 1770.144 1770.881 1771.619 1772.356 1773.094 1773.832 1774.569 1775.307 1776.044 1776.782
2410 1777.520 1778.257 1778.995 1779.732 1780.470 1781.207 1781.945 1782.682 1783.420 1784.157
2420 1784.895 1785.633 1786.370 1787.108 1787.845 1788.583 1789.320 1790.058 1790.795 1791.533
2430 1792.271 1793.008 1793.746 1794.483 1795.221 1795.958 1796.696 1797.434 1798.171 1798.909
2440 1799.646 1800.384 1801.121 1801.859 1802.596 1803.334 1804.072 1804.809 1805.547 1806.284
2450 1807.022 1807.759 1808.497 1809.234 1809.972 1810.710 1811.447 1812.185 1812.922 1813.660
2460 1814.397 1815.135 1815.873 1816.610 1817.348 1818.085 1818.823 1819.560 1820.298 1821.035
2470 1821.773 1822.510 1823.248 1823.986 1824.723 1825.461 1826.198 1826.936 1827.674 1828.411
2480 1829.149 1829.886 1830.624 1831.361 1832.099 1832.836 1833.574 1834.312 1835.049 1835.787
2490 1836.524 1837.262 1837.999 1838.737 1839.474 1840.212 1840.949 1841.687 1842.425 1843.162
2500 1843.900 1844.637 1845.375 1846.113 1846.850 1847.588 1848.325 1849.063 1849.800 1850.538
2510 1851.275 1852.013 1852.750 1853.488 1854.226 1854.963 1855.701 1856.438 1857.176 1857.914
2520 1858.651 1859.389 1860.126 1860.864 1861.601 1862.339 1863.076 1863.814 1864.552 1865.289
2530 1866.027 1866.764 1867.502 1868.239 1868.977 1869.714 1870.452 1871.189 1871.927 1872.665
2540 1873.402 1874.140 1874.877 1875.615 1876.353 1877.090 1877.828 1878.565 1879.303 1880.040
2550 1880.778 1881.515 1882.253 1882.990 1883.728 1884.466 1885.203 1885.941 1886.678 1887.416
2560 1888.153 1888.891 1889.628 1890.366 1891.104 1891.841 1892.579 1893.316 1894.054 1894.792
2570 1895.529 1896.267 1897.004 1897.742 1898.479 1899.217 1899.954 1900.692 1901.429 1902.167
2580 1902.905 1903.642 1904.380 1905.117 1905.855 1906.593 1907.330 1908.068 1908.805 1909.543
2590 1910.280 1911.018 1911.755 1912.493 1913.230 1913.968 1914.706 1915.443 1916.181 1916.918
2600 1917.656 1918.393 1919.131 1919.868 1920.606 1921.344 1922.081 1922.819 1923.556 1924.294
2610 1925.031 1925.769 1926.507 1927.244 1927.982 1928.719 1929.457 1930.194 1930.932 1931.669
2620 1932.407 1933.145 1933.882 1934.620 1935.357 1936.095 1936.832 1937.570 1938.307 1939.045
2630 1939.783 1940.520 1941.258 1941.995 1942.733 1943.470 1944.208 1944.946 1945.683 1946.421
2640 1947.158 1947.896 1948.633 1949.371 1950.108 1950.846 1951.583 1952.321 1953.059 1953.796
2650 1954.534 1955.271 1956.009 1956.747 1957.484 1958.222 1958.959 1959.697 1960.434 1961.172
2660 1961.909 1962.647 1963.385 1964.122 1964.860 1965.597 1966.335 1967.072 1967.810 1968.547
2670 1969.285 1970.022 1970.760 1971.498 1972.235 1972.973 1973.710 1974.448 1975.186 1975.923
2680 1976.661 1977.398 1978.136 1978.873 1979.611 1980.348 1981.086 1981.823 1982.561 1983.299
2690 1984.036 1984.774 1985.511 1986.249 1986.986 1987.724 1988.462 1989.199 1989.937 1990.674
2700 1991.412 1992.149 1992.887 1993.625 1994.362 1995.100 1995.837 1996.575 1997.312 1998.050
2710 1998.787 1999.525 2000.262 2001.000 2001.738 2002.475 2003.213 2003.950 2004.688 2005.426
2720 2006.163 2006.901 2007.638 2008.376 2009.113 2009.851 2010.588 2011.326 2012.063 2012.801
2730 2013.539 2014.276 2015.014 2015.751 2016.489 2017.226 2017.964 2018.701 2019.439 2020.177
2740 2020.914 2021.652 2022.389 2023.127 2023.865 2024.602 2025.340 2026.077 2026.815 2027.552
2750 2028.290 2029.027 2029.765 2030.502 2031.240 2031.978 2032.715 2033.453 2034.190 2034.928
2760 2035.666 2036.403 2037.141 2037.878 2038.616 2039.353 2040.091 2040.828 2041.566 2042.303
2770 2043.041 2043.779 2044.516 2045.254 2045.991 2046.729 2047.466 2048.204 2048.941 2049.679
2780 2050.417 2051.154 2051.892 2052.629 2053.367 2054.104 2054.842 2055.580 2056.317 2057.055
2790 2057.792 2058.530 2059.267 2060.005 2060.742 2061.480 2062.218 2062.955 2063.693 2064.430
2800 2065.168 2065.905 2066.643 2067.380 2068.118 2068.856 2069.593 2070.331 2071.068 2071.806
12 22 804 198 en -0(01)

GENERAL DATA
Nm 0 1 2 3 4 5 6 7 8 9
2810 2072.543 2073.281 2074.019 2074.756 2075.494 2076.231 2076.969 2077.706 2078.444 2079.181
2820 2079.919 2080.656 2081.394 2082.132 2082.869 2083.607 2084.344 2085.082 2085.820 2086.557
2830 2087.295 2088.032 2088.770 2089.507 2090.245 2090.982 2091.720 2092.458 2093.195 2093.933
2840 2094.670 2095.408 2096.145 2096.883 2097.620 2098.358 2099.095 2099.833 2100.571 2101.308
2850 2102.046 2102.783 2103.521 2104.259 2104.996 2105.734 2106.471 2107.209 2107.946 2108.684
2860 2109.421 2110.159 2110.896 2111.634 2112.372 2113.109 2113.847 2114.584 2115.322 2116.059
2870 2116.797 2117.535 2118.272 2119.010 2119.747 2120.485 2121.222 2121.960 2122.698 2123.435
2880 2124.173 2124.910 2125.648 2126.385 2127.123 2127.860 2128.598 2129.335 2130.073 2130.811
2890 2131.548 2132.286 2133.023 2133.761 2134.499 2135.236 2135.974 2136.711 2137.449 2138.186
2900 2138.924 2139.661 2140.399 2141.136 2141.874 2142.612 2143.349 2144.087 2144.824 2145.562
2910 2146.299 2147.037 2147.774 2148.512 2149.250 2149.987 2150.725 2151.462 2152.200 2152.937
2920 2153.675 2154.413 2155.150 2155.888 2156.625 2157.363 2158.100 2158.838 2159.575 2160.313
2930 2161.051 2161.788 2162.526 2163.263 2164.001 2164.738 2165.476 2166.214 2166.951 2167.689
2940 2168.426 2169.164 2169.901 2170.639 2171.376 2172.114 2172.852 2173.589 2174.327 2175.064
2950 2175.802 2176.539 2177.277 2178.014 2178.752 2179.490 2180.227 2180.965 2181.702 2182.440
2960 2183.177 2183.915 2184.653 2185.390 2186.128 2186.865 2187.603 2188.340 2189.078 2189.815
2970 2190.553 2191.291 2192.028 2192.766 2193.503 2194.241 2194.978 2195.716 2196.453 2197.191
2980 2197.929 2198.666 2199.404 2200.141 2200.879 2201.616 2202.354 2203.092 2203.829 2204.567
2990 2205.304 2206.042 2006.779 2207.517 2208.254 2208.992 2209.729 2210.467 2211.205 2211.942
3000 2212.680 2213.417 2214.155 2214.893 2215.630 2216.368 2217.105 2217.843 2218.580 2219.318
3010 2220.055 2220.793 2221.531 2222.268 2223.006 2223.743 2224.481 2225.218 2225.956 2226.693
3020 2227.431 2228.168 2228.906 2229.644 2230.381 2231.119 2231.856 2232.594 2233.332 2234.069
3030 2234.807 2235.544 2236.282 2237.019 2237.757 2238.494 2239.232 2239.969 2240.707 2241.445
3040 2242.182 2242.920 2243.657 2244.395 2245.132 2245.870 2246.608 2247.345 2248.083 2248.820
3050 2249.558 2250.295 2251.033 2251.771 2252.508 2253.246 2253.983 2254.721 2255.458 2256.196
3060 2256.933 2257.671 2258.408 2259.146 2259.884 2260.621 2261.359 2262.096 2262.834 2263.572
3070 2264.309 2265.047 2265.784 2266.522 2267.259 2267.997 2268.734 2269.472 2270.209 2270.947
3080 2271.685 2272.422 2273.160 2273.897 2274.635 2275.372 2276.110 2276.847 2277.585 2278.323
3090 2279.060 2279.798 2280.535 2281.273 2282.010 2282.748 2283.486 2284.223 2284.961 2285.698
3100 2286.436 2287.173 2287.911 2288.648 2289.386 2290.124 2290.861 2291.599 2292.336 2293.074
3110 2293.811 2294.549 2295.287 2296.024 2296.762 2297.499 2298.237 2298.974 2299.712 2300.449
3120 2301.187 2301.925 2302.662 2303.400 2304.137 2304.875 2305.612 2306.350 2307.087 2307.825
3130 2308.562 2309.300 2310.038 2310.775 2311.513 2312.250 2312.988 2313.726 2314.463 2315.201
3140 2315.938 2316.676 2317.413 2318.151 2318.888 2319.626 2320.364 2321.101 2321.839 2322.576
3150 2323.314 2324.051 2324.789 2325.526 2326.264 2327.002 2327.739 2328.477 2329.214 2329.952
3160 2330.689 2331.427 2332.165 2332.902 2333.640 2334.377 2335.115 2335.852 2336.590 2337.327
3170 2338.065 2338.802 2339.540 2340.278 2341.015 2341.753 2342.490 2343.228 2343.966 2344.703
3180 2345.441 2346.178 2346.916 2347.653 2348.391 2349.128 2349.866 2350.604 2351.341 2352.079
3190 2352.816 2353.554 2354.291 2355.029 2355.766 2356.504 2357.241 2357.979 2358.717 2359.454
3200 2360.192 2360.929 2361.667 2362.405 2363.142 2363.880 2364.617 2365.355 2366.092 2366.830
3210 2367.567 2368.305 2369.042 2369.780 2370.518 2371.255 2371.993 2372.730 2373.468 2374.205
3220 2374.943 2375.681 2376.418 2377.156 2377.893 2378.631 2379.368 2380.106 2380.844 2381.581
3230 2382.319 2383.056 2383.794 2384.531 2385.26 9 2386.006 2386.744 2387.481 2388.219 2388.957
3240 2389.694 2390.432 2391.169 2391.907 2392.645 2393.382 2394.120 2394.857 2395.595 2396.332
3250 2397.070 2397.807 2398.545 2399.282 2400.020 2400.758 2401.495 2402.233 2402.970 2403.708
3260 2404.445 2405.183 2405.920 2406.658 2407.396 2408.133 2408.871 2409.608 2410.346 2411.083
3270 2411.821 2412.559 2413.296 2414.034 2414.771 2415.509 2416.246 2416.984 2417.721 2418.459
3280 2419.197 2419.934 2420.672 2421.409 2422.147 2422.884 2423.622 2424.360 2425.097 2425.835
3290 2426.572 2427.310 2428.047 2428.785 2429.522 2430.260 2430.998 2431.735 2432.473 2433.210
3300 2433.948 2434.685 2435.423 2436.160 2436.898 2437.635 2438.373 2439.111 2439.848 2440.586
3310 2441.323 2442.061 2442.799 2443.536 2444.274 2445.011 2445.749 2446.486 2447.224 2447.961
3320 2448.699 2449.437 2450.174 2450.912 2451.649 2452.387 2453.124 2453.862 2454.599 2455.337
3330 2456.075 2456.812 2457.550 2458.287 2459.025 2459.762 2460.500 2461.238 2461.975 2462.713
3340 2463.450 2464.188 2464.925 2465.663 2466.400 2467.138 2467.875 2468.613 2469.351 2470.088
3350 2470.826 2471.563 2472.301 2473.039 2473.776 2474.514 2475.251 2475.989 2476.726 2477.464
3360 2478.201 2478.939 2479.677 2480.414 2481.152 2481.889 2482.627 2483.364 2484.102 2484.839
3370 2485.577 2486.314 2487.052 2487.790 2488.527 2489.265 2490.002 2490.740 2491.478 2492.215
3380 2492.953 2493.690 2494.428 2495.165 2495.903 2496.640 2497.378 2498.115 2498.853 2499.591
3390 2500.328 2501.066 2501.803 2502.541 2503.278 2504.016 2504.754 2505.491 2506.229 2506.966
3400 2507.704 2508.441 2509.179 2509.917 2510.654 2511.392 2512.129 2512.867 2513.604 2514.342
3410 2515.079 2515.817 2516.554 2517.292 2518.030 2518.767 2519.505 2520.242 2520.980 2521.718
3420 2522.455 2523.193 2523.930 2524.668 2525.405 2526.143 2526.880 2527.618 2528.355 2529.093
3430 2529.831 2530.568 2531.306 2532.043 2532.781 2533.518 2534.256 2534.993 2535.731 2536.469
3440 2537.206 2537.944 2538.681 2539.419 2540.156 2540.894 2541.632 2542.369 2543.107 2543.844
3450 2544.582 2545.319 2546.057 2546.794 2547.532 2548.270 2549.007 2549.745 2550.482 2551.220
3460 2551.957 2552.695 2553.433 2554.170 2554.908 2555.645 2556.383 2557.120 2557.858 2558.595
3470 2559.333 2560.071 2560.808 2561.546 2562.283 2563.021 2563.758 2564.496 2565.233 2565.971
3480 2566.708 2567.446 2568.184 2568.921 2569.659 2570.396 2571.134 2571.872 2572.609 2573.347
3490 2574.084 2574.822 2575.559 2576.297 2577.034 2577.772 2578.510 2579.247 2579.985 2580.722
3500 2581.460 2582.197 2582.935 2583.672 2584.410 2585.148 2585.885 2586.623 2587.360 2588.098
22 804 198 en - (01) 13

GENERAL DATA
Nm 0 1 2 3 4 5 6 7 8 9
3510 2588.835 2589.573 2590.311 2591.048 2591.786 2592.523 2593.261 2593.998 2594.736 2595.473
3520 2596.211 2596.948 2597.686 2598.424 2599.161 2599.899 2600.636 2601.374 2602.112 2602.849
3530 2603.587 2604.324 2605.062 2605.799 2606.537 2607.274 2608.012 2608.750 2609.487 2610.225
3540 2610.962 2611.700 2612.437 2613.175 2613.912 2614.650 2615.387 2616.125 2616.863 2617.600
3550 2618.338 2619.075 2619.813 2620.551 2621.288 2622.026 2622.763 2623.501 2624.238 2624.976
3560 2625.713 2626.451 2627.188 2627.926 2628.664 2629.401 2630.139 2630.876 2631.614 2632.351
3570 2633.089 2633.827 2634.564 2635.302 2636.039 2636.777 2637.514 2638.252 2638.990 2639.727
3580 2640.465 2641.202 2641.940 2642.677 2643.415 2644.152 2644.890 2645.627 2646.365 2647.103
3590 2647.840 2648.578 2649.315 2650.053 2650.791 2651.528 2652.266 2653.003 2653.741 2654.478
3600 2655.216 2655.953 2656.691 2657.428 2658.166 2658.904 2659.641 2660.379 2661.116 2661.854
3610 2662.591 2663.329 2664.066 2664.804 2665.542 2666.279 2667.017 2667.754 2668.492 2669.229
3620 2669.967 2670.705 2671.442 2672.180 2672.917 2673.655 2674.392 2675.130 2675.867 2676.605
3630 2677.343 2678.080 2678.818 2679.555 2680.293 2681.030 2681.768 2682.506 2583.243 2683.981
3640 2684.718 2685.456 2686.193 2686.931 2687.668 2688.406 2689.144 2689.881 2690.619 2691.356
3650 2692.094 2692.831 2693.569 2694.306 2695.044 2695.781 2696.519 2697.257 2697.994 2698.732
3660 2699.469 2700.207 2700.945 2701.682 2702.420 2703.157 2703.895 2704.632 2705.370 2706.107
3670 2706.845 2707.583 2708.320 2709.058 2709.795 2710.533 2711.270 2712.008 2712.745 2713.483
3680 2714.221 2714.958 2715.696 2716.433 2717.171 2717.908 2718.646 2719.384 2720.121 2720.859
3690 2721.596 2722.334 2723.071 2723.809 2724.546 2725.284 2726.021 2726.759 2727.497 2728.234
3700 2728.972 2729.709 2730.447 2731.185 2731.922 2732.660 2733.397 2734.135 2734.872 2735.610
3710 2736.347 2737.085 2737.823 2738.560 2739.298 2740.035 2740.773 2741.510 2742.248 2742.985
3720 2743.723 2744.460 2745.198 2745.936 2746.673 2747.411 2748.148 2748.886 2749.624 2750.361
3730 2751.099 2751.836 2752.574 2753.311 2754.049 2754.786 2755.524 2756.261 2756.999 2757.737
3740 2758.474 2759.212 2759.949 2760.687 2761.424 2762.162 2762.900 2763.637 2764.375 2765.112
3750 2765.850 2766.587 2767.325 2768.062 2768.800 2769.538 2770.275 2771.013 2771.750 2772.488
3760 2773.225 2773.963 2774.700 2775.438 2776.176 2776.913 2777.651 2778.388 2779.126 2779.864
3770 2780.601 2781.339 2782.076 2782.814 2783.551 2784.289 2785.026 2785.764 2786.501 2787.239
3780 2787.977 2788.714 2789.452 2790.189 2790.927 2791.664 2792.402 2793.139 2793.877 2794.615
3790 2795.352 2796.090 2796.827 2797.565 2798.302 2799.040 2799.778 2800.515 2801.253 2801.990
3800 2802.728 2803.465 2804.203 2804.940 2805.678 2806.416 2807.153 2807.891 2808.628 2809.366
3810 2810.103 2810.841 2811.579 2812.316 2813.054 2813.791 2814.529 2815.266 2816.004 2816.741
3820 2817.479 2818.217 2818.954 2819.692 2820.429 2821.167 2821.904 2822.642 2823.379 2824.117
3830 2824.854 2825.592 2826.330 2827.067 2827.805 2828.542 2829.280 2830.018 2830.755 2831.493
3840 2832.230 2832.968 2833.705 2834.443 2835.180 2835.918 2836.656 2837.393 2838.131 2838.868
3850 2839.606 2840.343 2841.081 2841.818 2842.556 2843.293 2844.031 2844.769 2845.506 2846.244
3860 2846.981 2847.719 2848.457 2849.194 2849.932 2850.669 2851.407 2852.144 2852.882 2853.619
3870 2854.357 2855.094 2855.832 2856.570 2857.307 2858.045 2858.782 2859.520 2860.258 2860.995
3880 2861.733 2862.470 2863.208 2863.945 2864.683 2865.420 2866.158 2866.896 2867.633 2868.371
3890 2869.108 2869.846 2870.583 2871.321 2872.058 2872.796 2873.533 2874.271 2875.009 2875.746
3900 2876.484 2877.221 2877.959 2878.697 2879.434 2880.172 2880.909 2881.647 2882.384 2883.122
3910 2883.859 2884.597 2885.334 2886.072 2886.810 2887.547 2888.285 2889.022 2889.760 2890.497
3920 2891.235 2891.973 2892.710 2893.448 2894.185 2894.923 2895.660 2896.398 2897.135 2897.873
3930 2898.611 2899.348 2900.086 2900.823 2901.561 2902.298 2903.036 2903.773 2904.511 2905.249
3940 2905.986 2906.724 2907.461 2908.199 2908.937 2909.674 2910.412 2911.149 2911.887 2912.624
3950 2913.362 2914.099 2914.837 2915.574 2916.312 2917.050 2917.787 2918.525 2919.262 2920.000
3960 2920.737 2921.475 2922.212 2922.950 2923.687 2924.425 2925.163 2925.900 2926.638 2927.375
3970 2928.113 2928.851 2929.588 2930.326 2931.063 2931.801 2932.538 2933.276 2934.013 2934.751
3980 2935.489 2936.226 2936.964 2937.701 2938.439 2939.176 2939.914 2940.652 2941.389 2942.127
3990 2942.864 2943.602 2944.339 2945.077 2945.814 2946.552 2947.290 2948.027 2948.765 2949.502
4000 2950.240 2950.977 2951.715 2952.452 2953.190 2953.927 2954.665 2955.403 2956.140 2956.878
4010 2957.615 2958.353 2959.091 2959.828 2960.566 2961.303 2962.041 2962.778 2963.516 2964.253
4020 2964.991 2965.729 2966.466 2967.204 2967.941 2968.679 2969.416 2970.154 2970.891 2971.629
4030 2972.366 2973.104 2973.842 2974.579 2975.317 2976.054 2976.792 2977.530 2978.267 2979.005
4040 2979.742 2980.480 2981.217 2981.955 2982.692 2983.430 2984.167 2984.905 2985.643 2986.380
4050 2987.118 2987.855 2988.593 2989.331 2990.068 2990.806 2991.543 2992.281 2993.018 2993.756
4060 2994.493 2995.231 2995.969 2996.706 2997.444 2998.181 2998.919 2999.656 3000.394 3001.131
4070 3001.869 3002.606 3003.344 3004.082 3004.819 3005.557 3006.294 3007.032 3007.770 3008.507
4080 3009.245 3009.982 3010.720 3011.457 3012.195 3012.932 3013.670 3014.407 3015.145 3015.883
4090 3016.620 3017.358 3018.095 3018.833 3019.570 3020.308 3021.046 3021.783 3022.521 3023.258
4100 3023.996 3024.733 3025.471 3026.208 3026.946 3027.684 3028.421 3029.159 3029.896 3030.634
4110 3031.371 3032.109 3032.846 3033.584 3034.322 3035.059 3035.797 3036.534 3037.272 3038.010
4120 3038.747 3039.485 3040.222 3040.960 3041.697 3042.435 3043.172 3043.910 3044.647 3045.385
4130 3046.123 3046.860 3047.598 3048.335 3049.073 3049.810 3050.548 3051.285 3052.023 3052.760
4140 3053.498 3054.236 3054.973 3055.711 3056.448 3057.186 3057.924 3058.661 3059.399 3060.136
4150 3060.874 3061.611 3062.349 3063.086 3063.824 3064.562 3065.299 3066.037 3066.774 3067.512
4160 3068.249 3068.987 3069.725 3070.462 3071.200 3071.937 3072.675 3073.412 3074.150 3074.887
4170 3075.625 3076.363 3077.100 3077.838 3078.575 3079.313 3080.050 3080.788 3081.525 3082.263
4180 3083.000 3083.738 3084.476 3085.213 3085.951 3086.688 3087.426 3088.164 3088.901 3089.639
4190 3090.376 3091.114 3091.851 3092.589 3093.326 3094.064 3094.802 3095.539 3096.277 3097.014
4200 3097.752 3098.489 3099.227 3099.964 3100.702 3101.439 3102.177 3102.915 3103.652 3104.390
14 22 804 198 en -0(01)en

GENERAL DATA
Nm 0 1 2 3 4 5 6 7 8 9
4210 3105.127 3105.865 3106.603 3107.340 3108.078 3108.815 3109.553 3110.290 3111.028 3111.765
4220 3112.503 3113.240 3113.978 3114.716 3115.453 3116.191 3116.928 3117.666 3118.404 3119.141
4230 3119.879 3120.616 3121.354 3122.091 3122.829 3123.566 3124.304 3125.042 3125.779 3126.517
4240 3127.254 3127.992 3128.729 3129.467 3130.204 3130.942 3131.679 3132.417 3133.155 3133.892
4250 3134.630 3135.367 3136.105 3136.843 3137.580 3138.318 3139.055 3139.793 3140.530 3141.268
4260 3142.005 3142.743 3143.480 3144.218 3144.956 3145.693 3146.431 3147.168 3147.906 3148.643
4270 3149.381 3150.118 3150.856 3151.594 3152.331 3153.069 3153.806 3154.544 3155.281 3156.019
4280 3156.757 3157.494 3158.232 3158.969 3159.707 3160.444 3161.182 3161.919 3162.657 3163.395
4290 3164.132 3164.870 3165.607 3166.345 3167.083 3167.820 3168.558 3169.295 3170.033 3170.770
4300 3171.508 3172.245 3172.983 3173.720 3174.458 3175.196 3175.933 3176.671 3177.408 3178.146
4310 3178.883 3179.621 3180.358 3181.096 3181.833 3182.571 3183.309 3184.046 3184.784 3185.521
4320 3186.259 3186.997 3187.734 3188.472 3189.209 3189.947 3190.684 3191.422 3192.159 3192.897
4330 3193.635 3194.372 3195.110 3195.847 3196.585 3197.322 3198.060 3198.798 3199.535 3200.273
4340 3201.010 3201.748 3202.485 3203.223 3203.960 3204.698 3205.436 3206.173 3206.911 3207.648
4350 3208.386 3209.123 3209.861 3210.598 3211.336 3212.073 3212.811 3213.549 3214.286 3215.024
4360 3215.761 3216.499 3217.237 3217.974 3218.712 3219.449 3220.187 3220.924 3221.662 3222.399
4370 3223.137 3223.875 3224.612 3225.350 3226.087 3226.825 3227.562 3228.300 3229.037 3229.775
4380 3230.512 3231.250 3231.988 3232.725 3233.463 3234.200 3234.938 3235.676 3236.413 3237.151
4390 3237.888 3238.626 3239.363 3240.101 3240.838 3241.576 3242.313 3243.051 3243.789 3244.526
4400 3245.264 3246.001 3246.739 3247.477 3248.214 3248.952 3249.689 3250.427 3251.164 3251.902
4410 3252.639 3253.377 3254.115 3254.852 3255.590 3256.327 3257.065 3257.802 3258.540 3259.277
4420 3260.015 3260.752 3261.490 3262.228 3262.965 3263.703 3264.440 3265.178 3265.916 3266.653
4430 3267.391 3268.128 3268.866 3269.603 3270.341 3271.078 3271.816 3272.553 3273.291 3274.029
4440 3274.766 3275.504 3276.241 3276.979 3277.716 3278.454 3279.191 3279.929 3280.667 3281.404
4450 3282.142 3282.879 3283.617 3284.354 3285.092 3285.830 3286.567 3287.305 3288.042 3288.780
4460 3289.517 3290.255 3290.992 3291.730 3292.468 3293.205 3293.943 3294.680 3295.418 3296.156
4470 3296.893 3297.631 3298.368 3299.106 3299.843 3300.581 3301.318 3302.056 3302.793 3303.531
4480 3304.269 3305.006 3305.744 3306.481 3307.219 3307.956 3308.694 3309.431 3310.169 3310.906
4490 3311.644 3312.382 3313.119 3313.857 3314.594 3315.332 3316.070 3316.807 3317.545 3318.282
4500 3319.020 3319.757 3320.495 3321.232 3321.970 3322.708 3323.445 3324.183 3324.920 3325.658
4510 3326.395 3327.133 3327.870 3328.608 3329.346 3330.083 3330.821 3331.558 3332.296 3333.033
4520 3333.771 3334.509 3335.246 3335.984 3336.721 3337.459 3338.196 3338.934 3339.671 3340.409
4530 3341.146 3341.884 3342.622 3343.359 3344.097 3344.834 3345.572 3346.310 3347.047 3347.785
4540 3348.522 3349.260 3349.997 3350.735 3351.472 3352.210 3352.948 3353.685 3354.423 3355.160
4550 3355.898 3356.635 3357.373 3358.110 3358.848 3359.585 3360.323 3361.061 3361.798 3362.536
4560 3363.273 3364.011 3364.749 3365.486 3366.224 3366.961 3367.699 3368.436 3369.174 3369.911
4570 3370.649 3371.386 3372.124 3372.862 3373.599 3374.337 3375.074 3375.812 3376.550 3377.287
4580 3378.025 3378.762 3379.500 3380.237 3380.975 3381.712 3382.450 3383.187 3383.925 3384.663
4590 3385.400 3386.138 3386.875 3387.613 3388.350 3389.088 3389.825 3390.563 3391.301 3392.038
4600 3392.776 3393.513 3394.251 3394.989 3395.726 3396.464 3397.201 3397.939 3398.676 3399.414
4610 3400.151 3400.889 3401.626 3402.364 3403.102 3403.839 3404.577 3405.314 3406.052 3406.789
4620 3407.527 3408.264 3409.002 3409.740 3410.477 3411.215 3411.952 3412.690 3413.427 3414.165
4630 3414.903 3415.640 3416.378 3417.115 3417.853 3418.590 3419.328 3420.065 3420.803 3421.541
4640 3422.278 3423.016 3423.753 3424.491 3425.229 3425.966 3426.704 3427.441 3428.179 3428.916
4650 3429.654 3430.391 3431.129 3431.866 3432.604 3433.342 3434.079 3434.817 3435.554 3436.292
4660 3437.029 3437.767 3438.504 3439.242 3439.979 3440.717 3441.455 3442.192 3442.930 3443.667
4670 3444.405 3445.143 3445.880 3446.618 3447.355 3448.093 3448.830 3449.568 3450.305 3451.043
4680 3451.781 3452.518 3453.256 3453.993 3454.731 3455.468 3456.206 3456.943 3457.681 3458.419
4690 3459.156 3459.894 3460.631 3461.369 3462.106 3462.844 3463.582 3464.319 3465.057 3465.794
4700 3466.532 3467.269 3468.007 3468.744 3469.482 3470.219 3470.957 3471.695 3472.432 3473.170
4710 3473.907 3474.645 3475.383 3476.120 3476.858 3477.595 3478.333 3479.070 3479.808 3480.545
4720 3481.283 3482.021 3482.758 3483.496 3484.233 3484.971 3485.708 3486.446 3487.183 3487.921
4730 3488.658 3489.396 3490.134 3490.871 3491.609 3492.346 3493.084 3493.822 3494.559 3495.297
4740 3496.034 3496.772 3497.509 3498.247 3498.984 3499.722 3500.459 3501.197 3501.935 3502.672
4750 3503.410 3504.147 3504.885 3505.622 3506.360 3507.098 3507.835 3508.573 3509.310 3510.048
4760 3510.785 3511.523 3512.260 3512.998 3513.736 3514.473 3515.211 3515.948 3516.686 3517.423
4770 3518.161 3518.898 3519.636 3520.374 3521.111 3521.849 3522.586 3523.324 3524.062 3524.799
4780 3525.537 3526.274 3527.012 3527.749 3528.487 3529.224 3529.962 3530.699 3531.437 3532.175
4790 3532.912 3533.650 3534.387 3535.125 3535.862 3536.600 3537.337 3538.075 3538.813 3539.550
4800 3540.288 3541.025 3541.763 3542.500 3543.238 3543.976 3544.713 3545.451 3546.188 3546.926
4810 3547.663 3548.401 3549.138 3549.876 3550.614 3551.351 3552.089 3552.826 3553.564 3554.302
4820 3555.039 3555.777 3556.514 3557.252 3557.989 3558.727 3559.464 3560.202 3560.939 3561.677
4830 3562.415 3463.152 3563.890 3564.627 3565.365 3566.102 3566.840 3567.577 3568.315 3569.052
4840 3569.790 3570.528 3571.265 3572.003 3572.740 3573.478 3574.216 3574.953 3575.691 3576.428
4850 3577.166 3577.903 3578.641 3579.378 3580.116 3580.854 3581.591 3582.329 3583.066 3583.804
4860 3584.541 3585.279 3586.016 3586.754 3587.492 3588.229 3588.967 3589.704 3590.442 3591.179
4870 3591.917 3592.655 3593.392 3594.130 3594.867 3595.605 3596.342 3597.080 3597.817 3598.555
4880 3599.292 3600.030 3600.768 3601.505 3602.243 3602.980 3603.718 3604.456 3605.193 3605.931
4890 3606.668 3607.406 3608.143 3608.881 3609.618 3610.356 3611.094 3611.831 3612.569 3613.306
4900 3614.044 3614.781 3615.519 3616.256 3616.994 3617.731 3618.469 3619.207 3619.944 3620.682
22 804 198 en - (01) 15

GENERAL DATA
Nm 0 1 2 3 4 5 6 7 8 9
4910 3621.419 3622.157 3622.895 3623.632 3624.370 3625.107 3625.845 3626.582 3627.320 3628.057
4920 3628.795 3629.532 3630.270 3631.008 3631.745 3632.483 3633.220 3633.958 3634.695 3635.433
4930 3636.171 3636.908 3637.646 3638.383 3639.121 3639.858 3640.596 3641.333 3642.071 3642.809
4940 3643.546 3644.284 3645.021 3645.759 3646.496 3647.234 3647.971 3648.709 3649.447 3650.184
4950 3650.922 3651.659 3652.397 3653.135 3653.872 3654.610 3655.347 3656.085 3656.822 3657.560
4960 3658.297 3659.035 3659.772 3660.510 3661.248 3661.985 3662.723 3663.460 3664.198 3664.935
4970 3665.673 3666.410 3667.148 3667.886 3668.623 3669.361 3670.098 3670.836 3671.573 3672.311
4980 3673.049 3673.786 3674.524 3675.261 3675.999 3676.736 3677.474 3678.211 3678.949 3679.687
4990 3680.424 3681.162 3681.899 3682.637 3683.374 3684.112 3684.850 3685.587 3686.325 3687.062
5000 3687.800 3688.537 3689.275 3690.012 3690.750 3691.488 3692.225 3692.963 3693.700 3694.438
16 2 804 198 en -0(01)e1

GENERAL DATA
Conversion table for units of pressure in gases, steam and fluids

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

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

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

760
22 804 198 en - (01) 17

17
GENERAL DATA
Conversion table for units of power, energy and heat quantity

mit 1 Nm = 1 kp m = 0,102 kp m
9,81
J kJ kW h kcal PS h kp m
1 J (= 1 Nm = 1 Ws) = 1 0,001 2,78 x 10-7 2,39 x 10-4 3,77 x 10-7 0,102
1 kJ = 1000 1 2,78 x 10-4 0,239 3,77 x 10-4 102
1 kW h = 3 600 000 3 600 1 860 1,36 367 000
1 kcal = 4 200 4,2 0,00116 1 0,00158 427
1 PS h = 2 650 000 2 650 0,736 632 1 270 000
1 kp m = 9,81 0,00981 2,72 x 10-6 0,00234 3,7 x 10-6 1
18 2 804 198e0
- (01)1)1
GENERAL DATA
Conversion table for units of mechanical stress (strength)

with 1 Pa = 1 N/m2 = 1 kp/m2 = 0,102 kp/m2
9,81
Pa N/mm2 daN/cm2 daN/mm2 kp/cm 2 kp/mm2
1 Pa (= 1 N/m2) = 1 10-6 10-5 10-7 0,102 x 10-4 0,102 x 10-6
1 N/mm2 (=1 M Pa) = 1 000 000 1 10 0,1 10,2 0,102
1 daN/cm2 (= 1 bar) = 100 000 0,1 1 0,01 1,02 0,0102
1 daN/mm2 (= 1 hbar) = 10 000 000 10 100 1 102 1,02
1 kp/cm2 (= 1 at) = 98 100 0,0981 0,981 0,00981 1 0,01
1 kp/mm2 = 9 810 000 9,81 98,1 0,981 100 1
22 804 198 en - (01) 19

GENERAL DATA
Practically equivalent units for pressure and mechanical stress (strength)

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

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

~ _ 1 p/cm2
~
= 1 Mp/cm2 _ 1 kp/mm2
~ _ 1 at
~ _ 1 kp/m2
~
100
20 22 804 198en (1)1)

GENERAL DATA
Units of temperature and conversion formulas
Units Conversion into
Nomenclature
Symbol K o
C R
o o
F
Kelvin K 1 (K-273,16o) 4/5 (K-273,16o) 9/5 (K-273,16o)+32o
Celsius o
C o
C+273,16o 1 4/5 oC 9/5 oC+32o
Réaumur o
R 5/4 oR+273,16o 5/4 oR 1 9/4 oR+32o
Fahrenheit o
F 5/9 (oF-32o)+ 273,16o 5/9 (oF-32o) 4/9 (oF -32o) 1
Example: Conversion from oR in oC : oC = 5/4 oR
The fundamental temperature unit is the Kelvin (K).
The symbol used is the T.
The equally used Rankine temperature scale for absolute temperatures is related to K
as follows:
o
Rank = 9/5 K.
22 804 198 en - (01) 21

21
GENERAL DATA
Power, energy and heat flow

1 Nm/s = 1 kp m/s = 0,102 kp m/s
9,81
W kW kcal/s kcal/h kp m/s PS HP
1 W( = 1 N m/s 1 0,001 2,39 x 10-4 0,860 0,102 0,00136 0,00134

= 1 J/s)
1 kW = 1 000 1 0,239 860 102 1,36 1,341
1 kcal/s = 4 190 4,19 1 3600 427 5,69 5,61
1 kcal/h = 1,16 0,00116 1 1 0,119 0,00158 0,00156

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

3 600
22
10 22 804 198en -0(01)en01
GENERAL DATA
Speed
1 km / h = 0,27778 m / s 1m/s = 3,6 km / h
1 mile / h = 1,60934 km / h 1 km / h = 0,62137 mile / h
1 kn (Knoten) = 1,852 km / h 1 km / h = 0,53996 kn
1 ft / min = 0,3048 m / min 1 m / min = 3,28084 ft / min
Conversion for
km / h m/s km / h mile / h kn ft / min km / h mile / h km / h

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

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

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

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

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

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

800 222 2880 497 1287 --- 244 4,5 s 2,8 s 7 min 30 s
1000 278 3600 621 1609 --- 305 3,6 s 2,2 s 6 min
1200 333 1) --- 746 --- --- 366 3s --- 5 min
1400 389 --- 870 --- --- 427 2,6 s --- 4 min 17 s
The Mach number "Ma" (no official unit of measurement) gives the factor by which a body is faster, than the speed
of sound.
Thus "Ma" = 1.3 means 1.3 times as fast as the speed of sound.
1) Approximate velocity of sound in the air.
22 804 198 en - (01) 23

23
GENERAL DATA
Units of mass (weight)
Conversion for
grain dram oz lb long cwt sh cwt long tn sh tn
in in in in in in in in
g g g kg kg kg t t
1,0 0,0648 1,77 28,3 0,454 50,8 45,4 1,02 0,907

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

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

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

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

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

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

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

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

8,5 0,551 15,1 241 3,86 432 386 8,64 7,71
9,0 0,583 15,9 255 4,08 457 408 9,14 8,16
9,5 0,616 16,8 269 4,31 483 431 9,65 8,62
Example: 1 lb = 0,454 kg; 5 long ton = 5,08 t; 42 oz = 1190 g.
24 22 804 198en -0(01)en01

GENERAL DATA
Units of volume, flow rates
Conversion for
in3 ft3 yd3 pt liq pt gal gal ft3 / min

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

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

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

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

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

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

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

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

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

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

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

9,5 156 269 7,26 5,40 4,50 43,2 36,0 16,1
Example: 1 in3 = 16,4 cm3; 3 gal (UK) = 13,6 l
22 804 198 en - (01) 25

GENERAL DATA
Fuel consumption
1 g / PS h = 1,3596 g / kW h 1 g / kW h = 0,7355 g / PS h
1 lb / HP H = 608,277 g / kW h 1 g / kW h = 0,001644 lb / HP H
1 liq pt / HP H = 634,545 cm3 / kW h 1 cm3 / kW h = 0,001576 liq pt / HP H
1 pt (UK) HP H = 762,049 cm3 / kW h 1 cm3 / kW h = 0,001312 pt (UK) / HP H
Conversion for Conversion for Conversion for
g/PS h g/kW h lb liq pt pt (UK) miles miles

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

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

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

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

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

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

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

240 g / PS h = 326,3 g / kW h 0,68 liq pt / HP H = 431,5 cm3 / kW h 18 miles / gal (US) = 13,1 l / 100 km
26 22 804 198 en -0(01)e

GENERAL DATA
CALCULATION EXAMPLES
Angles of slope
Travel speeds
V = 360 V= km/h
t t = Seconds needed for 100 m
Example: At a constant speed, a travel time of 18 seconds is needed for a distance of 100 meters.
V(km/h) = 360 = 20 km/h

18
22 804 198 en - (01) 227

GENERAL DATA
Hydraulic outputs (pumps/motors) Speeds of hydraulic motors
P=p˙Q P= kW
600 p = bar n = Vp ˙ np n = motor speed in rpm
Q= l/min VM motor speed in rpm
Vp = geometrical displacement of the
Example: For a pump with an effective discharge pump in cm3/revolution
rate of Q = 80 l/min, at a pressure of np = turning speed of the pump in rpm
p = 300 bar the output is to be calculated. VM= geometrical displacement of the
motor in cm3/rpm
P(kW) = 300 ˙ 80 = 40 kW
Example: For a given pump speed np = 2,150 rpm,
600 a geometrical displacement of the pump
Vp = 11 cm3/rpm and a geometrical dis-
placement of the motor of VM =8 cm3/rpm
we obtain
Stroking times of cylinders

n = 11 ˙ 2150 = 2956 min-1
8
t = VZyl.˙ 60 t = Sekunden/Seconds
Qp VZyl.= Volume of the cylinder(s) in
dm3
Qp = theoretical discharge rate of the

pump(s) in l/min
Example: For a given pump discharge rate of Qp =

80 l/min and a cylinder volume of VZyl. =
10 dm3 we obtain
t(Sek.) = 10 ˙ 60 = 7,5 Seconds

80
28 22 804 198 en -0(01)1)

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

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

screw black-plated or phosphatized
nut bright
thread oiled

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

The calculated tightening torques MA are valid for tightening of the screws by hand
Units of measurement
The tightening torques specified in the tables are expressed in Nm (newtonmeter). If older torque wrenches are
used for tightening, the Nm values must be converted to the formerly used kpm (kilopondmeter) unit. The
conversion is simple since 1 kpm is almost exactly the same as 10 Nm (exact coversion factor: 1 kpm = 9.81
Nm). The small difference can be ignored so that for conversion purposes the Nm value must only be divided
by 10.
Example: 1840
1840 Nm = = 184 kpm
10
22 804 198 en - (01) 29

GENERAL DATA
Bolts with standard thread DIN 13 - 13
Thread Material Tightening torques

nominal Ø quality MA in Nm
total total total
0,101) 0,122) 0,16 (L)3)
M5 8.8 4,9 5,5 6,5

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

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

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

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

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

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

10.9 3000 3300 4000
12.9 3500 3900 4700
1)
Screw and/or nut electro-galvanized.
2)
Screw black-plated or phophatized, thread oiled.
3)
Screws with liquid screw fixer, e.g. Loctite 242, 243.
30 22 804 198 en-(01)en01

GENERAL DATA
Bolts with metric fine thread DIN 13 - 13
Thread Material Tightening torques

nominal Ø quality MA in Nm
total total total
0,101) 0,122) 0,16 (L)3)
M 8x1 8.8 22 24,5 30
10.9 32 36 43
12.9 38 43 51
M 10x1 8.8 45 52 62
10.9 67 76 91
12.9 78 89 107
M 10x1,25 8.8 43 49 58
10.9 64 72 86
12.9 74 84 100
M 12x1,25 8.8 77 87 104

10.9 112 125 150
12.9 130 150 180
M 14x1,5 8.8 121 135 165
10.9 175 200 240
12.9 205 235 280
M 16x1,5 8.8 180 205 250

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

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

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

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

10.9 1350 1500 1850
12.9 1550 1800 2150
M 30x2 8.8 1370 1490 1740
10.9 1940 2120 2480
12.9 2270 2480 2900
1)
Screw and/or nut electro-galvanized.
2)
Screw black-plated or phophatized, thread oiled.
3)
Screws with liquid screw fixer, e.g. Loctite 242, 243.
22 804 198 en - (01) 31

31
GENERAL DATA
O&K Double - hex. bolts
Tightening torque
d1 x l1 Part No. SW l1 l2 d2 h s (Nm)
(mm) (mm) (mm) (mm) (mm) (mm) (mm)
M 10 x 30 1 183 269 11 30 20 17 7 4
M 10 x 45 0 974 642 11 45 26 17 7 4
M 10 x 55 0 974 643 11 55 26 17 7 4 60
M 10 x 80 0 974 644 11 80 26 17 7 4
M 10 x 100 0 974 645 11 100 26 17 7 4
M 12 x 30 1 183 270 13 30 22 19 8 5
M 12 x 50 0 974 646 13 50 30 19 8 5
M 12 x 65 0 974 647 13 65 30 19 8 5 100
M 12 x 90 0 974 648 13 90 30 19 8 5
M 12 x 120 0 974 649 13 120 30 19 8 5
M 14 x 60 0 974 650 15 60 34 21 9 6
M 14 x 105 0 974 651 15 105 34 21 9 6 160
M 14 x 150 1 129 496 15 150 40 21 9 6
M 16 x 40 0 269 245 19 40 35 24 19 6
M 16 x 70 0 974 652 19 70 38 24 10 6
M 16 x 90 0 941 458 19 90 38 26 10 4 250
M 16 x 100 0 269 244 19 100 38 24 10 6
M 16 x 120 0 974 653 19 120 44 24 10 6
M 20 x 120 2 417 924 22 120 52 30 12 6 490
Class of strength : 10.9, Surface protection : A3B
32 22 804 198 en -(01)

0 en01
GENERAL DATA
O&K Double - hex. necked - down bolts
Tightening torque
d1 x l1 Part No. SW l1 l2 d2 d3 h s (Nm)
(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (Nm)
M 14 x 85 1 187 089 15 85 18 21 11 7 6 130
M 16 x 90 0 990 145 19 90 20 28 13 10 6
M 16 x 190 0 996 167 19 190 20 28 13 10 6 215
M 16 x 210 0 996 168 19 210 20 28 13 10 6
M 18 x 95 0 990 144 22 95 23 30 14 11 6 270
M 18 x 140 2 455 068 22 140 23 30 14 11 6
M 20 x 100 0 257 954 24 100 25 34 16 12 6
M 20 x 140 1 122 621 24 140 25 34 16 12 6 400
M 22 x 100 0 978 791 27 100 27 37 18 12 7
M 22 x 140 0 268 852 27 140 27 37 18 12 7 550
M 24 x 2 x 100 0 253 709 30 100 30 39 20,5 13 7
M 24 x 2 x 120 0 978 790 30 120 30 39 20,5 13 7
M 24 x 2 x 140 0 994 227 30 140 30 39 20,5 13 7 770
M 24 x 2 x 160 0 268 281 30 160 30 39 20,5 13 7
M 24 x 2 x 180 1 121 567 30 180 30 39 20,5 13 7

M 27 x 2 x 120 0 257 953 32 120 34 44 23,5 14 8
M 27 x 2 x 140 2 157 959 32 140 34 44 23,5 14 8 1135
M 27 x 2 x 160 0 268 291 32 160 34 44 23,5 14 8
M 30 x 2 x 140 0 994 228 36 140 38 50 27 15 8
M 30 x 2 x 190 0 978 797 36 190 38 50 27 15 8 1700
M 30 x 2 x 200 4 525 286 36 200 38 50 27 15 8
M 30 x 2 x 260 1 183 509 36 260 38 50 27 15 8
Class of strength: 10.9, Surface protection : A3B
22 804 198 en - (01) 33

33
GENERAL DATA
Tightening torques for SAE flange-system
Tighten bolts in several stages. * *

Sequence: 1, 2, 3, 4
Thread Wrench size Tightening
M 10 11 mm 60 Nm
M 12 13 mm 100 Nm
M 14 15 mm 160 Nm
M 16 19 mm 250 Nm
** See THB "Fittings, pipes and hoses".
Tightening angles
6° = 1 min.
30° = 5 min.
45° = 7,5 min.
60° = 10 min.
90° = 15 min.
135° = 22,5 min.
220° = 36,7 min.
34 2 804 198 en - (01)

GENERAL DATA
Notes 2800145
22 804 198 en - (01) 35

35
GENERAL DATA
A P
Angles of slope ................................................. 27 Power, energy and heat flow............................. 22
Practically equivalent units for pressure and
mechanical stress (strength) ............................. 20
B
Bolts with metric fine thread DIN 13 – 13 ........... 31
Q
Bolts with standard thread DIN 13 – 13 ............. 30
Quantities of force, energy and power ................. 5
Quantities of space and mass ............................. 3
C
Calculation examples ........................................ 27
S
Conversion for units of area ................................ 7
SI - and additional units ...................................... 3
Conversion for units of length .............................. 6
Speed............................................................... 23
Conversion from foot and inch
to metric measures ............................................. 8 Speeds of hydraulic motors .............................. 28
Conversion from Newton-meter "Nm" into foot- Stroking times of cylinders ................................ 28
pounds "ft.lb."...................................................... 9
Conversion table for units of mechanical
stress (strength) ................................................ 19 T
Conversion table for units of power, energy Tightening angles ............................................. 34
and heat quantity .............................................. 18 Tightening torques............................................ 29
Conversion table for units of pressure in gases,
Tightening torques for SAE flange-system ........ 34
steam and fluids................................................ 17
Time-related quantities ....................................... 4
Conversion tables ............................................... 6
Travel speeds................................................... 27
F
U
Foreword............................................................. 1
Units of mass (weight) ...................................... 24
Fuel consumption.............................................. 26
Units of temperature and conversion formulas .. 21
Units of volume, flow rates................................ 25
G
General information........................................... 29
H
Hydraulic outputs (pumps/motors) ..................... 28
O
O&K Double - hex. Bolts ................................... 32
O&K Double - hex. necked - down bolts ............ 33
2 804 198 en - (01)

GENERAL DATA
2 804 198 en - (01)

3 842 955.000 en
May 2014
Service Manual
Sealing, protective, testing
and cleaning agents
6015 - 6090
3 842 955.000 en

Department: Product Health
Tel. +49 (0) 231 922-3
Fax +49 (0) 231 922-5005
Email: documentation.HEX@cat.com
are liable to compensation. All rights reserved in the event of patent, utility model, or registered design regis-
tration.
3 842 955.000 en
TABLE OF CONTENTS
FOREWORD _________________________________________________________________________ 1
SAFETY INSTRUCTIONS ______________________________________________________________ 1

Risks of disregarding the safety regulations _____________________________________________ 1
Personnel _______________________________________________________________________ 2
Tools and auxiliaries _______________________________________________________________ 2
Securing the working equipment ______________________________________________________ 2
Sealing, protective, testing and cleaning agents __________________________________________ 3
Hydraulic and lubricating system ______________________________________________________ 3
Modifications of the machine _________________________________________________________ 3
Recommissioning _________________________________________________________________ 3
CONSERVATION OF MACHINES, EITHER… ______________________________________________ 4

… pre-assembled machine modules, new delivered, but not assembled _______________________ 4
Fuel tank ________________________________________________________________________ 4
Hydraulic tank ____________________________________________________________________ 4
Hydraulic cylinders ________________________________________________________________ 4
Ports, tubes & hose ends ___________________________________________________________ 4
Machined surfaces ________________________________________________________________ 4
Cab ____________________________________________________________________________ 4
Gearboxes _______________________________________________________________________ 4
Batteries ________________________________________________________________________ 4
Diesel engines ____________________________________________________________________ 5
Motor module with electric motors _____________________________________________________ 5
Hydraulic pumps and motors _________________________________________________________ 5
Undercarriage with roller bearing _____________________________________________________ 5
Oil cooler module _________________________________________________________________ 5
Water cooler _____________________________________________________________________ 5
Valve block assembly for boom _______________________________________________________ 5
Switch cabinet ____________________________________________________________________ 5
Air filter unit ______________________________________________________________________ 5
…OR ALREADY COMMISSIONED, BUT NOT TAKEN TO PRODUCTION ________________________ 6
…OR MACHINES TAKEN OUT OF PRODUCTION AND PARKED FOR A LONGER PERIOD ________ 6
CONSERVATION OF SPARE PARTS _____________________________________________________ 7

Gearboxes _______________________________________________________________________ 7
Cylinder _________________________________________________________________________ 7
Hydraulic pumps and motors _________________________________________________________ 7
Diesel engine_____________________________________________________________________ 7
Spare parts in general ______________________________________________________________ 7
3 842 955.000 en
CONSERVATION AGENTS _____________________________________________________________ 8

Corrosion inhibitor _________________________________________________________________ 8
Sealing agent (Hylomar® SQ 321/M) ___________________________________________________ 8
Liquid thread adhesive _____________________________________________________________ 8
Metal adhesive (OMNIFIT® SEAL 54H)_________________________________________________ 9
Adhesives for plastics (SICOMET® 50) _________________________________________________ 9
Adhesive for o-rings (SICOMET® 40) _________________________________________________ 10
Solid lubricants paste spray (gleitmo® 815) _____________________________________________ 10
Compound spray (Silentan®) ________________________________________________________ 10
Mineral-based lubricating paste _____________________________________________________ 11
Lithium saponified grease __________________________________________________________ 11
Surface crack checking agent (Met-L-check®) __________________________________________ 11
APPENDIX A _______________________________________________________________________ 12
Hydraulic cylinder protection on the machine… ___________________________________________ 12
NOTES ____________________________________________________________________________ 14
NOTES ____________________________________________________________________________ 15
3 842 955.00 en
Foreword Safety Instructions

This Service Manual (SM) provides a compilation Warnings and symbols
of the directions for using Caterpillar Global Mining
Hydraulic Mining Shovels GmbH (CGM HMS The following signs are used in the manual to des-
GmbH) recommended sealing, protective, testing ignate instructions of particular importance:
and cleaning agents.
All of these agents have CGM HMS approval and Precautionary rules and
are necessary for various assembly procedures. measures designed to protect
the machine operator and other
The agents can all be ordered from CGM HMS persons from life-threatening
Spare Parts Service.
ganger or injuries and to prevent
This recommendation provides procedures and
extensive damage.
recommendations for the warehousing and/or stor-
age of CGM HMS shovels and spare parts sold by Information and precautionary
CGM HMS GmbH in Dortmund/Germany to the measures designed to prevent
nominated dealership and/or end-user and pre- damage to the machine or other
sents the basic requirement for the warranty period
as per the dealer agreement or warranty certificate. property.
All procedures and recommendations are valid for

a period of one (1) year only, unless otherwise
stipulated. Risks of disregarding the safety
regulations
If this basis period will be exceeded, please see
details in this recommendation or get in contact This CGM HMS hydraulic shovel has been built in
with CGM HMS GmbH in Dortmund/Germany. accordance with state-of-the-art standards and the
recognized safety rules.
However, operating the machine if a fault is sus-
pected or has occurred, or carrying out repair work
inexpertly may
 endanger the lives of persons in contact
with it
 damage the machine and other property.
The hydraulic shovel must be stopped immediately
on any damage being suspected or occurring to
ensure that the safety of the operator, of other per-
sons at the place of use or of other material prop-
erty is not compromised.
All components of CGM HMS machines are care-
fully coordinated. Trouble-free operation and a long
service life can only be achieved with original CGM
HMS spare parts.
1
3 842 955.00 en
Personnel
Tools and auxiliaries
The machine must not be started by unauthorized
persons. Tools, hoists, slings, trestles and other devices
It must therefore be secured or locked. must be in a reliable, safe state.
Observe the accident prevention regulations. Metal splinters may cause injury when attachment
bolts are being driven in or out. A brass or copper
The hydraulic shovel may be operated, serviced or
mandrel should therefore be used for this purpose,
repaired only by specially trained and qualified
and goggles must be worn.
personnel with the appropriate technical
knowledge. For climbing onto or off the machine, use only the
ladders, steps, platforms and handrails provided
If such knowledge is lacking, detailed instruction
for this purpose.
must be given by experienced personnel, e.g. from
CGM HMS. Always keep ladders, steps and platforms in a non-
slip state. Remove any oil, grease, earth, clay,
The personnel must have read and understood the
snow, ice and other foreign matter immediately.
Operation and Maintenance Manual and in particu-
lar the chapter ‘Fundamental Safety Instructions’.
Only such persons may start up the machine dur-
ing assembly work in order to adjust the attach- Securing the attachment
ments.
Incorrect operation of the machine or the attach- Secure the machine and the attachment against
ments may give rise to life-threatening situations. inadvertent and unauthorized starting. Position at-
During all works, always observe the start-up and tachment on the ground in such a way that no
shut-down procedures prescribed in the Operation movements can be made when mechanical or hy-
and Maintenance Manual. draulic connections become detached.
Personal protective gear and working clothing: Secure any equipment or component which is to
be mounted or dismantled or whose position is to
Wear a safety helmet, safety footwear, gloves and be changed using hoists or appropriate sling-
safety glasses. ing/supporting devices to prevent them from mov-
Wear closely fitting working clothing when working ing, slipping or falling inadvertently.
on the machine. Loose, wide garments may catch Systems and units (e.g. pipes, coolers, hydraulic
on machine parts and result in injury. reservoirs, compressed-air reservoirs) must be
Persons carrying out work at greater heights must properly depressurized before being opened.
be equipped with safety harnesses. Always put on Protective devices on moving machine parts may
a tested harness which must be equipped with fall be opened or removed only when the drive unit is
arrestors and safety lines. stationary and protected against inadvertent start-
If the work to be carried out requires auxiliaries, ing.
e.g. marshallers, the competences of each individ- Before recommissioning, all protective devices
ual helper must be clearly defined beforehand. must be installed.
The individual responsibilities must be carefully Before carrying out assembly work, the machine
observed to avoid unclear competences endanger- and the equipment must be secured against inad-
ing safety. vertent movement, e.g. by placing blocks under the
wheels or tracks and by standing the attachment
on the ground.
2
3 842 955.00 en
Manufacturers safety instructions

The safety instructions contained in this Service
Manual with respect to accident prevention and Unauthorized conversions or modifications of the
those set out on the packing of the sealing, protec- hydraulic shovel are forbidden for reasons of safe-
tive, testing and cleaning agents must be ob- ty.
served. The nominal pressure of pressure relief valves
must not be modified without explicit approval from
Hydraulic and lubricating system CGM HMS.
Do not remove the lead seals from pressure-relief
Always observe the safety regulations applicable to valves and pressure accumulators.
the product when handling oils, greases and other
chemical substances. Recommissioning
Unused but open bores, pipelines and hose con-
nections must be closed in a pressure-tight man- Prior to recommissioning:
ner.  Grease all lubricating points.
Refill collected hydraulic oil back into the hydraulic
system only through the return-flow filters. Dispose  Check all oil levels and make the neces-
of waste oil without polluting the environment. sary corrections.
Observe the correct working sequence when fitting
or replacing components or equipment. The work-  Carry out function checks of all repaired
ing sequence has been specified and tested by components
qualified experts.
When carrying out work and especially work on the  Check all functions of the shovel including
electrical system involving tools, spare parts, etc. the brakes during a test run. Release the
coming into contact with electric cables, the battery hydraulic shovel for re-commissioning only
must be disconnected beforehand. Disconnect first
after all functions have been found to work
the negative pole and then the positive pole. When
reconnecting the battery, connect first the positive correctly.
and then the negative pole.
Replace defective, mechanically pre-stressed units
only as an entirety. Never open them. In excep-
tional cases, open only when the system and the
operating sequence are precisely known. This Ser-
vice Manual contains no information on such work.
When the machine is at operating temperature, the
consumables are at least at the same temperature.
Precautions must therefore be taken to prevent
burning or scalding.
Be careful when handling acids, e.g. battery acid.
Acid splashes may injure the eyes and the skin.
Do not smoke when handling flammable liquids.
Be careful with open flames and unprotected light.
Not only fuel but also other consumables often
have a low flash point and catch fire easily.
3
3 842 955.00 en
Conservation of machines, Ports, tubes & hose ends

either…
Do not open the boxes containing the hoses. If the
boxes are opened or hoses are delivered separate-
… pre-assembled machine modules, ly, all hose ends have to be covered. Open ports
new delivered, but not assembled have to be covered by applicable plugs as well.
Most of the tubes are dry; i.e. there is no protec-
CGM HMS shovels will be shipped ex factory in tion, just the plugs at the end. Please check plugs
numerous packages. Large steel structures and regular and replace missing plugs immediately.
modules are unpacked. Other packages are wood- Prior to installation, tubes and hoses have to be
en boxes and the parts and components are pro- checked about dirt inside and to be cleaned if nec-
tected for a period of maximum two (2) months. In essary.
case that the unit will not be commissioned upon
arrival or shortly after arrival, the dealer / customer
/ user has to make sure that all boxes and pallets Machined surfaces
are properly stored and protected. If possible, all
boxes and pallets should be stored under roof. If necessary, re-coat any exposed machined bores
If the machine will not be assembled within three and surfaces with a suitable rust preven-
(3) months, the following measures have to be tive/Corrosion inhibitor (see chapter with recom-
done: mended protective, testing and cleaning agents).
Fuel tank
Cab
Fill fuel tank to prevent moisture condensation in
the tank. Coat filler neck and cap threads with oil. All windows, doors, holes and vents have to be
closed or covered by applicable material.
Hydraulic tank
Gearboxes
Fill tank to operating level. Coat filler neck and cap
threats with oil. All gearboxes are filled ex factory up to the normal
oil level. This kind of conservation is good for a pe-
riod of six months. Any longer storage period re-
Hydraulic cylinders quires a filling to the top level by oil as per our
specification.
Where possible, retract cylinders for a minimum Note:
exposure. Coat the remaining exposed piston rod Prior to getting the machine into operation, release
surface with a suitable or or grease (see chapter the oil down to the normal level.
with recommended protective, testing and cleaning
agents).
Hydraulic Cylinders have to be filled with hydraulic
oil as per our specification. It could remain in the
Batteries
cylinder during installation
Remove the batteries from the machine and store
them in the workshop. Protect the batteries from
temperature extremes. Coat the terminals and ca-
ble ends with acid resistant petroleum jelly.
4
3 842 955.00 en
Diesel engines
Water cooler
Please get in contact with the local dealer or sub-
sidiary of the engine manufacturer, in order to get 6030 / 6040 – is installed in the counterweight and
detailed information about engine protection. empty. All holes are covered. The protection has to
be checked on a regular basis and renewed if
necessary.
Motor module with electric motor 6050 - 6090 – will be shipped separately and emp-
ty. It is covered by a wooden box. The protection
has to be checked on a regular basis and renewed
Please get in contact to local dealer or subsidiary
if necessary.
of the motor manufacturer, in order to get detailed
information about motor protection. 6015 / 6018 – installed on the engine module; filled
with coolant and required conservation. Regular
checks of leakages are necessary. In case of leak-
ages, please refill, by using coolant and conserva-
Hydraulic pumps and motors tion fluid as per our instruction.
Check possible leakages. All hoses have to be Valve block assembly for boom
plugged, in order to keep dirt out of the system.
Note: All tubes and main valves have to be filled by suit-
Hydraulic pumps are with oil. Prior to take the ma- able conservation fluid and all open holes have to
chine into operation, release the hydraulic oil from be properly closed.
the hydraulic tank by opening the gate valves and Grease drum and grease unit
make sure that the pumps and motors are ex-
Has to be checked prior to take the machine into
hausted from air (for details about filling and bleed-
operation having regard to water condensate. If
ing the pumps, please refer to section 8 of the Ser-
necessary, contaminated grease has to be re-
vice Manual).
placed against new grease as per our specifica-
6090 – machines will be shipped without assem- tion.
bled suction system.
Switch cabinet
Undercarriage with roller bearing Hot and dry areas – on a regular basis, protected
plugs have to be checked, if the protection is still
The protection of the roller bearing has to be okay. If not, it must be renewed.
checked on a regular basis and renewed, if neces- Hot and wet areas (high humidity) – the desiccant
sary. has to be replaced on a regular basis, depending
on the condition.
Cold and dry areas – action to be taken is similar
Oil cooler module to the hot and dry areas
Cold and wet areas – take the same action as
Will be shipped completely closed and the oil level necessary in hot and wet areas.
is up to the highest possible point (bottom edge
hose connection). Please check machined surfac- Air filter unit
es. If necessary re-coat the resp. area, incl. any
drill holes. Checks have to be done on a regular
Will be delivered in a wooden box and this kind of
basis.
packing is good for approx. 6 months. After six
months and prior to taking the machine into opera-
tion, new filters have to be installed. Housing has
to be cleaned.
Note:
In case the machines will be delivered suction-unit
disassembled, the main pumps are not pre-filled
and necessary conservation must be applied!
5
3 842 955.00 en
…or already commissioned, …or machines taken out of

but not taken to production production and parked for a
When the machine has been completely assem-
longer period
bled, but will not be taken into production for a pe-
riod longer than two weeks, the following has to be For machines taken out of production for a period
done: longer than two weeks, all before mentioned re-
All requirements for machines not assembled has quirements for
to be made (if and when applicable), PLUS the fol- “Conservation of machines, new delivered, but not
lowing measures every two weeks: commissioned”
 Engines or motors have to be started and run and
up to operating temperature. “Conservation of machines already commissioned,
but not taken to production”
 All hydraulic functions have to be operated have to be done, if and when necessary.
several times, until the hydraulic oil reaches
the operating temperature. General Information:
 Travel the shovel at least 20 meter / 66 ft for- Prior to taking the machine into production, please
ward and backwards, to ensure that the track make sure that ALL components are filled with the
chain has completed a full turn. respective medium to the required level.
 Turn the superstructure 360 degrees in both

directions, at least five times, to ensure that
the grease for the roller bearing and for the
toothing of the swing ring is well distributed.
 Refill fuel and hydraulic oil, in case of con-
sumption.
 Check if all coated, open areas are still cov-
ered by rust protection or any other coating
material. If necessary, recoat unprotected are-
as. For cylinder protection see “Appendix A”.
6
3 842 955.00 en
Conservation of Spare Parts Hydraulic pumps and motors

Gearboxes All hydraulic pumps and motors delivered through
the parts department will be shipped properly
Scope packed and are protected for a period of 12
The following specifications apply to internal con- months maximum, stored under roof in closed
servation of gearboxes that are to be stored indi- buildings/stores. On arrival of the components,
vidually without oil filling. packages have to be checked for damages. In
A longer storage time requires the applicable con- case the packages are damaged, an appropriate
servation. conservation has to be made. If necessary, get in
contact to our service department.
Conservation period
The ex factory conservation measures protect
against rust for Diesel engines
- 6 months when stored indoor
Please get in contact with the local dealer or sub-
Conservation sidiary of the engine manufacturer, in order to get
Whatever the type of storage, gearboxes must be detailed information about engine protection.
protected against moisture and dirt. All gearboxes
in the warehouse have to be completely filled with
gearbox oil as per our specification. This oil has to
be drained down to the max. oil level. Spare parts in general
Any extension of the storage period requires re-
freshing of the conservation. All spare parts should be stored under roof in a
dry, clean and proper area. It must be sure that the
spare parts can be installed on the machine with-
out any rework.
Hydraulic cylinders
Scope
The following specifications apply to all cylinders.
Conservation has to be carried out to protect the
cylinders against fretting corrosion and aggressive
environmental influences.
Conservation
Cylinders on site should be stored indoor. They
have to be retracted as far as possible and filled
completely with hydraulic oil according to our spec-
ification. The oil can remain in the cylinder during
installation.
7
3 842 955.00 en
Conservation agents Liquid thread adhesive

Corrosion inhibitor The following product is approved by CGM HMS
for securing (medium tight) and sealing threaded
Application connections.
All pins, bearings and machined surfaces of the at- Threaded connections treated with these securing
tachment or in equipment components must be adhesives are resistant against vibrations although
treated with lubrication oil. they can still be loosened.
Consumption Application
The quantity required depends on the type and Screws and bolts can be used in the condition in
size of the component. which they are delivered.
Available Very dirty threads are to be cleaned with a grease
400 ml / 13.5 oz spray can, solvent. The solvent must be allowed to evaporate
CGM HMS part No. 0014064 completely.
For screws and bolts, apply a ring of the adhesive
to the first three thread pitches.
For blind-end threaded holes, coat the internal
Sealing agent (Hylomar® SQ 321/M) thread.
Application For threaded through-holes, apply the adhesive to
the screw/bolt thread.
For permanently elastic sealing of threads, en-
gines, gearboxes etc. Tighten the screw/bolt to the prescribed torque.
Features Available
Elastic at temperatures between -50° and +300°C. 50 ml / 1.7 oz bottle,
It prevents element formation between differing CGM HMS part No. 8432623
metal surfaces. Is non-inflammable, non-toxic and
is a bad conductor of heat.
Resistance
Resistant to all oils and lubricants, all fuels, air, wa-
ter, gases, water/glycol and water/methanol mix-
tures, and to continuous vibration.
Application
Brush onto cleaned, oil-free surfaces. Wait approx.
19 minutes between application and assembly to
allow the solvent content time to evaporate.
Re-using
Possible, provided that sealing surface is free of
dirt and grease. Points at which sealing film has
broken away can be re-sealed with fresh sealer.
Fresh sealer vulcanizes with older sealer without
any special treatment being necessary.
Removal
Hylomar is alcohol-soluble and can therefore be
removed by, for example, using a cloth saturated in
methylated spirits.
Available
25 g / 0.9 oz tube,
CGM HMS part No. 1471961
8
3 842 955.00 en
Metal adhesive (OMNIFIT® SEAL

Adhesives for plastics (SICOMET®
54H)
50)
This product is approved by CGM HMS GmbH.
Application Application
Swing bearing and track pads mountings. Plastic to plastic; plastic to rubber.
Clean all traces of paint and grease from all con- The adhesive contains acrylic cyanide ester which
tact surfaces using local thinner. brings about an instantaneous adhesion.
Apply a continuous strip (see Fig. 1), approx. 1mm Humidity should be between 50% and 60% during
/ 0.04” thick, in a ring around each bolt hole. Keep application.
the ring a slight distance away from being Hardening time: 2 – 5 seconds.
squeezed into the thread when the bolts are tight- Storage stability
ened up. 6 months at +22 °C / 71.6 °F.
Storage in a refrigerator (+5 °C / 41 °F) lengthens
the storage life. Fresh adhesive can be freeze
stored.
Solubility
In acetone, methylene-chloride, nitro-methane.
Irritating to eyes, respiratory

system and skin. Cyanoacry-
late. Bonds within seconds skin
and eyes.
Avoid any contact with skin and

eyes.
Fig. 1 Keep working areas well venti-

lated.
Tighten the bolts within 30 – 45 minutes. Harden-
Before using the adhesive:
ing begins after adhesive has been applied and
has contact to the air.
Read, understand and follow
Re-tighten the bolts after 50 – 60 operating hours
and in the intervals given in the machine’s Servic- manufacturer’s instructions de-
ing and Inspection Instructions. livered with the product.
Disassembly
Before lifting off a swing bearing, loosen it at sev-
eral points using a crow bar. Available
Available 20 ml / 0.68 oz tube,
200 g / 0.44 lb tube, CGM HMS part No. 0970376
9
3 842 955.00 en
Adhesive for o-rings (SICOMET® 40)

Solid lubricants paste spray
Application (gleitmo® 815)
Used as an adhesive to form endless rubber piping
(as supplied) into o-rings. Application
Place the rubber piping into groove and cut off High-performance lubricant for reducing friction
slightly longer than required. and wear, where low coefficients of friction are en-
Cut one end at a right angle (do not chamfer it) by countered, among others for fitting and removal of
pulling a sharp, clean, grease-free blade through it. bearings, bushings etc. and for badly accessible
Cut the other end to length with a straight cut. points.
Cut the rubber material 1 – 2 mm / 0.04” – 0.08” Method of application
shorter than needed so that the O-ring lies with Spray
light tension in the groove and does not fall out. Composition
Higher tension causes the ring to twist in its groove Molybdenum disulphide and other solid lubricants.
during installation and results in leakages.
Available
Glue the two ends together in butt joint. Push the
400 ml / 13.5 oz spray can
two ends together (with the hands) for at least 20
seconds. CGM HMS part No. 2764305
Irritating to eyes, respiratory

system and skin. Cyanoacry-
Compound spray (Silentan®)
late. Bonds within seconds skin
and eyes. Special lubricant, grease and bitumen free with EP
additives and an especially high viscosity.
Avoid any contact with skin and Application
eyes. Lubricant for swing bearings, exposed gear
wheels, racks, guides etc.
Keep working areas well venti- Adhesion and plasticity
lated. Very tough, no fracture formation
Method of application
Before using the adhesive: Spray
Read, understand and follow

Do NOT inhale solvents.
manufacturer’s instructions de-
livered with the product. Keep work-places well ventilat-
ed.
Available Avoid any contact with skin and

20 gr / 0.7 oz tube eyes.
Do NOT spray into open flames.
Store spray cans at temperature

below +50 °C / 122 °F.
Available
400 ml / 13.5 oz spray can
10
3 842 955.00 en
Mineral-based lubricating paste

Surface crack checking agent (Met-
Application L-check®)
Assembly paste for reduction of friction and fretting
corrosion on press and bearing seats, pins, Cracks and other faults in metal pieces, forged and
splines, V-roller etc. cast steel parts can be localized using a dye-
Compatibility to seal rings penetration check. This is the simplest method of
Good testing.
Method of application Further test, e.g. magnaflux (magnetic-powder) or
Brush ultra-sonic testing, require specialist knowledge
and special equipment.
Temperature range
Checking
-30 °C to +150 °C / -30 °F to +302 °F
Clean the area to be checked.
Available
Spray on the Red penetration fluid and allow 5 –
750 g / 1.65 lb can
10 minutes for it to penetrate.
Remove the Red penetration fluid using the special
cleaner.
Spray on the White developer.
Any cracks/faults shown up as red “veins” against
the white background. The extent of the “veining”
Lithium saponified grease and the time allowed for development provide indi-
cations as to the depth of the cracks/faults.
Application Wipe off the developer with a cloth.
Lithium saponified grease with solid constituent
(e.g. Molycote multi-purpose grease), resistant to Do not inhale solvents.
water, consistency 2 for highly stressed plain and
roller/ball bearings.
Keep work-places well ventilat-
Method of application
ed.
Brush, grease gun
Temperature range Avoid any contact with skin and
-30 °C to +130 °C / -22 °F to + 266 °F
eyes.
Available (in different packaging units)
e.g. 180 kg / 397 lb drum Do not spray into open flames.
Store spray cans at temperature
Part Nos. for other packaging units on request. below +50 °C / 122 °F.
General Information
If and when applicable, we recommend to use the The dye-penetration (Met-L-check) test requires
Fluid Film® corrosion protection, provided by only the following:
Caterpillar. Available
RED penetration fluid
Special CLEANER
WHITE developer fluid
11
3 842
2 955.00 en
Append
dix A He
ere the stick cylinder
c rod is fully protected (see
Fig
g. 3).
Hydraullic cylind
der prote
ection on
n Ad ection only nnecessary for the boom,
dditional prote
bucket and clam cylinder rood.
the mac
chine…
…protection
n without disa
assembly, ex
xample show
wn
on a 6060 F
FS.
Operate the e machine an nd put the sh

hovel attach-
ment in thiss position (se
ee Fig. 2).
Fig. 2
Fig
g. 3
Us
se a soft brussh to protect / cover the rod
r thin with
gre
ease (see Fig g. 4)
We ommend Lith ium saponified grease.
e like to reco
g. 4
Fig
12
3 842
2 955.00 en
Use tarpaulin to achieve e additional protection

p (se
ee If the
t machine needs to be started agaiin, the pro-
Fig. 5 and F
Fig. 6). tec b removed aand the rod must be
ction has to be
Perform thaat job on all cylinder
c rods of the boomm, cleeaned – for example
e withh petrol; pleas
se collect
stick and cla
am cylinderss. thee spillage. Once the macchine is back to the park
poosition, the co
onservation nneeds to be done
d again.
Fig. 5
Fig. 6
13
3 842 955.00 en
Notes
14
3 842 955.00 en
Notes
15
© Copyright Unless expressly permitted, the transfer and reproduction of this manual/file and
Caterpillar Global the sale and disclosure of its content is prohibited. Contraventions are liable to
Mining HMS GmbH compensation. All rights reserved in the event of patent, utility model, or registered
2014 design registration.
3 842 953.00 en
February 2014
Service Manual
for Fittings, Tube Assemblies
and Hose Assemblies
6015 - 6090
3 842 953.00 en

Tel. +49 (0) 231 922 4340
Fax +49 (0) 231 922 5005
are liable to compensation. All rights reserved in the event of patent, utility model, or registered design
registration.
Printed in Germany
3 842 953.00 en
CONTENTS
FOREWORD__________________________________________________________________________ 1

Requirements of Personnel ........................................................................................................................1
Pay attention to the hazard warnings on the machine ...............................................................................1
Pay attention to warnings and safety information in the manuals and instructions ...................................1
Depressurize components..........................................................................................................................2
Preset components.....................................................................................................................................2
Use original replacement parts...................................................................................................................2
PIPES FOR DIFFERENT MEDIA __________________________________________________________ 3

Materials for Tubes and Hoses ......................................................................................................3
Dependencies and Changes in Pipe Systems ...............................................................................3
Replacement Parts Service............................................................................................................3
Hose Assemblies............................................................................................................................4
Installation Examples..................................................................................................................................5
Separation and Mounting ...........................................................................................................................6
CONNECTIONS _______________________________________________________________________ 7
Requirements for Tube and Hose Assembly Connections.............................................................7
Instructions for Assembling Tube Joints.....................................................................................................7
Identification on drawings ...........................................................................................................................7
Connections, Adapters, Flanges, and Plugs ..............................................................................................8
General Assembly Requirements...............................................................................................................8
Tightening Sequence for Tube and Hose Assemblies ...............................................................................8
Assembly Instructions for Connectors with O-Ring Seals (ORFS) ............................................................9
Assembly Instructions for 37° Flare Couplings ........................................................................................10
Assembly Instructions for SAE J512 45° Flare Connectors .....................................................................11
Assembly Instructions for Air Conditioning System Connections ............................................................12
Assembly Instructions for Clamping Ring Connections ...........................................................................14
Assembly Instructions for Clamping Ring Connections ...........................................................................14
SAE 1926/ISO 6149 STOR connections (outside tube thread with O-ring) .................................15
Connection Expression Codes .................................................................................................................15
Visual Information on Heavy-Duty STOR and Light-Duty STOR Connectors..........................................15
Assembly Instructions for Adjustable STOR Connections ...........................................................16
Assembly Instructions for Non-Adjustable STOR Connections....................................................17
Assembly Instructions for Smooth ISO 9974 Screw-In Connections ...........................................19
Assembly Instructions for Four-Hole SAE J518/ISO 6149/1E4217 Flange Connections in
Hydraulics System........................................................................................................................21
3 842 953.00 en
Assembly Instructions for Threaded Drain Plugs .........................................................................22

Assembly Instructions for Tube Thread Connections...................................................................23
1E0279P Hose Clamps ................................................................................................................24
Basics .......................................................................................................................................................24
Screw Hose Clamps .................................................................................................................................24
Belleville Washer – Band Clamps ............................................................................................................24
T-Bolt Clamp with Spring – Band Clamps ................................................................................................24
Shaft Sleeve – Band Clamps....................................................................................................................24
V-Band Clamp ..........................................................................................................................................24
Additional Standard Elements for Flange Connections................................................................26
Seal rings..................................................................................................................................................26
Twelve Point Head Bolts ..........................................................................................................................26
Washers....................................................................................................................................................27
ANNEX _____________________________________________________________________________ 28
Seal Rings for Flange Connections..............................................................................................28
Washers for Flange Connections .................................................................................................28
Twelve point head bolts................................................................................................................29
ACCESSORIES ______________________________________________________________________ 32
Pre-Assembly Tools for Tube Flange Connections......................................................................32
“Zako” System ..............................................................................................................................32
Electro-hydraulic pre-assembly unit .........................................................................................................32
Manual Hydraulic Pre-Assembly Unit.......................................................................................................32
REFERENCE DOCUMENTS ____________________________________________________________ 33

3 842 953.00 en

In order to convey operating media, and transmit Requirements of Personnel
power and control pulses, the different units of a
machine are connected to each other by means of Work on hydraulic components and systems and
tube and hose assemblies. These units include, for on fuel systems and cooling systems may only be
example, components in the hydraulic system, carried out by specially trained professionals or by
cooling system, or fuel system of a machine. individuals who have been instructed and are
being managed and supervised by such
A multitude of pipe systems and bolted connection professionals.
systems are available on the market, especially in If personnel do not have the required expertise,
the area of hydraulic systems. Caterpillar Global then in-depth training must be provided by
Mining HMS GmbH has selected a number of experienced personnel, e.g. by Caterpillar Global
systems from this product range that meet the Mining HMS GmbH.
constructive and operational requirements of
Caterpillar Global Mining HMS GmbH equipment.
Pay attention to the hazard warnings
This manual provides an overview of the tube and on the machine
hose assemblies used at Caterpillar Global Mining
HMS GmbH, as well as their connection elements. Pay attention to all safety information and hazard
It also lists general work instructions that must warnings on the machine.
be observed when servicing, installing, or replacing Keep all safety information and hazard warnings at
these pipes and assemblies. and on the machine and make sure they are
complete and in a legible condition.
Detailed instructions and descriptions of Replace any illegible or missing information and
procedures for working on hydraulic systems and warnings immediately.
their related structural components can be found in Observe the lawful rules, regulations and
the operation and maintenance instructions for the guidelines of your respective country.
machine, and also in the Technical Manual.
Pay attention to warnings and safety
information in the manuals and
instructions
Descriptive and instructive text contains warning
your safety. For this reason, always pay attention
to all warnings and safety information.
1
3 842 953.00 en
Depressurize components
Even when systems are shut down, components
in the hydraulic system, fuel system, and cooling
system may contain motor fluids under high
residual pressure.
Before beginning work, depressurize all tube
assemblies, hose assemblies, cylinders, valve
blocks, radiators, hydraulic tanks for coolant, and
other structural components or units.
Instructions on depressurizing system components
or sections can be found in the descriptions and
work instructions in the Service Manual or in
operation and maintenance instructions.
Preset components
Never remove the seals on pressure relief valves,
pumps, and accumulators.
Do not change the nominal pressure of pressure
limiter valves or the preset values for pumps
without express permission from Caterpillar Global
Mining HMS GmbH.
Use original replacement parts

Only use original replacement parts from
Caterpillar Global Mining HMS GmbH. Only these
replacement parts are designed and inspected to
meet the high demands of Caterpillar Global
Mining HMS GmbH machines.
Third-party replacement parts may not fulfill these
high quality expectations; for example, tube and
hose assemblies made of material wrong strength
may burst; bolted connections may come off =
risk of injury.
Never repair tube and hose assemblies; always
install original replacement parts instead.
Tube assemblies repaired through welding,
for example, are especially sources of danger.
2
3 842 953.00 en
PIPES FOR DIFFERENT MEDIA

A distinction is made, depending upon their use, Dependencies and Changes in
between pipes for:
Pipe Systems
 hydraulic oil The efficiency level of a hydraulic system and the
steady-state temperature to be expected for
 compressed air hydraulic fluid at continuous operation are also
dependent on piping dimensions, how the pipes
 fuel were installed, design of tube bends and pipe
connection components.
 coolant
Every change in direction or cross section in a pipe
 air intake changes its flow restriction and can lead to the
formation of vortices and in turn to losses in
 exhaust fumes pressure in the pipe system. The objective in
installing a pipeline should therefore always be to
 lubricating oil be install a pipe system that is as simple as
possible, is clearly laid out, and has as few bolted
 lubricating grease joints as possible.
Materials for Tubes and Hoses In addition, the pipe system should be installed
so that components that need to be adjusted,
The material used for pipes (copper/steel/plastic serviced, or replaced on a regular basis are easily
tubes, reinforced rubber/plastic hoses) is accessible (e.g. valves, air pressure gauges,
determined by the following factors: ventilation organs, and filters).
 system installation and operating instructions Replacement Parts Service

 low assembly and maintenance costs as Hydraulic lines and hydraulic hoses are
a result of easy routing of pipes and manufactured so they are ready for installation.
assemblies. All pipes (tubes, hoses, and bolted joints) are
described in the replacement part list associated
Seamless precision EN 10305-4 steel tubes and with the device and must be obtained from the
hose assemblies are generally used for pressure Caterpillar Global Mining HMS GmbH replacement
pipes and (a very small number of) bypass returns parts service. The article number for each part
in hydraulic systems. appears on the replacement part list and must be
specified when ordering.
Some hose types are provided with a steel wire
helix between textile braids in order to increase
columnar strength and dimensional stability. These
hose types are often used as suction hoses whose
internal pressure can be lower than atmospheric
pressure.
High-pressure hoses contain multiple non-tear

braided textile or steel interlining that are based on
the operational pressure range and absorb tensile
and compressive forces. Steel wire inlays are also
vulcanized into extreme pressure hoses. Almost all
hose types are provided with outer rubber
composed of oil-resistant, synthetic India rubber
with an especially high abrasion resistance.
3
3 842 953.00 en
Hose Assemblies Hose assemblies come delivered ready for

installation. They may be fitted on both sides as
Hose assemblies must be carefully coordinated on follows:
the basis of how they will be used. The following
factors must be taken into consideration in the  with bolted connections (Fig. 1),
process:  with flange type couplings (Fig. 2)
 operating pressure  each with a bolted connection and a flange

type coupling (Fig. 3).
 pressure peaks
 hydraulic fluid temperature
 hose length
 bending angles and radii
In addition, hose assemblies must be resistant to:
 mineral oil
 water and its emulsions
 gas and air bubbles
Only the manufacturer of a given machine knows Fig. 1

its requirements exactly, e.g. those for an extreme
pressure hose of a hydraulic system. This is why
only original hose assemblies from Caterpillar
Global Mining HMS GmbH must be used in the
case of Caterpillar Global Mining HMS GmbH
equipment as well.
Fig. 2
Fig. 3
The length of hose assemblies may change slightly

when they are subjected to high pressure.
Permissible tolerances in this case range from
-4% to +2%, based on nominal dimensions of the
assembly. This factor must be taken into
consideration during installation.
4
3 842 953.00 en
Fig. 5 shows installation mistakes that must be

Installation Examples avoided.
Hose assemblies must be installed without preload
and mounted without twisting, otherwise damage
could occur to the hose material and connection
fittings. In addition, the restoring torque of a hose
assembly that was not installed without twisting
could loosen the connection fitting and lead to
leakage.
Note:
Twisting hoses during installation can dramatically
shorten their lifetime. A twist of 5° can reduce the
lifetime of a hose by 70%.
A hose assembly that is installed with both

connections lying in a straight line is said to be
stretched. Hose assemblies that are stretched Fig. 5
must be installed with a “sag;” only then can the
changes in length caused by variations in pressure Impermissibly high stresses to connections and
or temperature be compensated for. hoses must not occur in hose assemblies that are
Fig. 4 shows proper installation of hose subjected to changes in bending stress during
assemblies. operation. As a result, these hose assemblies must
be dimensioned according to the following factors:
 The bend radius of the hose assembly must be

selected to be sufficiently large.
 Sufficient hose material must be provided to

accommodate movement.
 Appropriate fittings, e.g. angle pipe joints, must

be used for tight bends.
Fig. 6 shows good implementation examples.
Fig. 4
Fig. 6
5
3 842 953.00 en
Mistakes such as those shown in Fig. 7 must be Separation and Mounting

avoided.
When assembling new tubes, make sure that the
angle of the cut runs perpendicular to the tube.
If no pipe cutters are available, a sharp knife may
also be used to separate plastic tube assemblies.
Cutting edges must also be deburred.
Mounting
Fig. 7
Fig. 8
 First, place the swivel nut onto the tube end (1)
followed by the clamping ring (2).
The flat taper (3) of the clamping ring must point to
the end of the tube.
 Push the insertion sleeve (4) into the tube (5)
until it meets the edge.
 Insert the tube end with the insertion sleeve (6)
into the bolted connection until it stops.
 Slide the clamping ring onto the threaded
connection then tighten the swivel nut
handtight.
To avoid damage to the tube, do not overtighten

the swivel nut – only a maximum of 1.5 to
1.75 turns.
The edge (7) of the swivel nut should extend
approximately up to the thread run-out (8) of the
threaded connection after the swivel nut is
completely tightened.
6
3 842 953.00 en
CONNECTIONS Instructions for Assembling Tube

Joints
The most recent version of CAT Standard 1E0279 Note:
describes and establishes procedures on working The instructions and specifications of the
with and assembling fastening elements and manufacturer of the delivered components are to be
threaded components. The components and followed at all times during the assembly.
instructions relevant to this section have been The selection of suitable shape and design of the
taken from this standard. Please consult the shear sleeve remains with the manufacturer.
Caterpillar Production Systems Division for Slight deviations from these specifications are
detailed information on the facts and procedures therefore possible.
described in this standard. A threaded connection should always consist of
components from the same manufacturer.
Requirements for Tube and Hose A shear sleeve connection may be loosened and
re-tightened multiple times.
Assembly Connections The tightening torque values and tolerances
Tube and hose assembly connections must fulfill specified by suppliers must be applied and
the following requirements: maintained.
The mechanical requirement is the dynamic
 It should be possible to loosen and torque.
re-install them multiple times. Correct tightening can only be guaranteed using
process checks (e.g. conformity with the assembly
 They must be properly sealed for all operating instructions, torque identification and marking,
conditions. supervised tool provision and use, random checks
of the static tightening torque, etc.) or by
 Flow cross sections should correspond to monitoring the tightening torque performed during
those of associated pipes as far as possible. the assembly/installation process.
Components must be marked in accordance with
 Due to possible pressure surges and proper assembly procedure.
vibrations, the strength of the connection must The preset value for each assembly tool must
be at least as high as that of the tube. correspond to the nominal value specified in
1E0279. Wrenches must be calibrated and
traceable by means of ISO/MQ quality procedures.
Identification on drawings
Drawings, when available, must be reviewed in
order to determine the tightening requirements for
threaded elements. When a drawing is available,
the instructions specified in it must always be used.
If no drawing is available, the tables in section 17
of the Service Manual must be used for work.
CAT standard 1E0279 also contains rules
for drawing labeling.
Section 17 of the Service Manual (“Conversions”)

contains detailed information on tightening torques.
This section also includes tables with reference
values for tightening torques of fastening elements.
7
3 842 953.00 en
Connections, Adapters, Flanges, Any damaged connection pieces must always be

disposed of and replaced.
and Plugs Torque wrenches must be adjusted so that they
The most recent version of CAT Standard 1E0279 compensate for factors like angle of orientation and
describes and establishes procedures on working extensions. This will avoid excessive or insufficient
with and assembling connections, adapters, tightening.
flanges, and plugs. The components and
instructions relevant to this section have been
taken from this standard. Please consult the Tightening Sequence for Tube and
Caterpillar Production Systems Division for
detailed information on the facts and procedures Hose Assemblies
described in this standard. The tightening sequence is a crucial factor in
ensuring connection points are properly aligned.
General Assembly Requirements Note:
Always use two wrenches in order to prevent
Note: adapters/hoses/tubes from twisting – one as a
If the connector or its counterpart is composed of a torque wrench and the other as a backup wrench.
nonferrous metal such as aluminum or brass, a
torque of 50% of the specified value must be used. The sequence must be followed as described
Protective caps and plugs should only be removed below:
immediately before assembly.
All sealing surfaces must be free of impurities  Tighten all fluid line components handtight.
and/or damage.  Tighten components on sealing surfaces
Carry out a visual examination in order to identify (1, Fig. 9).
defective parts.  Tighten clamps (2, Fig. 9).
2
1
1
645727
Fig. 9
8
3 842 953.00 en
Assembly Instructions for  Tighten the swivel nut on the connector by

hand until the sealing faces make contact.
Connectors with O-Ring Seals
 Use the backup wrench to hold the connector
(ORFS) in the desired position in order to prevent
The most recent version of CAT Standard 1E2651 connection pieces from moving.
describes and establishes procedures on working  Tighten the connection to the final torque.
with and assembling connectors with O-ring seals.
The components and instructions relevant to this Note:
section have been taken from this standard. If the connector or its counterpart is composed of a
Please consult the Caterpillar Production Systems nonferrous metal such as aluminum or brass, a
Division for detailed information on the facts and torque of 50% of the specified value must be used.
procedures described in this standard.
The following table lists a selection of tightening
 Make sure the O-ring is properly seated in the
torque values based on the threads in use:
groove of the connector.
ORFS swivel nut ORFS bulkhead nut

1 1
2
3
4
645728 645729
1: Swivel nut 1: Bulkhead nut

2: Tube
3: Sleeve
4: O-ring
Thread size Dynamic tightening Static test torque Dynamic tightening Static test torque
torque torque
inches Nm Nm Nm Nm
9/16-18 27±4 19 45±7 30
11/16-16 45±5 30 80±12 55
13/16-16 65±10 45 100±15 70
1-14 110±17 75 130±20 90
1-3/16-12 140±21 100 180±27 125
1-7/16-12 220±33 155 350±53 245
1-11/16-12 300±45 210 420±63 295
2-12 350±53 245 500±75 350
9/16-18 27±4 19 45±7 30
Note: The tightening torque ranges in this table specify the limit values for the final tightening torque for
each connection for each connection.
9
3 842 953.00 en

Assembly Instructions for 37° Flare in the desired position in order to prevent
Couplings connection pieces from moving.
The most recent version of CAT Standard 1E2275  Tighten the connection to the final torque.
describes and establishes procedures on working
with and assembling 37° flare couplings. The
components and instructions relevant to this
section have been taken from this standard. Note:
Please consult the Caterpillar Production Systems If the connector or its counterpart is composed of
Division for detailed information on the facts and a nonferrous metal such as aluminum or brass, a
procedures described in this standard. torque of 50% of the specified value must be used.
 Tighten the swivel nut on the connector by
hand until the sealing faces make contact. The following table lists a selection of tightening
torque values based on the threads in use:
37° flare with swivel nut Bulkhead fitting with 37º flare and nut
1 1
2
3
645730 645731
1: Swivel nut 1: Bulkhead nut

2: Tube
3: Sleeve
Thread size Dynamic tightening Static test torque Dynamic tightening Static test torque
torque torque
inches Nm Nm Nm Nm
5/16-24 10±2 7 13±2 10
3/8-24 13±2 10 17±3 12
7/16-20 20±3 12 30±5 20
1/2-20 25±4 20 35±5 25
9/16-18 30±5 20 40±6 30
3/4-16 60±9 40 70±11 50
7/8-14 90±13 63 100±15 70
1-1/16-12 120±18 85 160±24 110
1-3/16-12 130±20 90 180±27 125
1-5/16-12 160±24 110 260±39 180
1-5/8-12 260±39 180 350±53 245
1-7/8-12 260±39 180 400±60 280
2-1/2-12 350±53 245 500±75 350
10
3 842 953.00 en

Assembly Instructions for SAE J512 in the desired position in order to prevent
45° Flare Connectors connection pieces from moving.
The most recent version of CAT Standard 1E2273  Tighten the connection to the final torque.
describes and establishes procedures on working
with and assembling SAE J512 45° flare couplings Note:
and couplings with swivel nuts. The components Tightening torque values were adapted to
and instructions relevant to this section have been situations in which the connector or its associated
taken from this standard. Please consult the parts are not composed of metal. It is not
Caterpillar Production Systems Division for necessary to reduce tightening torque to 50%
detailed information on the facts and procedures (as would be the case for nonferrous metals).
described in this standard.
 Put the nut on the tube with the threaded side The following table lists a selection of tightening
towards the end of the tube. torque values based on the threads in use:
 Tighten the nut by hand until it reaches the
receiving thread.
Swivel nut and 45° flare
645732 645733
Thread size Dynamic tightening torque Static test torque
inches Nm Nm
5/16-24 7±1 5
3/8-24 10±2 7
7/16-20 13±2 10
7/16-24 13±2 10
1/2-20 20±3 15
5/8-18 35±5 25
11/16-16 35±5 25
3/4-16 40±6 30
7/8-14 55±8 40
1-1/16-12 100±15 70
1-1/4-12 110±17 80
11
3 842 953.00 en
connecting them (special oil compatible with

Assembly Instructions for Air R-134a).
Conditioning System Connections Note:
 Use a refrigerant oil with a mineral oil base to Never apply a different lubricant to seals and
clean all connectors and seals when connections (also see CAT Standard 1E2721).
A/C swivel nut A/C swivel nut with 45º flare A/C (self-sealing quick-
with O ring release device)
645736
645734 645735
Steel tubes Aluminum tubes

Thread Dynamic Static Dynamic Static test Dynamic Static test Dynamic tightening Static test
size tightening test tightening torque tightening torque torque torque
torque torque torque torque
inches Nm Nm Nm Nm Nm Nm Nm Nm
5/8 13±2 10 30±5 20 25±4 20
3/4 25±4 20 50±8 35 35±5 25
7/8 40±6 30 60±9 40 40±6 30 45±7 30
1 40±6 30 60±9 40 40±6 30
1-
45±7 30 70±11 50 50±8 35
1/16
1-1/4 60±9 40
12
3 842 953.00 en
The following table lists air conditioning system

valve stems and Slimline connectors
including available threaded designs and tightening
torques
Low pressure High pressure Schrader DS Slimline DS Slimline-DS

swivel nut Slimline screw
(8 mm)
645740 645741
645739
645737
645738
Thread size: Thread size: Thread size: Thread sizes: Thread sizes:
M8x1 M10x0.75 0.206 x 36NS M27x2 and M33x2 M27x2 and M33x2
Dynamic Static test Dynamic Static test Dynamic Static test Dynamic Static test Dynamic Static test
tightening torque tightening torque tightening torque tightening torque tightening torque
torque torque torque torque torque
Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm
2±0.5 1.5 2.5±1 2 0.5±0.1 0.4 45±7 30 20±3 12
13
3 842 953.00 en
 Tighten the connection to the final torque.

Assembly Instructions for Clamping
Ring Connections Note:
 Put the nut on the tube with the threaded side Tightening torque values were adapted to
towards the end of the tube. situations in which the connector or its associated
parts are not composed of metal. It is not
 Slide the clamping ring sleeve onto the tube necessary to reduce tightening torque to 50%
(this does not apply for Hi-Duty). (as would be the case for nonferrous metals).
 Insert the tube into the bolted connection.
 Use the backup wrench to hold the connector The following table lists a selection of tightening
in the desired position in order to prevent torque values based on the threads in use:
connection pieces from moving.
1E2429 Air brake SAE 512 Press fit 1E2274 Press fit Hi-Duty
(without flare)
I
Outer 4 4 4
II
tube 1 3 1 3 1 3
diameter III
2 2 2
645742 645743 645744 645745
1: Fitting 1: Fitting 1: Fitting I : Nut

2: Nut 2: Nut 2: Nut II : Tube
3: Sleeve 3: Sleeve 3: Sleeve III : Fitting
4: Tube 4: Tube 4: Tube
Copper Non-metallic Copper Non- Copper Non-metallic

metallic
Turns Turns Turns Turns
after tightening after tightening after tightening after tightening
by hand by hand by hand by hand
mm Turns Turns Turns Turns

3.18 1-1/4 1-1/4 1-1/2
4.76 1-1/4 1-1/4 1-1/2
6.35 2 3 1-1/4 2 1-1/4 1-1/2
7.94 1-1/4 2 1-1/4 1-1/2
9.53 2 4 2-1/4 2 1-1/4 1-1/2
12.7 2 4 2-1/4 2 1-1/4 1-1/2
15.88 3 3-1/2 2-1/4 2 1-1/4 1-1/2
19.05 3 3-1/2 2-1/4 2 1-1/4 1-1/2
22.23 2-1/4 1-1/4 1-1/2
14
3 842 953.00 en
SAE 1926/ISO 6149 STOR Visual Information on Heavy-Duty

connections (outside tube thread STOR and Light-Duty STOR
with O-ring) Connectors
The following overview (Fig. 10) shows how the
Connection Expression Codes correct fitting assembly can be identified when
STOR connectors are specified:
Classification is based on the title blocks of the
connector expression. The following variants are
possible: 1 I
 the connector is equipped with a heavy-duty
(HD) STOR end when the following CAT
standard is noted in the connector expression 2
title block: 1E2651
3
 the connector is equipped with a light-duty
(LD) STOR end when the following CAT II
4
standards are noted in the connector
expression title block: 1E2390, 1E2425,
5
1E2429, 1E2273, 1E2274, 1E2275, 1E4173
6
645746
Fig. 10
Fitting assembly STOR connector

1 ORFS I Heavy-duty (HD)
STOR
2 37° flare II Light-duty (LD)
STOR
3 45° flare II Light-duty (LD)
STOR
4 NPTF II Light-duty (LD)
STOR
5 NPSM II Light-duty (LD)
STOR
6 Hose II Light-duty (LD)
(with flange) STOR
15
3 842 953.00 en
Assembly Instructions for  Tighten the structural component handtight

until the lockring makes contact with the
Adjustable STOR Connections surface of the counterpart (3).
 Unscrew the connector in order to align it to its
Note: counterpart or mount it to a tube or a hose (4).
If the connector or its counterpart is composed of a  Tighten the connector up to its final
nonferrous metal such as aluminum or brass, a position (5).
torque of 50% of the specified value must be used.
Note:
The following graphic overview (Fig. 11) shows the
The lockring may become damaged if it is
individual steps required for assembling adjustable
tightened too much and not supported by the
STOR connections. These steps are as follows:
locknut.
 Put the locknut and lockring aside while the Use a backup wrench as you tighten the connector
O-ring remains in position (1). to its final position. This will allow the connector to
 Tighten the lock nut until it makes contact with retain its alignment.
the lockring. This will prevent the lockring from
being damaged as you make the connection in The adjustable connection is now completely
the counterpart (2). assembled (6). The components required for
 Guide the structural component out (2) into its assembly are highlighted in (6).
counterpart (3).
1 2 3 4 5
C
B
6
645747
Fig. 11
1-6 Instructions for Assembly

A Locknut
B Lockring
C O-ring
16
3 842 953.00 en
Assembly Instructions for Non-

Note:
Adjustable STOR Connections Assembly tools for applying torque that have
speeds over 1000 min-1 may damage the O-ring
Note: during connection and therefore must not be used.
If the connector or its counterpart is composed of a  Tighten the connector completely in
nonferrous metal such as aluminum or brass, a accordance with the two tables below
torque of 50% of the specified value must be used. (SAE J1926 connections with straight thread
and O-ring (STOR) and ISO 6149 connections
 Make sure an O-ring with the correct with straight thread and O-ring (STOR)).
dimensions is installed.
 Tighten the connector handtight so it is locked
in its counterpart.
Fixed and adjustable STOR Hexagonal STOR Hexagonal STOR plug
adapters socket head plug
SAE
J1926
645748 645749 645750
Thread size Dynamic Static HD Dynamic Static LD Dynamic plug Static plug test Dynamic plug Static plug test
HD test LD test tightening torque tightening torque
tightening torque tightening torque torque torque
torque torque
inches Nm Nm Nm Nm Nm Nm Nm Nm
5/16-24 - - 10±2 7 7±1 5 13±2 10
3/8-24 20±3 15 13±2 10 13±2 10 20±3 12
7/16-20 30±5 20 30±5 20 20±3 15 40±6 30
1/2-20 45±7 30 30±5 20 25±4 20 45±7 30
9/16-18 55±8 40 40±6 30 45±7 30 60±9 40
3/4-16 100±15 70 80±12 55 80±12 55 100±15 70
7/8-14 140±21 100 110±17 75 110±17 75 130±20 90
1-1/16-12 220±33 155 130±20 90 180±27 125 220±33 155
1-3/16-12 260±39 180 200±30 140 220±33 155 260±39 180
1-5/16-12 350±53 245 180±27 125 300±45 210 350±53 245
1-5/8-12 400±60 280 300±45 210 350±53 245 400±60 280
1-7/8-12 420±63 295 350±53 245 420±63 295 420±63 295
2-1/2-12 500±75 350 420±63 295 500±75 350 500±75 350
HD = heavy-duty STOR; LD = light-duty STOR

17
3 842 953.00 en
Fixed and adjustable STOR Hexagonal STOR Hexagonal STOR plug

adapters socket head plug
ISO 6149
645748 645749 645750
Thread size Dynamic Static HD Dynamic Static LD Dynamic plug Static plug test Dynamic plug Static plug test
(metric) HD test LD test tightening torque tightening torque
tightening torque tightening torque torque torque
torque torque
Nm Nm Nm Nm Nm Nm Nm Nm
M8x1 - - 10±2 7 10±2 7 10±2 7

M10x1 20±3 15 17±3 12 17±3 12 20±3 12
M12x1.5 40±6 30 30±5 20 25±4 20 35±5 25
M14x1.5 50±8 35 35±5 25 45±7 30 45±7 30
M16x1.5 60±9 40 45±7 30 55±8 40 55±8 40
M18x1.5 80±12 55 50±8 35 70±11 50 90±13 63
M20x1.5 - - - - 80±12 55 110±17 75
M22x1.5 140±21 100 80±12 55 100±15 70 130±20 90
M27x2 220±33 155 120±18 85 180±27 125 220±33 155
M30x2 260±39 180 160±24 110 220±33 155 260±39 180
M33x2 350±53 245 180±27 125 300±45 210 350±53 245
M42x2 400±60 280 260±39 180 350±53 245 400±60 280
M48x2 420±63 295 300±45 210 420±63 295 420±63 295
M60x2 500±75 350 350±53 245 500±75 350 500±75 350
18
3 842 953.00 en
Assembly Instructions for  Turn the connector by hand in the port until the
seal makes contact with the connection.
Smooth ISO 9974 Screw-In  Turn the connector a maximum of one turn
Connections counter-clockwise (loosening rotation
direction), in order to achieve the required
Note: alignment (this does not apply for fixed
If the connector or its counterpart is composed of a connectors!).
nonferrous metal such as aluminum or brass, a  Use the backup wrench to hold the connector
torque of 50% of the specified value must be used. in the desired position.
 Tighten the locknut to the values specified in
 Make sure a seal ring or O-ring and lockring the tables below (smooth ISO 1179 screw-in
with the correct dimensions is installed. connections and smooth ISO 9974 screw-in
 Turn the locknut into the upper position connections).
(this does not apply for fixed connectors!).
Fixed and adjustable smooth Smooth hexagonal
screw-in adapters socket head plug
2
3
4
1
ISO 1179
1
5
645752
645751
1: Lockring 1: Seal ring

2: E-ring
3: Locknut
4: Lockring
5: O-ring
BSPP thread size Dynamic HD Static HD test Dynamic LD Static LD test Dynamic plug Static plug test torque
tightening torque tightening torque tightening torque
torque torque
inches Nm Nm Nm Nm Nm Nm
1/8-28 - - 25±4 20 17±3 15
1/4-19 55±8 40 40±6 30 30±5 20
3/8-19 80±12 55 80±12 55 55±8 40
1/2-14 110±17 75 100±15 70 110±17 75
3/4-14 200±30 140 200±30 140 260±39 185
1-11 350±53 245 350±53 245 350±53 245
1-1/4-11 500±75 350 500±75 350 400±60 280
1-1/2-11 600±90 420 600±90 420 420±63 295
19
3 842 953.00 en
Fixed and adjustable Smooth hexagonal

smooth screw-in adapters socket head plug
2
3
4
1
ISO 9974
1
5
645752
645751
1: Lockring 1: Seal ring

2: E-ring
3: Locknut
4: Lockring
5: O-ring
Thread size (metric) Dynamic HD Static HD test Dynamic LD Static LD test Dynamic plug Static plug test torque
tightening torque tightening torque tightening torque
torque torque
Nm Nm Nm Nm Nm Nm
M10x1 - - 20±3 15 13±2 10
M12x1.5 45±7 30 30±5 20 25±4 20
M14x1.5 60±9 40 50±8 35 30±5 20
M16x1.5 80±12 55 60±9 40 55±8 40
M18x1.5 110±17 80 80±12 55 60±9 40
M20x1.5 140±21 100 - - 70±11 50
M22x1.5 160±24 110 140±21 100 80±12 55
M26x1.5 - - 200±30 140 120±18 85
M27x2 200±30 140 - - 140±21 100
M33x2 400±60 280 350±53 245 220±33 155
M42x2 500±75 350 500±75 350 350±53 245
M48x2 600±90 420 600±90 420 400±60 280
20
3 842 953.00 en
Assembly Instructions for Four-

Note:
Hole SAE J518/ISO 6149/1E4217 After the final tightening of the bolts, the gap
Flange Connections in Hydraulics between the flanges must not exceed 4 mm on
both sides. Example: A flange may have 2 mm on
System each side, or 0 mm on one side and 4 mm on the
other.
Note:
If the tightening torque is not specified on the
If the connector or its counterpart is composed of a
drawing, then the bolts are tightened according to
factory standards 1E0279A or 1E0279B!
 The flange must be positioned in such a way  Tighten the bolts.
that the lower flange surface lies parallel with
the port. The following graphic overview shows the
 Screw the bolts in evenly by hand so that the individual steps required for assembling 4-hole
distance between the flanges remains minimal. flange connections. These steps are as follows:
Tightening bolts:
1) 100% tightening torque on bolts
1/5 and 2/6.
2) 100% tightening torque on bolts 3 and 4.
3) Repeat 100% tightening torque on bolts
1/5 and 2/6.
645725
Tightening bolts gradually:

1) 80% of the table value on bolts 1/5 and 2/6.
3) 100% of the table value on bolts 1/5
and 2/6.
645726
Thread SW Tightening torque

M 10 11 mm 60 Nm
M 12 13 mm 100 Nm
M 14 15 mm 160 Nm
M 16 19 mm 250 Nm
21
3 842 953.00 en
Assembly Instructions for  Screw the plug into the port by hand.
 Tighten the connection using the final
Threaded Drain Plugs tightening torque, in accordance with the
table below.
Note:
If the connector or its counterpart is composed of a
Type A Type B Type C Type D
645753 645754 645755
645756
1: Lockring
Thread size Dynamic Static Dynamic Static test Dynamic Static test Dynamic Static test
tightening test tightening torque tightening torque tightening torque
torque torque torque torque torque
inches Nm Nm Nm Nm
1/2 20±3 12 13±2 10
5/8 35±5 25
3/4 50±8 35
7/8 70±11 50 55±8 40
1-1/8 70±11 50 70±11 50
1-5/16 90±13 63 90±13 63
1-3/8 90±13 63
1-1/2 90±13 63 110±17 75
2 130±20 90
22
3 842 953.00 en
Assembly Instructions for Tube  Apply thread sealant 1E2200E to the tapered
outer pipe thread in the event one of the
Thread Connections following conditions does not apply:
 The connector is a lubrication connection.
Note:
Tightening torques for tapered male pipe threads  The connector is used in exhaust system
(e.g. NPT, NPTF, BSPT) connected using straight engine parts that are not water-cooled.
NPSF or BSPP inner pipe threads are achieved
using 50% of the tightening torque and the  The pipe thread is pre-treated with sealant
tolerances specified in the table below. (e.g. 1E2181).
The "Turns After Tightening by Hand" method must
not be used for straight female pipe threads!
 The connector is connected using a NPSM
One clockwise turn over the maximum tightening
swivel nut.
torque is permissible for purposes of correct
alignment.
 Tighten the swivel nut/connector by hand on
the connector/port.
 Tighten the connection in accordance with the
table below.
Tapered tube (fixed) NPSM swivel nut

1
2
645757 645758
1: Swivel nut
2: Fitting
Thread size Turns after Dynamic tightening Static test torque Dynamic tightening Static test torque
tightening by hand torque torque
inches Nm Nm Nm Nm
1/16 2 10±2 10 7±1 5
1/8 2 17±3 12 10±2 7
1/4 2 25±4 20 13±2 10
3/8 2 40±6 30 25±4 20
1/2 2 55±8 40 30±5 20
3/4 2 70±11 50 40±6 30
1 1-1/2 100±15 70 45±7 30
1-1/4 1-1/2 110±17 75 55±8 40
1-1/2 1-1/2 120±18 85 70±11 50
2 1-1/2 160±24 110 80±12 55
23
3 842 953.00 en
1E0279P Hose Clamps

Belleville Washer – Band Clamps
Basics The clamp is properly installed when the belleville
washer stack is almost flat (also see table below).
There are basically two types of hose clamps: The static torque tested within 10 minutes after
 A specific tightening torque must be achieved installation may differ from installation torque by as
for screw hose clamps. much as 40%.
 Band clamps use springs to apply the required T-Bolt Clamp with Spring – Band
pressure and must be installed with tensioned
springs without exceeding the tension Clamps
(tightening torque), as this would damage The static torque tested within 10 minutes after
the clamp. assembly may differ from assembly torque by as
much as 20%.
Screw Hose Clamps
These clamps must be mounted to a new hose Shaft Sleeve – Band Clamps
using the tightening torque values specified in the The static torque tested within 10 minutes after
table below. The corresponding tightening torque assembly may differ from assembly torque by as
values must also be applied when they are re-used much as 40%.
or re-tightened. Static torque must be tested within
10 minutes after assembly. V-Band Clamp
After the clamp is brought into its installation
position, it must be tightened to 75% of the
required tightening torque. Use a soft tip hammer
to tap against the clamp, first from below (opposite
the bolt), then from the left, then from the right, and
finally next to the bolt. Finally, tighten the clamp to
its full torque (100%).
24
3 842 953.00 en
Clamp type Size Dynamic Static test Maximum Dynamic Figure

tightening torque tightening tightening
torque torque torque at
re-
assembly
— mm Nm Nm Nm Nm
—
Screw ≥ 7.5
clamp width 1.4±0.3 0.6 0.8±0.3
≥ 12
width 4.5±0.7 2 3±0.5
≥ 14
width 7.5±1 4 4.5±0.7
645759
≤ 50.8 1
diameter 7.5±1 4.5 11
Belleville
washer > 50.8
diameter
11±1 6.5 16
645760
1: Belleville spring
T-bolt 7.5±1 6 11
645761
1: Tightening torque at 7.5±1
Shaft 7.5±1 5 11 64 6
645762
sleeve
A B
645763
A: Work area
B: Mounting clamp area
25
3 842 953.00 en
Additional Standard Elements for

Twelve Point Head Bolts
Flange Connections
Twelve point head bolts are used in areas where
space is limited, and therefore for SAE flange
Seal rings connections as well. These twelve point head bolts
A one-piece plastic seal ring is used as a seal ring. were developed internally by Caterpillar Global
Mining HMS GmbH. They feature a metric thread
(DIN ISO 262), strength class 10.9 (DIN 267) and
surface protection A3B (DIN 267).
Fig. 12
It is re-usable and can be replaced by the 2-piece

seal ring that was used previously.
Table 1 in the Annex lists all available sizes Fig. 13
including corresponding article numbers.
Twelve point head bolts (Fig. 13) provide the
following advantages:
 higher corrosion protection, since they are

galvanized
 small wrench sizes (SW),

e.g.: M 10 = SW 11
for comparison: a hexagon head bolt M 10
requires SW 17
 clean, frictional tightening using commercially

available box-end wrenches or socket
wrenches
 no risk of contamination, as in hexagonal
 better turning of wrench through twelve point

shape
Table 3 of the Annex lists available bolt sizes.
26
3 842 953.00 en
Washers Fig. 15 shows a tube/hose connection with a

Washers (Fig. 14) are necessary when flange baffle ring:
connections are used to join tubes or hoses and
both connection fittings are equipped with a seal
groove. A selection of washers appears in the
Annex in Table 2.
Fig. 15
2 Seal ring
Fig. 14 3 F-ring (clamp ring) with seal groove

4 Flange, one-piece
5 Twelve point head bolt
6 Tube
8 Intermediate washer
9 Flange half
10 Hydraulic hose with SAE flange coupling
11 Hex nut
Washers are centered by means of the outer

twelve point head bolts.
Table 2 of the Annex lists specifications on
washers of different sizes.
27
3 842 953.00 en
Annex
Seal Rings for Flange Connections
Size DN Article no.
1/2" 13 1 414 001
3/4" 20 1 725 417
1" 25 1 725 418
1 ¼" 32 1 725 419
1 ½" 40 1 725 420
2" 50 1 725 421

Table 1
Washers for Flange Connections

Size DN Pressure range Article no. Washer
thickness
(mm) (bar) (psi) (mm)
¾" 20 210 3.000 --- ---
420 6.000 974 763 8
1" 25 210 3.000 974 759 6
420 6.000 974 764 8
1 ¼" 32 210 3.000 974 760 6
420 6.000 974 765 8
1 ½" 40 210 3.000 974 761 6
420 6.000 974 766 8
2" 50 210 3.000 974 762 6
420 6.000 --- ---

Table 2
28
3 842 953.00 en
Twelve point head bolts
d1 x l1 Article no. SW l1 l2 d2 h s Tightening torque

(mm) (mm) (mm) (mm) (mm) (mm) (mm) (Nm)
M 10 x 30 1 183 269 11 30 20 17 7 4
M 10 x 45 0 974 642 11 45 26 17 7 4
M 10 x 55 0 974 643 11 55 26 17 7 4
60
M 10 x 70 1 265 319 11 70 17 7 4
M 10 x 80 0 974 644 11 80 26 17 7 4
M 10 x 100 0 974 645 11 100 26 17 7 4
M 10 x 110 2 247 493 11 110 17 7 4
M 12 x 30 1 183 270 13 30 22 19 8 5
M 12 x 35 1 234 306 13 35
M 12 x 40 1 265 079 13 40
M 12 x 45 1 220 477 13 45
M 12 x 50 0 974 646 13 50 30 19 8 5
M 12 x 55 3 754 320 13 55
M 12 x 65 0 974 647 13 65 30 19 8 5
M 12 x 80 1 265 320 13 80 100
M 12 x 90 0 974 648 13 90 30 19 8 5
M 12 x 95 3 754 676 13 95
M 12 x 100 1 188 358 13 100
M 12 x 105 1 598 812 13 105
M 12 x 110 3 754 321 13 110
M 12 x 115 3 744 619 13 115
M 12 x 120 0 974 649 13 120 30 19 8 5
M 12 x 130 3 749 906 13 130
M 14 x 45 1 265 073 45
M 14 x 55 3 748 514 55
29
3 842 953.00 en
M 14 x 60 0 974 650 15 60 34 21 9 6
M 14 x 65 3 684 998 15 65
M 14 x 70 3 737 280 15 70
M 14 x 80 3 742 272 15 80
M 14 x 85 3 754 741 15 85
160
M 14 x 90 1 268 708 15 90
M 14 x 95 3 754 318 15 95
M 14 x 105 0 974 651 15 105 34 21 9 6
M 14 x 120 3 719 932 15 120
M 14 x 150 1 129 496 15 150 40 21 9 6
M 14 x 160 2 482 273 15 160
M 14 x 165 1 542 262 15 165
M 14 x 180 1 717 052 15 180
M 16 x 40 0 269 245 19 40 35 24 19 6
M 16 x 70 0 974 652 19 70 38 24 10 6
M 16 x 75 3 684 999 75
M 16 x 80 3 743 414 80
M 16 x 90 0 990 145 19 90 38 26 10 4 250
M 16 x 95 3 754 676 95
M 16 x 100 0 269 244 19 100 38 24 10 6
M 16 x 110 3 740 130 110
M 16 x 120 0 974 653 19 120 44 24 10 6
M 16 x 130 1 599 991 130
M 16 x 150 3 750 206 150
M 16 x 160 3 742 265 160
M 16 x 190 0 996 167 190
M 16 x 200 3 686 511 200
M 16 x 205 3 692 386 205
M 16 x 210 0 996 168 210
M 20 x 50 2 418 131 50
M 20 x 80 3 754 739 80
M 20 x 90 1 975 158 90
M 20 x 100 0 257 954 100
M 20 x 120 2 417 924 22 120 52 30 12 6 490
M 20 x 140 1 122 621 140
30
3 842 953.00 en
M 22 x 100 0 978 791 100

M 22 x 140 0 268 852 140
M 24 x 110 0 253 709 110
M 24 x 120 0 978 790 120
M 24 x 130 4 525 324 130
M 24 x 140 0 994 227 140
M 24 x 160 0 268 281 160
M 24 x 180 1 121 567 180
M 27 x 120 0 257 953 120
M 27 x 140 2 157 959 140
M 27 x 160 0 268 291 160
M 30 x 140 0 994 228 140
M 30 x 150 4 525 317 150
M 30 x 190 0 978 797 190
M 30 x 200 4 525 286 200
M 30 x 260 1 183 509 260
Strength class: 10.9, surface protection: A3B
Table 3
31
3 842 953.00 en
Accessories
Pre-Assembly Tools for Tube Flange Connections
“Zako” System
The following pre-assembly units may be used:
Electro-hydraulic pre-assembly unit

Electro-hydraulic pre-assembly unit, consisting of
 control unit with foot switch
 mounting cylinder
 connection hose
 article no. 1 590 880
Manual Hydraulic Pre-Assembly Unit

Manual hydraulic pre-assembly unit, consisting of
 hand pump
 mounting cylinder
 connection hose
article no. 1 590 881

In addition, a clamping jaw is required for
tube 50 x 6, article no. 1 590 882.
32
3 842 953.00 en
Reference Documents
CAT Standards 1E2200E
1E2390
1E2425
1E2429
1E2273
1E2274
1E2275
1E4173
1E2651
1E2721
1E2181
SAE J512
J514
J1453
J1926
ISO 1179
6149
9974
33
Printed in Germany
3 842 954.000 en
February 2014
Repair
Welding Manual
6015 - 6090
3 842 954.000 en

Department: Technical Documentation
Tel. +49 (0) 231 922-4340
Fax +49 (0) 231 922-5005
are liable to compensation. All rights reserved in the event of patent, utility model, or registered design regis-
tration.
3 842 954.000 en
TABLE OF CONTENTS
FOREWORD_________________________________________________________________________ 1
SAFTY _____________________________________________________________________________ 1
1. BASIC PRINCIPLES_________________________________________________________________ 2
1.1 Component stresses ______________________________________________________________ 2
1.2 Stress types_____________________________________________________________________ 2
1.3 Behavior of the material with different types of stress _____________________________________ 4
1.4 Notches on components ___________________________________________________________ 5
1.5 Information on avoiding notches ____________________________________________________ 10
2. PLANNING THE REPAIR AND REINFORCEMENT OF STEEL COMPONENTS_________________ 18

2.1 Causes of damage ______________________________________________________________ 18
2.2 Preparatory measures____________________________________________________________ 18
2.3 Extent of the repair work __________________________________________________________ 19
2.4 Preventive investigations__________________________________________________________ 22
2.5 Determining cracks and other defects ________________________________________________ 22
3. OPERATING TECHNIQUES FOR REPAIRS_____________________________________________ 23

3.1 Gouging and welding cracks _______________________________________________________ 23
3.2 Welding on a metal cylinder using the back-step welding method __________________________ 28
3.3 Cracks in box sections ___________________________________________________________ 30
3.4 Recommended groove shapes for electrodes – manual welding ___________________________ 34
3.5 Work sequence when welding______________________________________________________ 36
3.6 Closing openings, renewing component areas _________________________________________ 38
4. REINFORCEMENT OF STEEL COMPONENTS __________________________________________ 49

4.1 Doubler plates __________________________________________________________________ 49
4.2 Deformation of plates as the result of repair work _______________________________________ 53
4.3 Reinforcement by improving the shape _______________________________________________ 54
5. MATERIALS, WELD FILLERS________________________________________________________ 57

5.1 Materials in welded components ____________________________________________________ 57
5.2 Weld fillers for Caterpillar Global Mining HMS – welded components, with reference to the material
partners and welding process (Tables 1 and 2) ___________________________________________ 58
6. HEAT TREATMENT OF THE MATERIALS ______________________________________________ 60

6.1 Preheating for tack welding, welding, grooving, and flame cutting __________________________ 60
6.2 Preheating and interpass temperatures; heating up and cooling down rates for repair welding ____ 62
6.3 Hot forming of plates _____________________________________________________________ 64
6.4 Flame straightening plates ________________________________________________________ 64
6.5 Stress-free annealing of steel components ____________________________________________ 64
6.6 Stress-relieving steel components __________________________________________________ 65
6.7 Treatment of welding fillers ________________________________________________________ 67
3 842 954.000 en
6.8 Monitoring the temperature ________________________________________________________ 67
7. COLD FORMING OF PLATES ________________________________________________________ 68
8. HARDFACING ____________________________________________________________________ 69
8.1 Adding missing materials/supplementing worn material __________________________________ 69
8.2 Correcting component shapes to improve the force path _________________________________ 71
8.3 Hardfacing for wear protection _____________________________________________________ 71
9. WEAR PROTECTION (ARMORING) ___________________________________________________ 72

9.1 Basic principles _________________________________________________________________ 72
9.2 Hardfacing of wear protection layers_________________________________________________ 72
9.3 Weld fillers: ____________________________________________________________________ 74
9.4 Repairing the hardfacing __________________________________________________________ 75
9.5 Repairing cracks in the area of hardfacing ____________________________________________ 77
9.6 Welding on plates or strips of wear-resistant steel plates _________________________________ 78
9.7 Welding on plates or strips with wear-resistant coating___________________________________ 83
9.8 Welding on wear-resistant pin assembly ______________________________________________ 84
9.9 Welding on cutting edges on excavator buckets ________________________________________ 85
10. REPAIRS BY WELDING CAST-IRON COMPONENTS____________________________________ 87

10.1 Spheroidal graphite cast-iron (GGG)________________________________________________ 87
10.2 Gray cast iron (GG) _____________________________________________________________ 88
11. REPAIRING PAINTWORK IN REPAIR AREAS__________________________________________ 90
ANNEX ____________________________________________________________________________ 91
Conversion from feet and inches into meters _____________________________________________ 91
Conversion of length dimensions ______________________________________________________ 91
Temperature units and conversion formulas ______________________________________________ 92
Hardness-strength comparison ________________________________________________________ 93
3 842 954.000 en
3 842 954.000 en
Foreword Safety
In spite of expert design, precise stress analysis, Accident prevention regulations must be ob-
careful production, vigilant maintenance and reserved.
sponsible operation, damage to components of
Work on containers that contain, or have con-
construction machinery and industrial trucks can-
tained substances
not be avoided. Natural abrasive wear must always
be expected in areas exposed to mechanical  that are combustible or assist combustion,
stresses and abrasion.
 that can cause explosions,
Experience with the early detection of damage and
its causes and the choice of suitable repair meth-  that can generate gases, vapors, mists, or
ods and their actual implementation will help to dust that are hazardous to health during
guarantee a high level of operational availability of work,
any machine. may only be executed under expert supervision
Before proceeding with welding, back gouging, hot and only by experienced personnel specifically
or cold working, and heat treatment, the repairer trained for this kind of work.
must know the component’s material. Systems and units (e.g. pipes, radiator assem-
This technical manual contains a large amount of blies, hydraulic tanks, air storage tanks) must
information on welding methods and practice. This be de-pressurized before opening.
information will help you to plan and carry out When assembling or dismantling work equip-
repair and reinforcement work correctly. It is as- ment or its components, or when installing or
sumed that the maintenance personnel has the uninstalling units,
necessary expertise. The particular features of the
relevant damage must be taken into account.  always protect against accidental or unau-
thorized start-up. Place equipment on the
The latest edition of the technical manual entitled floor to prevent movement when discon-
“Repair Welding,” SN 2 114 500.00, has been necting mechanical or hydraulic connec-
revised and also takes into account the introduc- tions.
tion of EN standards. A few points have been
added. Therefore, all work should only be done  When being fitted or removed, use lifting
according to the information contained in this gear or suitable suspension/support de-
edition. vices to prevent equipement or compo-
nents from accidental movement, sliding or
falling.
Anyone working at height must wear a safety
harness.
If temporary personnel, e.g. spotters, are need-
ed to do the work, the responsibilities of the
individual concerned must be clearly estab-
lished in advance and strictly observed during
the work so that there is no confusion from a
safety point of view.
Tools, lifting gear, rigging hardware, chocks,
and other aids must be in a safe operating and
working condition.
Please see 2.2 “Preparatory Measures” for
further information.
1
3 842 954.000 en
1. Basic principles 1.2 Stress types

1.1 Component stresses Stress (tensile and compressive stress) may have
a static or mainly static (Fig. 2), pulsating (Fig. 3),
Components may be exposed to different stresses. or changing (Fig. 4) effect on the component.
These stresses hardly ever consist of individual Pulsating and changing loads may have a gradual
forces, but usually several forces at the same time or sudden impact.
(Fig. 1).
Fig. 2
+F tensile
-F compressive
Fig. 1
It is very difficult to determine mathematically

component stress resulting from forces acting Fig. 3
simultaneously and from different directions. How-
ever, stress values and stress concentrations can
be determined with modern computing methods.
Fig. 4
2
3 842 954.000 en
Example of different types of stress, illustrated on  In the “digging” working cycle, the boom ex-
the boom of an excavator (Fig. 5 and 6). It is tends. The bottom flange is in the tensile
exposed to bending stresses. range, the top flange in the pressure range.
 In the “raising” working cycle, the boom is
compressed. The top flange is now in the ten-
sile range and the bottom flange in the pres-
sure range.
Therefore, the stresses have a changing effect on
the boom.
Fig. 5
Fig. 6
3
3 842 954.000 en
1.3 Behavior of the material with differ- The cause of this material behavior lies in the
ent types of stress gradual damage of the cohesion forces at the
material grain boundaries and also, in the ad-
The admissible mechanical stresses for the engi- vanced stage, in the creation and increase of
neering strength of a component (N/mm2) change defects in the material structure (Fig. 8).
with the same material between static and chang-
ing load (Fig. 7).
Fig. 8
1. An idealized material structure is exposed to

changing stresses. The material deforms elas-
tically on the sliding planes at the grain bound-
aries. The sliding planes have no defects.
2. Through the continuous elastic deformation,
material grains are displaced on the sliding
planes that have the first defects.
3. The defects increase in size as the number of
elastic deformation processes increases.
Fig. 7
The admissible mechanical stresses are well below

the tensile strength values specified in the stan-
dards. The example illustrates a rolled steel DIN
EN 10025-2 - S355J2+N, with product thicknesses
≥ 3 mm ≤ 100 mm.
4
3 842 954.000 en
1.4 Notches on components However, they can also be caused by other me-
chanical effects on the component (Fig. 10 and
All the defects affecting the ideal force flow in a 11). For example, through punch numbers, chisel
component are called notches. marks, marking lines, and damage by loading gear.
There are 3 different types of notches, depending
on their creation and effect on the component:
- mechanical notches
- metallurgical notches
- shape-related notches
1.4.1 Mechanical notches
Mechanical notches can occur in the area of the
weld during a welding process (Fig. 9).
Fig. 10
Fig. 11
1. Punch numbers
Fig. 9
2. Chisel marks
1. Undercut
3. Marking lines
2. Root not fused
4. Notching by loading gear
3. Pores in the weld metal
4. Lack of fusion
5. Grinding marks
6. Excess penetration
7. Underbead cracking
5
3 842 954.000 en
Mechanical notches cause stress concentrations Because of their properties, these material
(Fig. 12). zones—how narrow they may be—behave differ-
ently when exposed to stress.
Expansion is limited and constraints occur.
Metallurgical notches can be kept at a tolerably low
level through optimum welding and heat treatment
methods.
Metallurgical notches, e.g. as they may occur after
a non-correctly performed welding operation, may
also be mitigated by stress-relief annealing.
1.4.3 Shape-related notches
Shape-related notches are design-based. Stress
concentrations occur due to the re-directing of lines
of force (Fig. 14).
Fig. 12 Furthermore, shape-related notches often lie in
2 Root not fused heat-affected zones with metallurgical notches.
Shape-related notches can be largely reduced
4 Lack of fusion through skilled design measures. They must be
minimized in practice so that they do not have a
This leads to enlargement of the notches. This
significant negative effect on the engineering
process can repeat itself, resulting in component
strength of the component.
break. Mechanical notches mainly occur in fabrica-
tion, but also later when the machine is in use
(signs of usage). They can be detected visually or
revealed by nondestructive testing and then reme-
died.
1.4.2 Metallurgical notches
Metallurgical notches result from the thermal
influencing of the material, i.e. always in the area
of welded joints (Fig. 13).
Fig. 13
Fig. 14
As a result of the heat introduced during the weld-
ing process, and depending on the distance from
the heat source, zones occur with different metal-
lurgical and mechanical/technological properties.
6
3 842 954.000 en
1 + 2 Hardness curve However, with regard to the force path, an ideal

butt weld, where the difference in plate thickness is
Shape-related notches can be eliminated subse-
reduced by beveling to a ratio of 1:4, can still be
quently by shape changes.
made cost-effectively (Fig. 16).
Examples (Fig. 15):
a + b: Badly executed butt-type joints of compo-
nents of different thicknesses. c: Improved execu-
tion.
Execution c may be adequate if there is a relatively
small difference in the thickness of the two plates.
Fig. 16
Forces should be able to flow through the calcula-

ble part of the components with as little disruption
as possible. They should not be able to flow into
auxiliary elements (Fig. 17).
Fig. 17
The welds used to secure such auxiliary elements

are usually over-estimated. They are not able to
absorb any component forces.
Fig. 15
7
3 842 954.000 en
1.4.4 Notching effect Possible notches (mechanical and metallurgical) at

butt joint welds:
Depending on its shape notches have different
effective or notching factors.
The effect of notching factors on the fatigue Weld seam Description
strength of a component is illustrated in the graph
(Fig. 18). 1 Material not affected; no
weld seam
2 Ideal weld seam; root pass

gouged, surface levelled,
non-destructive testing,
stress-free annealed, pre-
heated for welding (if neces-
sary)
3 Practical weld seam; root

pass gouged, surface lev-
elled, preheated for welding
(if necessary)
4 Root pass cleaned and

counter-welded; otherwise
untreated
Welded on to backing plate

(see section 3.5.1.5)
5 Not counter-welded; root

defects to be expected
Welded on to backing plate

(see section )
6 Seam welded from one side;

Root pass defective
Fig. 18
Position and path of the curves apply to:

In case 2 practically only the metallurgical notch is
Material: DIN EN 10025-2: S355J2+N effective.
Load cycles: ≥ 2 x 106 (2 million), there-

fore “fatigue-resistant”
Stress population: Small, medium and bigger

stresses with about the
same frequency.
8
3 842 954.000 en
1.4.5 Practical experience

To reduce the weight of the component, materials
of a higher strength and smaller plate thicknesses
are often used.
The component contours are maintained.
However, you have to keep in mind that, regard-
less of geometric dimensions and material, the
stability of the component is only dependent on the
modulus of elasticity E. It is more or less the same
for S690QL and for S355J2+N.
This means that a component consisting of thinner
plates is exposed to greater deformation and
therefore loses its usage properties. Notches may
also have a greater effect.
High strength, fine-grained steels, e.g. S690QL,
have advantages compared to fine-grained steel
S355J2+N only in the case of static or mainly static
loads and low-notch processes (Fig. 19).
The notch sensitivity of structural steels rises with
increasing strength.
Therefore, the use of S355J2+N is recommended
for machines with notch-sensitive steel compo-
nents exposed to changing loads.
In this regard, the notches resulting from traces of
usage should also be considered.
Fig. 19
Position and path of the curves apply to:
Material: S355J2+N, S690QL
Load cycles: ≥ 2 x 106 (2 million)
Small, medium and bigger

Stress population: stresses with about the
same frequency.
9
3 842 954.000 en
1.5 Information on avoiding notches 1.5.2 Grinding tools

Grinder disc on an angle grinder (Fig. 21):
If notches in a component are avoided, or at least
their severity is reduced, the tolerable stresses Only suitable for rough material removal. Not
increase (N/mm2). The life of the component is suitable for low-notch grinding with controlled
closer to the fatigue strength. Damage can be alignment of the marks.
largely avoided.
1.5.1 Grinding marks
Grinding marks running longitudinally to the weld
axis are hazardous mechanical notches.
When grinding, always make sure that the marks
run transversely to the weld axis (Fig. 20).
Fig. 21
Grindstone (Fig. 22):

Suitable for grinding weld surfaces, run-off
tabs, plate edges, at least for the final finish-
ing process.
Fig. 20
These conditions do not have to be met if grinder Fig. 22

discs are used. In some situations, it is necessary
to finish by hand using abrasive paper.
Therefore, the use of grindstones or polishing discs
is recommended, at least for the last pass.
10
3 842 954.000 en
Grindstone (Fig. 23): 1.5.3 Run-off tabs

Suitable for grinding parts of the component The highest mechanical stresses occur in the edge
that are difficult to access. areas of components.
Defects in the weld seam, e.g. caused by arc
strikes or end craters in the edge area, should be
avoided. The welding groove at the component
edges must be filled completely.
Fig. 23
Steel milling cutter (Fig. 24):

Suitable for rounding small radii.
Fig. 25
Therefore, the weld seam must be extended by

run-off tabs by approximately 50 mm (Fig. 25). Arc
strikes and end craters then lie in this extension.
The cross-section view of the run-off tabs used
depends on the shape of groove.
After welding, the run-off tabs must be removed by
flame cutting and the transitions ground to make
them notch-free, followed by MT testing.
Observe the grinding recommendations (chapter
1.5.1).
Fig. 24
11
3 842 954.000 en
1.5.4 Fastening auxiliary elements If necessary, find alternative fixing solutions to

protect the base (Fig. 28).
When fastening auxiliary elements, do not weld in
the edge areas of highly stressed components.
The welds should end at a defined distance from
the edge of the component.
Arc strikes and end craters must be as far away
from the component edge as possible (Fig. 26 and
27).
Fig. 28
Examples:
 Attaching pipe clips to a very narrow base.
 Fixing straps for pipes, lamps, cables, and
similar without welding on the highly stressed
bottom flange.
Fig. 26
Fig. 27
12
3 842 954.000 en
1.5.5 Rib run-off 1.5.6 Undisturbed force flow

Form a “soft” rib run-off on highly stressed compo- Form auxiliary elements (a crane lug in this in-
nents and weld round it (Fig. 29). stance) so that the force flow is not disturbed or
interrupted.
Fig. 30
If the force flow is interrupted, stress concentra-

tions will occur, leading to cracks (Fig. 31).
Fig. 29
The welder must position the component and

himself so that it is possible to weld round the run-
off without arc strikes and end craters.
The weld transitions must be absolutely notch-free.
This can only be achieved by grinding (Fig. 30).
Fig. 31
Recommendation: Remove lugs after assembly.

Grind clean the surfaces.
13
3 842 954.000 en
1.5.7 Ribs and reinforcements

Ribs, reinforcements, etc., in components must be
continuously welded if the components are ex-
posed to pulsating or changing loads (Fig. 32).
Fig. 32
Interruption of the welds is not recommended,

even if this would make the assembly of the com-
ponent easier (Fig. 33).
Triaxial stresses in the case of intersecting welds Fig. 33
represent a much smaller risk for the component
than defective welding, or even no round welding
at all in the gaps. If the recesses are too big, they
can lead to damage through the “softening” of the
component corner, even with perfect welding.
14
3 842 954.000 en
1.5.8 Welding method

Metallurgical notches can be reduced considerably Maximum bead and pass widths:
if the correct welding method is used.
Solid wire:
The string bead method must be used to repair
weld components (Fig. 34).
Wire diameter Width
0.8 8.0
1.0 10.0
1.2 12.0
1.6 16.0
Rod electrodes:
Rod diameter Width

3.2 8.0
4.0 10.0
5.5 12.0
In the case of multipass welding, the seam toes

require a terrace formation (Fig. 35) or cascade
formation (Fig. 36). This is necessary to avoid
Fig. 34 defects through arc strikes or end craters in the
various passes on a line.
The advantages of the string bead method are:
The distances between the start and end points
 Low thermal input (Joule/cm) per welding must be at least 20 mm.
bead. The heat affected zone (HAZ) in the ba-
sic material remains very narrow; a metallurgi- Explanation of the diagrams:
cal notch with only a small notching effect oc-
curs.
IxUx60
Thermal input: (J/mm) =
v
I = amperage (A)
U = voltage (V)
v = welding speed (mm/s)
 Each bead is tempered (assisted) by over-
welding with the next bead.
 The weld pool can be effectively controlled,
resulting in:
- Good penetration at the weld edges, Fig. 35
- Avoidance of weld pool overflow (cold lap).
- Avoidance of incomplete fusion.
Fig. 36
15
3 842 954.000 en
1.5.9 Welding so-called “temper beads” 1.5.10 Buffering weld edges

By welding temper beads, both the mechanical The formation of the heat affected zones (HAZ),
properties of the weld metal in the cover pass and particularly for weld metals with a high carbon
those of the heat affected zone (HAZ) are signifi- equivalent, is very important for the durability of the
cantly improved in the area near the surface. weld.
The aim must be to achieve
 a narrow heat affected zone (HAZ)
 a small reduction in the strength of the material
and the HAZ
 a small increase in hardness at the HAZ/base
material transition.
This aim is largely achieved by what is known as
buffering the weld flanks before junction welding.
When buffering, the introduction of heat (Joule/cm)
must be minimized during welding.
The following requirements must be met when
carrying out the buffering process:
Fig. 37
 The buffer must be welded with rod electrodes
Information on Fig. 37: of a type suitable for the base material
 Beads 6 and 7 are known as temper beads.  Rod electrodes - diameter 3.2 mm.
 By welding beads 6 and 7, the weld metal of  The base material must be preheated accord-
beads 1 and 3, and 4 and 2 is re-heated. The ing to the type of material.
metal is tempered.
 The string bead welding method must be used.
 An ideal material structure with improved
expansion and toughness properties can be  The interpass temperature of the materials
achieved in this tempered weld metal with only must be considered accordingly.
an insignificant reduction in strength.  If run-off tabs are provided at the end of the
 The cover pass can be levelled by grinding if weld: weld the buffer beyond the arc strike as
necessary. far as the end of the run-off tab.
 Carefully clean the finished buffer before
overwelding (slag residue at the contact line of
a bead with the adjacent bead).
 Start with junction welding without intermediate
cooling of the component.
For junction welding of 2 separate components or
fragments buffering should take place before
assembling in the most advantageous welding
position for both parts. Assembly of the warm parts
is to be planned before heating, e.g. by means of a
suitable device.
16
3 842 954.000 en
1.5.11 Welding sequence The welding sequence illustrated must be ob-

served when welding weld intersections (Fig. 38).
Definition:
Determine in which direction a seam is to be
welded and in which order several seams are to be
welded.
Key to symbols:
Fig. 38
By determining the welding sequence, it is possible

to specify that:
 the component must maintain a stress-free
state as much as possible; distortion through Fig. 39
the effect of welding stresses has to be ac-
cepted; In order to avoid defects, and therefore mechanical
notches, weld intersections in the edge area of
 the component must remain as dimensionally components must have no arc strikes or end
stable as possible; internal stresses in the craters. Arc strikes or end craters must be at least
component caused by the welding process 40 mm from the weld intersection.
have to be accepted.
When repairing components by welding, it is usu-
ally necessary to maintain the dimensional stability
of the component.
17
3 842 954.000 en
2. Planning the repair and rein- 111 EN- 287-1 111 P BW 3 B t13 PE ss nb
forcement of steel compo-
nents 111 EN- 287-1 111 P FW 3 B t13 PD ml
When repairing and reinforcing steel components,
work in a systematic way, i.e. first identify the 135 EN- 287-1 135 P BW 3 S t13 PE ss nb
precise extent of the damage, establish the cause
and then determine and apply suitable measures. 135 EN- 287-1 135 P FW 3 S t13 PD ml
Unsystematic reinforcement work leads to new
damage. 136 EN- 287-1 136 P BW 3 B t13 PE ss nb
2.1 Causes of damage
136 EN- 287-1 136 P FW 3 B t13 PD ml
Damage may have many causes:
 Dimensioning  If possible, the welding work should be done in
Incorrect assessment of the possible stresses a workshop where the necessary tools and lift-
and types of stress, dimensioning and design ing gear are available.
errors, unsuitable structural materials.
 If welding work has to be done on site, the
 Production component must be protected from the weath-
Mechanical and metallurgical notches, meas- er, such as rain, snow, dew, wind, etc. This
uring errors, material confusion, material de- can be done by means of tarpaulins erected to
fects. form a tent, for example.
 Incorrect operation of the machine  It is very important that the site is clean and
Handling mistakes through lack of experience, tidy.
misuse through over-estimating efficiency,
misuse through activities for which the ma-  Remove the component. Remove any attach-
chine is not intended. ments from the component, in particular
hinged attachments.
 Accidents (Example: Tri-Power pin assembly and steer-
Accidents in transit, when moving or in use, ing gear).
e.g. through stone damage when excavating in
a quarry.  When removing the component, carefully plug
any exposed hose and pipe connections, open
2.2 Preparatory measures bolt holes and housings so that no dirt can
penetrate.
Irrespective of the cause of the damage, the most
practical procedure has to be established in order  Clean the component to be repaired thor-
to restore the operational availability of the ma- oughly. In particular, the parts of the compo-
chine. nent to be worked on have to be cleaned very
carefully.
Important preconditions in order to be able to
perform repair and reinforcement work:  Welding grooves and surfaces for fillet welds
must be completely metallically bright.
 repair, conversion or reinforcement work on
steel components of construction machinery  Do not overweld paint or primer.
may only be done by specialists who have ad-
equate experience of the design and manufac-  Remove lubricants from bearings completely
ture of components exposed to dynamic so that they do not liquefy through the effects
stresses. If in doubt, contact Caterpillar Global of the heat and flow into the welding area.
Mining HMS Customer Services, who will also  Protect machined surfaces, pin assembly,
consult the corresponding technical depart- bearings, piston rods, electrical installations,
ments if necessary. etc. from weld splatter and grinding dust by
 Only experienced welders may carry out covering with non-flammable materials.
repair, conversion or reinforcement work. A  Before welding equipment with electronic
welder with the following test certificates al- components, disconnect all the connector as-
ready satisfies the basic requirements. semblies from the components. Example: In
the case of hydraulic excavators with PMS
Name of test system, disconnect all the connector assem-
blies from the load-limiting controller (PMS
Box).
18
3 842 954.000 en
 Disconnect the battery before welding compo- 2.3 Extent of the repair work
nents that are not removed from the machin-
ery. Disconnect the negative terminal first, then The procedure to be followed in the event of dam-
the positive terminal. But connect the positive age is explained on the basis of the diagram.
terminal first and then the negative terminal. When damage is reported, one of 3 decisions has
 The material (type and quality) of the compo- to be made: (Fig. 40).
nent must be identified before welding starts.
 Only use weld filler materials that are suitable
for the component material.
Fig. 40
2.3.1 Scrap the component

The damage is so extensive that a skilled repair is
technically no longer possible or only at extremely
high cost.
The decision-making boundary is variable. Where-
as in Germany, and in most industrial countries, it
will be decided to scrap the component, other
countries have to repair, because procuring a new
part is difficult—even impossible sometimes—for a
variety of reasons. For example, reasons include
lack of currency, customs, long delivery periods,
downtime of the machinery. Relatively low wage
costs may also work in favor of the decision to
repair.
19
3 842 954.000 en
2.3.2 Temporary repair Observe the following rules:

The component must be repaired immediately to  drill out any cracks immediately, provided they
maintain the availability of the machine, e.g. be- are still relatively short (Fig. 42).
cause of an order completion date (Fig. 41).
This will reduce the rate at which the cracks are
In spite of the time pressure, any temporary repair likely to spread. However, this is not a repair.
still has to be made with due care. Otherwise,
further damage will occur.
Fig. 42
Identifying the actual end of a crack is particularly

important. Depending on where they start, cracks
may run through a component in a curve (Fig. 43).
Fig. 41
Fig. 43
A + B drilled out correctly

C drilled out incorrectly.
20
3 842 954.000 en
One way to find the end of a crack is to carry out a 2.3.3 Lasting repair
non-destructive crack test using one of the known
methods. For internal cracks, use the ultrasound
test and X-ray test and for external cracks, the dye
penetration test and the magnaflux test.
After drilling out the crack, the hole can also be
checked for further cracks.
 Long cracks should be prepared and welded
immediately, even if the boundary conditions
are not favorable.
The damaged area must be monitored continu-
ously. If the repair weld fails the process described
must be repeated.
 Never weld on “reinforcements.” They are not
only useless, but also conceal the area of the
damage and make monitoring impossible. The
damaged area may grow and any future repair
will become impossible as a result.
Fig. 44
If it is decided to repair the damaged component

permanently (Fig. 44), the following rules must be
observed:
 determine the cause of the damage and rem-
edy it if it was caused by the design or produc-
tion process. Simple measures are often ade-
quate to determine the cause of the damage:
- personal experience and comparison with
damage patterns found on similar compo-
nents.
- these measures include visual inspection
of the damaged area to determine the
causes for the crack start point, e.g. me-
chanical notches, missing welds, inade-
quate root welds, etc. and
- visual assessment of the fracture surfaces
in order to determine the crack origin via
the path of the lines of rest. Also from the
structure of the fracture surface you can
draw conclusions about the quality of the
material.
21
3 842 954.000 en
- A simple material test is the hardness 2.4 Preventive investigations

comparison with known materials.
Preventive investigations have been used in medi-
- The wall thickness of plates, steel castings cine for a long time. Doctors have shown us that
or forgings can be measured and com- small illness foci can be remedied by simple opera-
pared with the drawing dimensions. tions provided they are found at an early stage.
- If there is any doubt, the component can Once the disease has reached the advanced
be re-calculated by a neutral organization. stage, often nothing can be done.
- In difficult cases, the involvement of a la- The regular checking of construction machinery is
boratory is recommended in order to carry also a preventive investigation, for example. It is an
out precise material analyses, hardness integral part of VBG 40.
curves, structure assessments, surface Test procedure and subsequent measures:
assessments, for example.
 Clean the equipment.
- Sometimes, a report from an independent
laboratory may also be necessary to settle  Check critical parts of the component visually.
liability issues. Record all findings.
 Any repair with a high expectancy of fatigue  Contact the manufacturer to discuss the test
strength has to be planned properly and care- result.
fully executed.  Plan and execute the necessary repairs.
All feasible advantages should be used at  Stock components likely to suffer damage.
each stage of the work.
 Stock wearing parts.
Even what are known as “trivialities” may be 2.5 Determining cracks and other de-
very important for the success of a repair.
fects
The repair work must be supervised. It must be Cracks and other defects in plates, forgings and
decided in advance when inspections will be steel castings can be detected by check proce-
made. dures.
2.5.1 Surface crack test using the dye penetra-
It is advisable to explain the theoretical back-
tion method
ground of the repair to the welder who will do
the work. He will then also feel responsible for The dye penetration method is the easiest way to
the success of the work. find cracks on the surface of the material.
 In the case of design-related or overload 1. Carefully clean the area to be tested.
damage, it may be necessary to strengthen the
2. Spray on red penetration fluid and leave for 5-
component after the repair.
10 minutes.
NB: the reinforcement must be practical. It 3. Remove the red penetration fluid using a
must be possible to prove the benefit of the re- special cleaning agent.
inforcement by means of a calculation.
4. Spray on white developer. Any cracks will be
Unconsidered reinforcements are useless, ex- revealed as narrow red lines on a white back-
pensive, convey a false sense of safety, in- ground. The intensity of the “bleed” and waiting
crease the weight of the component and may time will provide information on the depth of
impede its function. the crack.
Then rub off the developer with a cloth.
They are also “unattractive.”
22
3 842 954.000 en
2.5.2 Conduct the surface crack test using the 3. Operating techniques for re-
magnaflux method
pairs
Using the magnaflux method, cracks can be de-
tected on the surface of the material and up to a For repair welding, operating techniques have to
maximum of 0.2 mm below the surface. be used that are not necessary when making a
steel component.
The component is magnetized and then sprayed
with a fluid containing fine (dust-fine) iron particles. Many of the operating techniques described are
The iron particles settle on the cracks and make the result of wide-ranging experience and have
them visible. proved successful in practice.
2.5.3 Ultrasonic inspection 3.1 Gouging and welding cracks
The ultrasonic inspection is used to detect defects The “ARC AIR” method is the most suitable meth-
inside materials of a thickness from 8 mm and in od for gouging cracks (Fig. 45).
welds. The ultrasonic inspection may only be
performed by qualified testers.
Qualification: UT 2 of an internationally recognized
test organization.
2.5.4 Caterpillar Global Mining HMS check
procedure standards
The Caterpillar Global Mining HMS standards or
purchase specification contain detailed information
on the check procedure:
07 47 04, Part 1 Dye penetration meth-

od, magnaflux method Fig. 45
An arc is struck between a carbon electrode and

07 47 01, plate Ultrasonic inspection of the material to be removed. A directed compressed
1 welds air jet is used to blow away the melted base mate-
rial.
07 47 01, plate Ultrasonic inspection of Gouging with a gas-oxygen gouge or gouging

2 castings and forgings electrodes is also possible.
It is important to start the gouging at the end of the
The Caterpillar Global Mining HMS standards can crack and work toward the component edge. If the
be obtained from Caterpillar Global Mining HMS process is reversed, the crack may spread further
Dortmund, Standards Department. Indicate the through the effect of the heat.
language (German or English).
It must be assumed that the crack has already
reached the grain boundaries of the material,
where it cannot be located visually or by other
check procedures (Fig. 46).
Therefore, start the gouging process not at the end
of the crack, but just before the crack.
Preheat the crack area to gouge it (see 6.1).
After gouging under heat, finish the welding groove
by grinding. The surfaces must be metallically
bright.
23
3 842 954.000 en
Welding is then done from the top (Fig. 48).
Fig. 46
A Visible crack
B Damage at the grain boundaries
Fig. 48
If, in the case of fixed positions, the crack is acces- Welding on so-called weld pool backing plates
sible from both sides, gouge a groove from the should not be used if it is possible to weld from
bottom initially (Fig. 47). Groove depth approxi- both sides. A pool backing plate in the root area of
mately 1/3 of the material thickness. the weld seam actually represents a mechanical
notch/shape notch.
3.1.1 Ramified cracks
Ramified cracks should be gouged and welded in
steps (Fig. 49).
Fig. 47
Then weld here first.

The crack is then gouged from the more easily
accessible top as far as the seam welded from the
bottom.
Fig. 49
24
3 842 954.000 en
Otherwise, material areas between the cracks may 3.1.2 Cracks in hub connections
drop out, resulting in gaps that cannot be bridged.
Fig. 51 shows a bearing hub connection in a box
Also gouge and weld long cracks gradually (Fig. girder, which is only accessible from one side.
50).
Fig. 51
1. Hub
2. Web plate
3. Square-edge weld
4. Fillet counter-weld, welded before the box
section is closed.
The main features of the example are the fillet weld
counter-weld on the outside edge and the web
Fig. 50
plate in contact.
When cooling part welds, the surrounding cold The following defects may occur:
areas prevent excessive shrinkage and distortion
of the component.
25
3 842 954.000 en
3.1.2.1 Fracturing in the center of the weld (Fig.

52)
Fig. 55
Fig. 52
One possible cause is a cracked fillet weld coun-

ter-weld.
Remedy:
Gouge the crack carefully (Fig. 53).
Weld the gouged groove (Fig. 54).
Gouge around the web plate (2) in the area of the
fillet weld counter-weld as far as the collar of the
hub (1) (Fig. 54).
Fig. 53
Fig. 54
26
3 842 954.000 en
3.1.2.2 Sharp, exactly radial crack in the edge

not in contact
A possible cause is lack of fusion in the weld edge
not in contact (see arrow in Fig. 56).
Fig. 58
Fig. 56
Remedy:
Gouge the crack carefully (Fig. 57).
Fig. 57
27
3 842 954.000 en
3.2 Welding on a metal cylinder using 3.2.1 Work sequence

the back-step welding method 1. Mount and align the dome according to the
This example describes the welding of a machined information in the drawing. Firmly tack weld the
dome on to a chassis. outside of the dome. Check the dimensions af-
ter tack welding.
The back-step welding method can be used any-
where where maximum distortion-free welding is
necessary.
This applies to round welds and longitudinal welds.
Fig. 59 shows how the weld is to be made between
the dome web plate and the base plate.
Fig. 61
2. Weld 1/3 of the inside of the dome (Fig. 61).

Use a 3.20-mm diameter rod electrode.
Weld using the back-step welding method,
step length: approximately 250 mm
Fig. 59
Fig. 62 shows an example of the back-step
A. Outside of the dome method.
B. Inside of the dome
The dome is welded in the position in which it is
used.
Welding position: horizontal
Use the right electrode position to avoid lack of
fusion (9, Fig. 60) on the dome edge.
Fig. 62
Fig. 60
28
3 842 954.000 en
3. Neatly grind the welding groove from the 5. Finish the welding of the seam inside the
outside of the dome. Remove any slag from dome,
the 1st pass that has seeped through. Grind off
the last 2/3 with a 4- or 5-mm diameter rod
any cracked tack welds completely.
electrode.
Do not overweld cracked tack welds!
6. Clean the welds and test.
6.1 There must be no undercuts, pores, arc
strikes, end craters, splatter, slag, etc.
6.2 Use the dye penetration method to check
for surface cracks. There must be no
cracks.
7. Check the dimensions. Do not use hot
straightening for any unevenness in the area of
the dome/flange (risk of distortion through in-
ternal welding stresses).
Fig. 63
4. Weld the seam on the outside of the dome

completely.
2nd pass rod electrode:
diameter 3.20 mm
3rd and 4th pass rod electrode:
diameter 4 mm or 5 mm
Weld all the beads using the back-step meth-
od. The seam toes must be in a terrace forma-
tion.
29
3 842 954.000 en
3.3 Cracks in box sections removed.

The gouging and welding of cracks from the out- Resultant notches lead to new damages.
side only is not recommended.
When welding without a pool backing plate, the
root area is usually not completely included, or
excessive penetration occurs (Fig. 64).
Fig. 64
In either case, new cracks will occur, starting from

the mechanical notches in the root area.
Welding on pool backing plates that have been
inserted through the groove is not recommended
either (Fig. 65).
Fig. 65
The backing plates do not abut exactly, so any

flash and slag residue underneath cannot be
30
3 842 954.000 en
3.3.1 Opening the box section Notice:

If the crack is only accessible from one side, ac- Ribs are often evident on the other side of the
cess has to be created from the second side. This plate; they are particularly visible on painted sur-
can be done by opening the component in less faces.
highly stressed areas (Fig. 66 and 67).
Gouge the crack from inside first (1/3 plate thick-
ness) and weld. Then finish the outside and close
the box section again.
3.3.2 Cutting out part sections of a flange plate
Fig. 68-73 show how a box section component can
be carefully opened.
The part section (1, Fig. 68) of the top flange (2) is
to be removed.
Fig. 66
Fig. 68
Pierce the flange plate (2, Fig. 69) behind the web
plate (3) with the flame (4). Cut as closely past the
web plate as possible in the longitudinal direction.
There must be no torch marks on the web plate.
Fig. 67
The openings may also be entrance openings in

bigger components. Size of entrance openings
approximately 500 mm x 500 mm.
Consulting Design is recommended if experience
with the internal construction of the component is
Fig. 69
lacking. A drawing showing the position of any rib
structures inside the box should be available. If
necessary, it needs to be determined by means of
small sight holes where openings of adequate size
can be made.
31
3 842 954.000 en
Cut off the residual strips of the flange plate (5, Fig. Otherwise, the web plate (3, Fig. 73) will be dam-
70) from the inside. aged unnecessarily (5 = damage area/flame cut
surface).
Fig. 70
Fig. 73
Flame cut the welding bevel for welding on the new
flange plate part section (Fig. 71). Welding on pool backing plates.
The openings in components to reach the 2nd side
when welding cracks have to be closed carefully
again after welding.
In this case, welding is done from one side on pool
backing plates (Fig. 74).
Fig. 71
Cut in the transverse direction of the flange plate

from the web plate to the center and not with the
torch flame on the web plate as illustrated (3, Fig.
72).
Fig. 74
The weld geometry illustrated and the welding

sequence are to be followed carefully. Only in this
way can a weld seam be achieved with a relatively
small root notch factor.
Of course, a weld seam with this root notch factor
needs to be permitted in the selected component
area. Clarify this before the component is opened.
Fig. 72
32
3 842 954.000 en
In general, this also applies to the welding of T- If the groove is wider than necessary, start with
joints (Fig. 75). hardfacing on one of the seam edges to avoid
excessive transverse shrinkage. Only then the
edges are connected (Fig. 77).
Fig. 75
The same method can also be used to weld plates

of different thicknesses (Fig. 76).
The method in Fig. 76 is undoubtedly better.
Bevel the thicker plate in a ratio of 1:4.
Fig. 77
The same applies to welding T-joints when the

groove is too wide.
Fig. 76
The welding groove must never be too narrow,

because otherwise the planned welding sequence
cannot be observed.
33
3 842 954.000 en
Pool backing plates 3.4 Recommended groove shapes for

Pool backing plates are usually made from 30 x 6 electrodes – manual welding
or 25 x 4 flat steel (Fig. 78). Aim for the following weld shapes for repairs or
welding work outside the manufacturer’s works.
These weld shapes can be used for plate thick-
nesses up to 30 mm. The dimensions indicated
apply to this plate thickness.
The opening angle can be reduced to 45° in the
case of gas-shielded metal-arc welding.
For bigger plate thicknesses, the opening angle
has to be reduced until there is a maximum groove
opening of approximately 30 mm. Welds other than
square edge welds preferably have to be gouged,
ground and counter-welded.
3.4.1 Butt joints
Recommended weld shapes:
- groove weld (Fig. 81)
Fig. 78
- Double-groove weld (Fig. 82)
Pool backing plates for non-rectilinear welds are
cut out of accordingly thick plates (Fig. 79) or - Bevel weld (Fig. 83)
welded together from flat steel (Fig. 81). Weld and
- Double-bevel weld (Fig. 84)
grind the joints on both sides.
- Square-edge weld (Fig. 85)
Fig. 81
Fig. 79
Fig. 82
Fig. 80
34
3 842 954.000 en
3.4.2 T-joints
Recommended weld shapes:
- Bevel weld (Fig. 86)
- Double-bevel weld (Fig. 87)
- Square-edge weld (Fig. 88)
Fig. 83
Fig. 86
Fig. 84
Fig. 87
Fig. 85
Welding process accord-

Opening angle β
ing to DIN EN ISO 4063
Manual metal arc welding
60
(111).
MAG (135) 45
Welding wire (136) 45
Fig. 88
35
3 842 954.000 en
3.5 Work sequence when welding 3.5.1.3 Double-groove weld (Fig. 91), weld
accessible from 2 sides
3.5.1 Butt weld
+ Easily accessible side
- Side not easily accessible
3.5.1.1 Groove weld (Fig. 89)
Fig. 91
A. Weld prepared
B. Groove overhead-welded
Fig. 89
C. Root gouged
A Weld prepared
D. Seam welded
B Groove welded
3.5.1.4 Double-groove weld (Fig. 92), weld
C Root gouged from underneath
accessible from 2 sides by turning the
D Root welded component
3.5.1.2 Groove weld (Fig. 91), weld accessible
from 2 sides by turning the component
Fig. 92
A. Weld prepared
Fig. 90
B. Root welded
A Weld prepared
C. Plate turned, root gouged
B Groove welded
D. Seam welded
C Plate turned, root gouged
D Root welded
36
3 842 954.000 en
3.5.1.5 Groove weld with pool backing plate 3.5.2 T-joint

Groove weld with 25 x 4 pool backing plate (Fig. 3.5.2.1 T-joint (Fig. 94), accessible from 2 sides
93), weld accessible from 1 side
Fig. 94
A. Web and flange plate tack welded

B. Bevel weld welded
C. Root gouged
D. Seam welded
3.5.2.2 T-joint with pool backing plate (Fig. 95),
Fig. 93
accessible from 1 side
A. Pool backing plate attached
B. Welding groove made and 1st root bead
welded
C. 2. Root bead welded
D. Seam welded
Fig. 95
A. Pool backing plate welded on

B. Root bead welded
C. Root bead welded
D. Seam welded
37
3 842 954.000 en
3.6 Closing openings, renewing com- Weld seams [2] and [3] alternately. Weld long
ponent areas seams using the back-step method
Openings (Fig. 96) with adequate vision should be Back-step welding:

as small as possible, but at the same time big
enough to be able to work unhindered.
Experience: 300 mm long and 200 mm high open-
ings are usually adequate.
3.6.1 Closing a work opening
Fig. 97
Weld seam [4] like seam [1].
Fig. 96
This example (Fig. 96) is suitable for plate thick-

nesses up to 25 mm.
Fig. 98 shows a hoe stick. The moment diagram
shown below clearly shows where the highest
loads, and therefore also the highest stresses,
occur. Therefore, weld [1] is the weld that lies in
the area of the higher flange stress.
Weld seam [1] from the center to the right and left
to about the center of the radii. End the upper Fig. 98
beads or pass approximately 15 mm before the
end of the bead or pass underneath. Allow the fully
welded seams to cool down to approximately +
50°C.
38
3 842 954.000 en
3.6.2 Closing a web plate opening
Fig. 101
Fold 30 x 4 flat steel pool backing plate (3) or

cut out of a 4 mm plate. Do not tack weld pool
backing plates from flat steel, because there is
no depth of coverage for the radii.
4. Attach the pool backing plate (3) to the web
Fig. 99 plate (2) using screw clamps (Fig. 102). Weld
1. On the web plate (2, Fig. 99 + 100), bevel the peripheral 3 mm fillet weld, do not tack weld
welding bevels to approximately 10°. The width (Fig. 103).
b of the bevel can be seen in Fig. 112 with ref-
erence to the plate thickness.
Fig. 102
After welding the fillet weld, remove splatter

from the abutment surface for the filler plate
(arrow, Fig. 103).
Fig. 100
2. Gouge longitudinal welds between the flange

plate (1) and the web plate (2) approximately
100 mm at the repair opening (Fig. 100).
3. Install the pool backing plate (3, Fig. 101) only
at the web plate edges.
Fig. 103
39
3 842 954.000 en
Produce the filler plate (5, Fig. 104) for the repair Fix the filler plate (5, Fig. 106) using screw
opening. Use a new plate of the same thickness for clamps. This can be done in workshops up to
this. Bevel the filler plate as shown. See Fig. 112 box widths of 1.5 meters.
for the bevel width (b).
Fig. 106
Fig. 104
If screw clamps cannot be used, fix the filler
plate using the so-called “retainers” (6, Fig.
5. Install the filler plate (5, Fig. 105). 107). Weld the retainer (6) to the web plate (2)
Make sure the welding grooves are perfect. with fillet welds. Then secure the filler plate (5)
by driving in wedges (7).
The filler plate is to abut the pool backing plate
completely. Flame-cut the retainers after welding the filler
plate.
In the case of distortion, the pool backing plate
has to be straightened, if the backing plate is Clean grind the welded areas.
accessible. Do not hammer off the retainers.
Fig. 107
Fig. 105
40
3 842 954.000 en
Weld in the filler piece (Fig. 108).
Fig. 109
Fig. 108
You must follow the welding sequences illus-

trated. The symbols used have the following
meanings:
Weld seam [1] to approximately the center of

the radii. Weld the first bead exactly between
the filler piece (5) and the pool backing plate
(3). The upper bead must end approximately
15 mm before the bead underneath. The filler
piece may shrink after the seam [1] has been
welded.
Then weld the two seams [2] and [3]. In this
case, make sure there is a clean toothing with
the ends of the seam [1] (grind the seam
ends). Pull the other ends through as far as the
flange plate. Grind out the seam ends [2], [3]
on the flange plate as shown in Fig. 108 so
that the same groove shape is produced as in
the case of the web plate and filler plate.
Finally, weld seam [4]. Make sure there are no
seam toes or weld heels of weld [4] at the end
of welds [2] and [3]. Weld seam [4] continu-
ously with string beads as much as possible.
At last, grind the surfaces of the welds [1], [2],
[3] level with the plate (Fig. 109).
41
3 842 954.000 en
3.6.3 Renewing part of a flange plate Bevel welding bevels to 10°.

3.6.3.1 Abutting flange plate Determine width (b, Fig. 111), see (Fig. 112).
In the case of a box girder with 2 web plates (Fig.
110), a new flange plate piece has to be welded in. PLATE THICKNESS t BEVEL WIDTH b
8 2.0
10 2.0
12 2.5
15 3.0
20 3.0
25 4.5
30 5.5
35 6.5
40 7.0
45 8.0
50 9.0
Fig. 112
Fig. 110 1. Gouge the longitudinal welds between the web
plate (2, Fig. 113) and flange plate (1) at the
flange connection approximately 100 mm.
Fig. 111
Fig. 113
42
3 842 954.000 en
Install the pool backing plate (3, 4, Fig. 114,115) at Weld the pool backing plates (3, Fig. 117) to
the two remaining flange plate ends (1). Fit neatly the web plates (2) with fillet welds.
into place and avoid gaps.
Fig. 114 Fig. 117
3. Tack weld the pool backing plates (4, Fig. 118)

to the outside of the web plate and flange
plate.
Fig. 115
Use 25 mm x 4 mm flat steel as the pool back-

ing plate (3, 4). Fit pool backing plate (3) pre-
cisely between the two web plates (2). Adapt
the outer pool backing plates (4) to the Fig. 118
grooves of the web plates (2) and allow them
4. Tack weld run-off tabs (5, Fig. 119) to pool
to project approximately 30 mm.
backing plates (4). See also section “Run-off
2. Tack weld the pool backing plates (3) between tabs” in this respect.
the web plates. If welding deformation occurs
(Fig. 116), straighten the pool backing plates.
Fig. 116
Fig. 119
43
3 842 954.000 en
Install a new flange plate section (6, Fig. 120). Do Weld the flange plate piece. Observe the weld-
not re-use the old flange plate piece previously cut ing sequences shown (Fig. 122). The symbols
out. Make sure that the new flange plate abuts used have the following meaning:
neatly.
Fig. 122
Seam [1] – transverse seam that lies in the ar-

ea of the higher stresses of the flange plate.
Weld the seam completely.
Seam [2] + [3] – weld the longitudinal seams in
the direction of the arrow.
Fig. 120
Seam [4] – weld the transverse seam com-
5. Weld the two fillet welds (Fig. 121) as illus- pletely.
trated. Weld fillet welds continuously, no tack
welds. Seam [5] + [6] – weld the longitudinal seams in
the direction of the arrow.
Weld seams [1] and [4] with string beads. Weld
as far as the 50 mm long run-off tabs (4). After
welding, neatly detach the run-off tabs.
Ground the surfaces of the transverse seams
clean and level with the plate. Cleanly gouge
the longitudinal seams in the area of the trans-
verse seams. The grinding marks are to run in
the longitudinal direction of the force. Then, if
possible, carry out the ultrasonic inspection on
the transverse seams.
Notice:
When welding the longitudinal seams [2], [3],
Fig. 121 [5], [6] there must be no weld seam toes or
heels in the area of the transverse seams (pool
backing plate).
Fig. 123
44
3 842 954.000 en
3.6.3.2 Internal flange plate

In the following example, in the case of a box
girder with 2 web plates, a new internal web plate
piece is welded in (Fig. 124).
Fig. 126
3. Install the pool backing plates (3, Fig. 127,

128) at the two remaining flange plate ends
(1). Use 25 x 4 mm flat steel as the pool back-
ing plate (3). Fit the pool backing plate (3)
Fig. 124
neatly and without gaps between the two web
Work sequence plates (2).
Fig. 127
Fig. 125
1. Bevel welding bevels to 15°. Determine width

(b, Fig. 125) from the diagram (Fig. 112).
2. Gouge the longitudinal welds between the web
plate (2, Fig. 126) and flange plate (1) at the
flange connection approximately 100 mm.
45
3 842 954.000 en
Weld the flange plate piece. Observe the weld-

ing sequences shown (Fig. 130) at all costs.
See 3.6.3.1, point 5, for execution of the welds.
Fig. 128
4. Tack weld the pool backing plates (3) between

the web plates. (Fig. 128 + 129). Straighten the
pool backing plates if welding deformation oc- Fig. 130
curs.
Fig. 129
46
3 842 954.000 en
3.6.3.3 Possible causes of damage to flange Reason for the damage:

plates
Non-metal inclusions from the melt (segregation)
The following defects may occur at the flange are distributed in the center of the plate over the
plates of box sections. entire plate.
1. Transverse cracks Measures:
The flange plate may crack transversely to the The plate cannot be repaired by welding.
component in the flange plate.
The damaged plate has to be replaced to achieve
a permanent repair. The plate areas that have not
yet cracked are likely to crack later through the
dynamic stressing of the component.
3. Longitudinal cracks
The flange plate may crack in the longitudinal
direction of the component parallel to the edge of
the plate (Fig. 133).
Fig. 131
Reason for the damage:

Impeded expansion of the component through
component elements, such as bearing mountings,
ribs, doubler plates, etc., not being dimensioned or
welded properly.
Measures:
Fig. 133
It is nearly always possible to repair the component
by welding. For a permanent repair, the component Reason for the damage:
has to be opened so that the welds in the highly
stressed areas of the component can be counter- The component is not stable enough. The flange
welded. plate deforms with changing loads. This causes
material constraints at the weld/flange plate transi-
2. Plate separation tion.
As shown in the diagram, the plate can crack more Measures:
or less exactly in the center (Fig. 132).
The flange plate cannot be repaired by welding.
For a permanent repair, the plate in the crack area
has to be replaced. The plate thickness of the new
plate has to be increased in order to reduce defor-
mation to a tolerable level.
Fig. 132
47
3 842 954.000 en
3.6.3.4 Repair of a boom with top flange 3. Repair damage inside the box and in the side
walls.
The top flange of the boom is cracked (arrows, Fig.
91). 4. Weld on a new top flange (Fig. 136). Increase
the plate thickness by 5-10 mm.
1. Remove the supporting block (1, Fig. 134).
Fig. 136
Fig. 134
5. Weld on the supporting block again (Fig. 137).
2. Remove the top flange in the area of the
damage (Fig. 135). Provided they are installed and welded care-
fully, it is not necessary to machine the re-
Recommendation: Remove the top flange in the moved parts as a rule.
bent area completely.
Fig. 137
Fig. 135
48
3 842 954.000 en
4. Reinforcement of steel com-  Thickness of doubler plates

The thickness of doubler plates should not ex-
ponents ceed 60% of the thickness of the plate to be
A component can be reinforced by welding using reinforced (Fig. 139).
the following methods:
 Covering a repaired area of damage with
doubler plates. In this case, the aim is to re-
duce the mechanical stresses (N/mm2) in the
repair area.
 Remedying defects by shape changes, e.g. the
problem of “open sections/closed sections,”
shape of the reinforcement ribs, formation of
frame corners, etc.
 Remedying defects by shape changes through
hardfacing, e.g. on steel castings.
Fig. 139
The need for component reinforcement should be
In mathematical terms, thicker doubler plates
proved by a simple calculation, if possible.
cannot be connected to the plate to be rein-
4.1 Doubler plates forced, because the welds would be too big.
They produce excessively large shape-related
4.1.1 Dimensions notches and increase the weight of the com-
 Length of doubler plates ponent beyond the necessary weight.
Metallurgical and shape-related notches occur  Width of doubler plates
at the ends of the doubler plates. Stress con- For steel components, the stresses are usually
centrations may lead to damage (part A, Fig. highest in the edge area. Therefore, the doub-
138). ler plate should be as wide as the plate to be
reinforced (A, Fig. 140).
Fig. 140
For production reasons, doubler plates thinner

than 8 mm should not be beveled. In these
cases, the doubler plate (B, Fig. 140) has to be
Fig. 138 narrower to leave space for a fillet weld. The
Therefore, the doubler plates should be suffi- top edges (arrow, Fig. 140) of the plate to be
ciently long so that their ends lie in areas ex- reinforced and of the doubler plate should not
posed to low basic stresses (part B, Fig. 138). be melted on.
49
3 842 954.000 en
4.1.2 Shape The narrow plate strips, possibly flat steel or wide
flat steel, are easier to bend and fit (Fig. 143).
Doubler plates should have the simplest shapes
possible. The ends should be rectilinear (Fig. 141 +
142).
Welding slots should be provided to relieve the
transverse welds (Fig. 141).
Fig. 143
Plate shapes which are not rectilinear (Fig. 144 +

145) are difficult to manufacture and offer no advan-
tages in terms of power flow.
Fig. 141
Plate strips can also be welded on. However, con-

tinuous longitudinal seams have to be welded.
Advantages:
The edge areas that experience has shown to have
high stresses are reinforced. Weight-saving (Fig.
142).
Fig. 144
Fig. 142
50
3 842 954.000 en
Fig. 147
The welds in the welding slots are ideal shear

connections between the doubler plate and the plate
to be reinforced.
Fig. 145
Circular welding holes are unfavorable (Fig. 148):
4.1.3 Welding slots

In addition to the welds on the outside contours, the
welds in the welding slots should also help to opti-
mize the attachment of doubler plates (Fig. 146 and
147).
Fig. 146
Drill out the ends of the slots (Fig. 146). Fig. 148
Slot width ≥ 2 x plate thickness (Fig. 147). The parts of the weld that lie transverse to the force
flow are not load bearing and cannot be considered
in the calculation.
The cross-section of the doubler plate is significantly
reduced.
Stress concentrations are formed at the hole edges.
51
3 842 954.000 en
4.1.4 Installation The break-out point in the base material has to be

ground carefully before welding up the slot.
Doubler plates should sit “snug,” i.e. as close as
possible, on the plate to be reinforced. The air gap
should preferably be “0”. For relatively small com-
ponents and thin plates, fix the doubler plates with
screw clamps (Fig. 149).
Fig. 149
For bigger components and thicker plates, wedge

the doubler plates (Fig. 150). However, this is only
possible in the edge areas of the plates. Welding on
the wedge brackets and removing them has to be
done very carefully. Never knock the brackets off.
Fig. 151
4.1.5 Welds at T joints

Doubler plates in the area of T-joints should be
welded on so that all 3 plates are connected (Fig.
152).
Fig. 150
The central area of plates can be fixed with screw

connections (Fig. 151). This is highly recommended
for large plate areas. The stud screws are best fitted
in the area of the welding slots. After tack welding,
the welded-on screw may only be knocked off.
Fig. 152
52
3 842 954.000 en
4.2 Deformation of plates as the result of  Rolling (Fig. 155):

repair work Cold forging;
Plates used for repair or reinforcement work can No problems expected after forging.
deform in different ways.
Information on problems with different types of
deformation:
 Folding (Fig. 153):
Cold forging;
Maintain the minimum radius of curvature.
Watch for longitudinal cracks in the area of the
curve.
Fig. 155
 Multi-edge folding (Fig. 156):

Cold forging:
Cracks have to be expected at the effective
lines of the tools at the plate edges. After the
multi-edge folding process, break the plate edg-
es 2 x 2 mm at the top and bottom.
Fig. 153
 Pressing (Fig. 154):

Cold or hot forging;
With cold forging, monitor the minimum radius of
curvature and also longitudinal cracks in the ar-
ea of the curve.
Fig. 156
Fig. 154
53
3 842 954.000 en
4.3 Reinforcement by improving the It is a good idea to grind the transition areas (Fig.
shape 158).
4.3.1 Rib run-off
Ribs that end at highly stressed component ele-
ments must run off as illustrated in Fig. 157. This
also applies to ribs of secondary importance.
Fig. 158
In this case, the weld must not be ground off.

4.3.2 Open sections/closed sections
The torsional resistance moment of a closed section
is approximately 500 times higher than that of an
open section with otherwise similar dimensions.
Consequently, stress peaks occur at the transition
from the open section to the closed section. They
are caused by restricted deformation and con-
straints (Fig. 159).
Fig. 157
t a h R e L1 L2
o
mm mm mm mm mm mm mm
6 4 6 10 60 20 30 12
8 4 6 10 60 20 30 12
10 4 6 10 80 20 30 12
12 5 8 10 100 20 40 14
15 6 9 10 120 30 50 18
20 8 12 10 160 30 60 22
26 8 12 10 180 30 70 22
30 10 15 10 200 30 70 28
Fig. 159
T Torsional moment
O Open section
G Closed section
54
3 842 954.000 en
Therefore, a continuous transition has to be created 4.3.3 Reinforcement through hardfacing

between the open section and the closed section
Shape-related notches found on steel components
(Fig. 160).
can be corrected or at least improved by hardfacing.
The work must be carefully planned and executed
(Fig. 161).
Fig. 160
Continuous welding around the transition is neces-

sary.
Fig. 161
55
3 842 954.000 en
4.3.4 Improvement of radii at ribs Then create a new, better contour by flame cutting
(Fig. 164). Ensure a stable cutter control
Fig. 162 shows a rib contour where the stress level
in the marked area is too high.
Fig. 164
Fig. 162 1 Flame cut here

To improve this, weld on a plate of the same thick- Neatly grind the flame cut and create the new con-
ness (Fig. 163): for welding steps, see section. tour (Fig. 165).
Fig. 163 Fig. 165
1. Weld groove 2 Grind here

2. Weld from one side The finishing work facilitates the gradual, continual
inflow of the component forces.
3. Gouge the root pass from the opposite side
4. Weld from the opposite side
5. Grind the weld surfaces
56
3 842 954.000 en
5. Materials, weld fillers

5.1 Materials in welded components
Warning
Before proceeding with welding, back gouging, hot
The material properties cannot be
or cold forging, and heat treatment, the repairer
determined through simple hard-
must know the component’s material.
ness measurements or even by a
The following information at least must be known: spark test. These test methods
lead to incorrect conclusions.
- Strength class
- Heat treated state
- Reference analysis, carbon equivalent The right weld fillers for the materials must then be
chosen. In this case, the machine manufacturer or
- Material thicknesses the weld filler supplier should be consulted. Rec-
The repair work depends on this very important ommendations can be obtained from the catalogs
information. of the weld filler manufacturers.
This information can be obtained from drawings and The materials used by Caterpillar Global Mining
parts lists. HMS and also the weld fillers suitable for them are
listed on the following pages.
At Caterpillar Global Mining HMS, for example, the
operator can ask the manufacturer for the necessary
information.
If there is time to plan the repair work, the material
type can also be determined by the materials labo-
ratory.
57
3 842 954.000 en
5.2 Weld fillers for Caterpillar Global Mining HMS – welded components, with refer-
ence to the material partners and welding process (Tables 1 and 2)
See annex for the reference numbers for weld fillers.
Material 1 Material 2 Weld filler: Metal active gas Weld filler: Manual arc
welding welding
(MAG-135) (manual 111)
S235JR S235JR G 46 4 M G4Si1 E 42 5 B 32 H5
AWS A 5.18 (ER70 S-6) AWS A5.1 (E7018-1)
S235JR S355J2+N G 46 4 M G4Si1 E 42 5 B 32 H5
AWS A 5.18 (ER70 S-6) AWS A5.1 (E7018-1)
S235JR G21Mn5+QT G 46 4 M G4Si1A E 42 5 B 32 H5
G20Mn5+QT WS A 5.18 (ER70 S-6) AWS A5.1 (E7018-1)
S355J2+N S355J2+N G 46 4 M G4Si1 E 42 5 B 32 H5
AWS A 5.18 (ER70 S-6) AWS A5.1 (E7018-1)
S 46 6 FB S3Si (UP) -
AWS ASME 5.17 (EH 12 K)
S355NH S355NH G 46 4 M G4Si1 E 42 5 B 32 H5
S235JR S355NH AWS A 5.18 (ER70 S-6) AWS A5.1 (E7018-1)
S235JRH S355J2+N
S355J2+N S690QL G 46 4 M G4Si1 E 42 5 B 32 H5
AWS A 5.18 (ER70 S-6) AWS A5.1 (E7018-1)
S355J2+N G20Mn5+QT G 46 4 M G4Si1 E 42 5 B 32 H5
AWS A 5.18 (ER70 S-6) AWS A5.1 (E7018-1)
S355J2+N G21Mn5+QT G 46 4 M G4Si1 E 42 5 B 32 H5
G20Mn5+QT AWS A 5.18 (ER70 S-6) AWS A5.1 (E7018-1)
S690QL S690QL G 69 6 M Mn4Ni1,5CrMo E 69 5 Mn 2 NiCrMo B 42 H5
AWS A5.28 (ER110S-G) AWS A5.5 (E11018-G)
G21Mn5+QT G21Mn5+QT G 46 4 M G4Si1 E 42 5 B 32 H5
G20Mn5+QT G20Mn5+QT AWS A 5.18 (ER70 S-6) AWS A5.1 (E7018-1)
G20Mn5+QT
G24Mn6+QT2 S690QL G 69 6 M Mn4Ni1,5CrMo E 69 5 Mn 2 NiCrMo B 42 H5
(formerly:25CrMo4V) AWS A5.28 (ER110S-G) AWS A5.5 (E11018-G)
Wear protection (buttons, S690QL G 46 4 M G4Si1 E 42 5 B 32 H5

chock blocks, corner AWS A 5.18 (ER70 S-6) AWS A5.1 (E7018-1)
protection, base plate)
Teeth holder S690QL G 46 4 M G4Si1 E 42 5 B 32 H5
AWS A 5.18 (ER70 S-6) AWS A5.1 (E7018-1)
Corner blade S690QL 2/3 with G 46 4 M G4Si1 E 42 5 B 32 H5

AWS A 5.18 (ER70 S-6) AWS A5.1 (E7018-1)
1/3 with G 69 6 M Mn4Ni1,5CrMo E 69 5 Mn 2 NiCrMo B 42 H5
AWS A5.28 (ER110S-G) AWS A5.5 (E11018-G)
Wear plates (Hardox 500,
Dillidur 500, XAR 500, S690QL G 46 4 M G4Si1 E 42 5 B 32 H5
Brinar 500 Cr) (ESCO cutting edge) AWS A 5.18 (ER70 S-6) AWS A5.1 (E7018-1)
1) G 46 4 M G4Si1 according to DIN EN ISO 14341-A
2) G 69 6 M Mn4Ni1,5CrMo according to DIN EN ISO 16834-A
3) S 46 6 FB S3Si according to DIN EN ISO 14171-A
4) E 42 5 B 32 H5 according to DIN EN ISO 2560-A
5) E 69 5 Mn 2 NiCrMo B 42 H5 according to DIN EN ISO 18275
Table 1
58
3 842 954.000 en
Material 1 Material 2 Weld filler: Metal active gas

welding
(MAG-136)
S235JR S235JR T 46 4 MM 1H5

AWS A5.18 (E70C-6MH4)
S235JR S355J2+N T 46 4 MM 1H5
AWS A5.18 (E70C-6MH4)
S235JR G21Mn5+QT T 46 4 MM 1H5
G20Mn5+QT AWS A5.18 (E70C-6MH4)
S355J2+N S355J2+N T 46 4 MM 1H5
AWS A5.18 (E70C-6MH4)
-
S355NH S355NH T 46 4 MM 1H5
S235JR S355NH AWS A5.18 (E70C-6MH4)
S235JRH S355J2+N
S355J2+N S690QL T 46 4 MM 1H5
AWS A5.18 (E70C-6MH4)
S355J2+N G20Mn5+QT T 46 4 MM 1H5
AWS A5.18 (E70C-6MH4)
S355J2+N G21Mn5+QT T 46 4 MM 1H5
G20Mn5+QT AWS A5.18 (E70C-6MH4)
S690QL S690QL T 69 5 Mn2NiCrMo M M 2 H5
AWS A5.28 (E110C-K4MH4)
G21Mn5+QT G21Mn5+QT T 46 4 MM 1H5

G20Mn5+QT G20Mn5+QT AWS A5.18 (E70C-6MH4)
G20Mn5+QT
G24Mn6+QT2 S690QL T 69 5 Mn2NiCrMo M M 2 H5
(formerly:25CrMo4V) AWS A5.28 (E110C-K4MH4)
Wear protection (buttons, S690QL T 46 4 MM 1H5
chock blocks, corner AWS A5.18 (E70C-6MH4)
protection, base plate)
Teeth holder S690QL T 46 4 MM 1H5
AWS A5.18 (E70C-6MH4)
Corner blade S690QL T 46 4 MM 1H5
AWS A5.18 (E70C-6MH4)
T 69 5 Mn2NiCrMo M M 2 H5
AWS A5.28 (E110C-K4MH4)
Wear plates (Hardox 500, T 46 4 MM 1H5
Dillidur 500, XAR 500, S690QL AWS A5.18 (E70C-6MH4)
Brinar 500 Cr) (ESCO cutting edge)
6) T 46 4 MM 2H5 according to DIN EN ISO 17632-A
7) T69 5 Mn2NICRMO MM H5 according to DIN EN ISO 18276-A
Table 2
59
3 842 954.000 en
6. Heat treatment of the materials

When repairing steel components, it is often
necessary to use heat. Observe the heat treat-
ment instructions according to the materials and
work methods used.
6.1 Preheating for tack welding,
welding, grooving, and flame cut-
ting
Preheating for tack welding, welding, grooving,
and flame cutting is necessary for two main rea-
sons:
 It prevents a too fast heat outflow from the
Fig. 167
heat affected zone. By specifically lengthening
the cooling time, the formation of hard and Butt joint (Fig. 168)
brittle structure states is avoided.
Two-dimensional heat dissipation. Fast heat
 Any moisture in the vicinity of the welding outflow through large component cross-sections.
area dries up. The penetration of harmful hy-
drogen and oxygen into the liquid welding
pool via the arc is prevented.
Influence of the wall thickness on the welded
joint
When preheating components for welding, the
volume of heat to be introduced depends on the
component dimensions and the welded joint.
T-joint (Fig. 166)
Three-dimensional heat dissipation. Very fast heat
outflow through large component cross-sections.
Fig. 168
Butt joint (Fig. 169)

Two-dimensional heat dissipation. Slow heat
outflow through small component cross-sections.
Fig. 166
T-joint (Fig. 167)

Three-dimensional heat dissipation. Slow heat
outflow through small component cross-sections.
Fig. 169
60
3 842 954.000 en
Avoiding hardness peaks The preheating temperature mainly depends on

the material, shape, and thickness of the compo-
Preheating prevents the formation of structure
nent, the welding method, and climatic factors.
states that are undesirable because they are too
hard and brittle. When doing repair work, the temperatures speci-
fied in the following list must be kept.
If there is any doubt, in order to guarantee an
expert repair, the welding company must obtain
information on the necessary preheating tempera-
tures from a specialist welding engineer of the
relevant Caterpillar Global Mining MHS factory via
Caterpillar Global Mining HMS Customer Service.
Fig. 170
1. Hardness, not permitted*

2. Hardness, permitted*
3. Hardness in the base material, heat affected,
without preheating
4. Hardness in the base material, heat affected,
with preheating
5. Weld metal
6. Base material, not heat affected
7. Hardness scale
HV = hardness
* depending on the material
61
3 842 954.000 en
6.2 Preheating and interpass temperatures; heating up and cooling down rates for
repair welding
Wall thick- Preheating tempera-
Name of material Interpass temperature
nesses ture
Room temperature
S235JR all max. 250 °C
(minimum 20 °C)
< 40 mm min. 20 °C max. 250 °C

S355J2+N
≥ 40 mm min. 100 °C max. 250 °C
< 80 mm min. 100 °C max. 220 °C

S690QL
≥ 80 mm min. 150 °C max. 220 °C
< 50 mm min. 50 °C
G20Mn5+QT max. 250 °C
≥ 50 mm min. 100 °C
< 50 mm min. 100 °C

G21Mn5+QT max. 250 °C
≥ 50 mm min. 150 °C
G24Mn6+QT2 < 50 mm min. 100 °C

max. 220 °C
(formerly: GS-25 CrMo 4 V) ≥ 50 mm min. 150 °C
Esco casting 1)
(teeth holders, cutting edges,
blades, corner blade, wear all min. 150 °C max. 220 °C
protection)
Wear plates 2) < 20 mm min. 100 °C

(Hardox 500, Dillidur 500, and max. 220 °C
XAR 500) ≥ 20 mm min. 150 °C
1) When tack welding, corner blades and wear protection of Esco steel castings do not have to be preheated.
2) When tack welding, wear plates do not have to be preheated. Preheating and interpass temperatures must
be measured according to DIN EN ISO 13916.
62
3 842 954.000 en
Preheating process: Temperature measurement

When preheating, the heat must be introduced at If two plates of the same material but of unequal
a rate of 30° -50° C/h (90°-120°F). This can be thickness are welded together, the thicker plate
done by using one of the following methods: determines the choice of preheating temperature.
The interpass temperature is measured on the
 Electric heat mats weld.
If the fasteners for the heat mats are welded If two different materials are welded together, the
onto the component, the welding areas must plate with the highest requirement determines the
be preheated locally. After removing the fas- preheating and interpass temperature.
teners, ground the welded areas in order to
eliminate any micro-cracks in the compo-
nent’s material.
Butt weld:
 Gas heaters t ≤ 50 mm: A= 4 x t max. 50 mm
Gas heaters have to be positioned on the t > 50 mm: A = 75 mm
component so that there can be no local
over-heating of the component. If necessary,
the component must be protected against
overheating with the aid of heat deflectors.
 Gas burners
Gas burners should burn with a soft, low ox-
ygen flame. Because of the risk of local
overheating, the gas flames must not touch
the component. Protect the component
against overheating with heat deflectors.
For all heating methods, cover the component by
insulating mats to prevent too much heat being
transmitted to the environment. After welding, do
not accelerate the cooling process with com-
pressed air, draughty air or water. Depending on Fig. 171
the material (see details), the welding area has to
cool down slowly to room temperature, RT = 20°C
(70°F) at a rate of 30°C to 50°C/h (90°C to Fillet weld:
120°F). Cover the components must with insulat- t ≤ 50 mm: A= 4 x t max. 50 mm
ing mats to cool down.
t > 50 mm: A = 75 mm
For technical and economic reasons, it is recom-
mended that repair welding lasting over several
shifts is done with the necessary preheating, and
controlled cooling is carried out continuously, i.e.
in one operation. (day shift, night shift, etc.). If the
welding is done in the day shift only, cool down to
room temperature accurately and heat up to the
required preheating temperature.
Fig. 172
63
3 842 954.000 en
6.3 Hot forming of plates 6.5 Stress-free annealing of steel com-

On absorbing heat, steel loses the mechanical ponents
properties that it possesses in the cold state. This 6.5.1 Range of application
property can be used for hot forming purposes.
This supply specification applies to the production
In repair practice, only normalized plate qualities, of welded components for Caterpillar Global
e.g. S235JR, S355J2 + N can be hot formed. Mining HMS GmbH and its suppliers
Tempered plate qualities can only be cold formed, 6.5.2 Scope
or at temperatures between 400°C (750°F) and
550°C (1020° F). At approximately 800°C This supply specification is valid for Caterpillar
(1470°F), tempered plated qualities, such as Global Mining HMS GmbH. It takes precedence
S690QL, would be too highly tempered and lose and applies to the stress-free annealing of:
their mechanical properties. They would have to Welded constructions of plate and casting steels
be re-tempered, which is hardly possible in repair of qualities S355J2+N, S690QL and G21Mn5+QT
practice. / G20Mn5+QT
Normalized or tempered plate qualities must Tempered steel castings after repair welding
never be formed in the temperature range of
approximately 100°C – 350°C (210°F – 660°F) 6.5.3 General information
because in this temperature range, known as blue The stress-free annealing of steel components
heat, the material is brittle and tends to crack in mainly depends on the type of construction and its
the area where it is formed. welding sequence, the material and the load.
6.4 Flame straightening plates The temperature of the annealing furnace must
Plates can be cold or hot straightened. not exceed 150°C when the component is intro-
duced. The component must be correctly posi-
For cold straightening, the necessary forming tioned and supported on the furnace car in order
forces are applied from outside via tools, e.g. to avoid any unnecessary changes in shape
presses or rollers. For flame straightening, the through its own weight when annealing. The
interaction through the local introduction of heat is component must also be free from oil, grease,
utilized: expansion of the material in the heated rust, scale, moisture, and residue.
area, upsetting of the hot material at the transition
to the cold area, shrinkage of the heated area and Cavities in welded constructions must be provided
straightening through internal stresses. The with an air pressure equalization opening. Choose
an area with low operating stress for this opening.
material should be heated red hot if an effective
straightening effect is expected. Again, the mate- The position of the bolt hole is indicated on the
rial quality has to be considered for this, too. Only drawing.
normalized plates can be hot straightened without The hole must have a diameter of at least 5 mm.
losing mechanical properties. Welding torches or electrodes must not be used.
The flame straightener temperature must not After cooling, weld up the bolt holes and then
ground the welds level with the plate.
exceed 700°C.
6.5.4 Heat-up rate
The annealing furnace is to be heated so that the
component heats up at a rate of approximately 30
°C/h – 50 °C/h. In the case of gas-fired furnaces,
the components have to be protected from the
direct gas flame by a protective plate.
6.5.5 Annealing temperature
For the stress-free annealing of welded construc-
tions an annealing temperature of 580 °C ± 10 °C
is defined.
For stress-free annealing after repair welding of
steel casting, the annealing temperature must be
at least 30°C – 50°C below the tempering tem-
perature (560°C – 580°C).
A uniform temperature distribution has to be
provided in the furnace chamber. The temperature
64
3 842 954.000 en
difference must not exceed a range of 20°C. This 6.6 Stress-relieving steel components
needs to be verified by an adequate number of
temperature monitoring instruments. Since the stress-relief annealing of repaired
components is only seldom possible and ma-
6.5.6 Dwell time chined surfaces may lose their dimensional stabil-
After the annealing temperature has been ity as the result of the annealing process, other
reached on the component, a minimum dwell time forms of stress-relief have to be adopted.
of 4.5 minutes/mm wall thickness is necessary to 6.6.1 Stress relief through heating
ensure that the relevant component cross-
sections are heated through uniformly. The dwell One way of reducing high local internal stresses,
time depends on the maximum weld thickness. e.g. after hardfacing or repairing welds, is what is
known as the stress relief of the component area.
6.5.7 Cool-down rate
The area around the presumed stress concentra-
The cool-down rate of the component from the tion has to be heated to 250°C – 300°C (480°F –
annealing temperatures should not exceed 570°F). Electric heat mats, gas heaters, or burn-
50°C/h. The component should be cooled down to ers can be used as the heat source.
a component temperature of approximately 350°C
with the furnace closed. The remaining cooling to Heat at a rate of approximately 30°C/h (90°F/h).
room temperature (20°C) can take place in static For components of simple design with a wall
air with the furnace open or outside the furnace. thickness of less than approximately 25 mm, a
6.5.8 Comments dwell time of 3 hours is sufficient. For more com-
pact components with wall thickness of more than
Components intended for stress-free annealing approximately 25 mm, a 5-hour dwell time is
are labelled on the drawing. needed.
Stress-free annealing of finish-machined sur- Cool at a rate of approximately 30°C/h (90°F/h).
faces/bolt holes is subject to the approval of the
design department of Caterpillar Global Mining Cover the component with insulating mats
HMS GmbH. Finished surfaces/bolt holes can be throughout the heat process. The temperature
protected by covers to prevent oxidizing. Compile difference in the component, e.g. between large-
a dimensional report before annealing. volume and compact areas and thin-walled areas
with ribbing must not be higher than 50°C (120°F).
6.5.9 Reporting
It must be confirmed in the report that all the
requirements of this supply specification have
been considered. The annealing parameters are
to be proved by a copy of a furnace graph.
65
3 842 954.000 en
6.6.2 Caulking welds 6.6.2.2 Caulking tools

Restricted shrinkage when the weld is cooled can For caulking, use compressed air driven riveting
lead to high internal stresses (tensile stress) and hammers and flat chisel tools with a suitably
cracks. Unrestricted shrinkage can cause compo- shaped cutting edge.
nent deformation (angular shrinkage).
The riveting hammers should be of a convenient
Both undesirable conditions can be resolved by shape and fitted with a throttle valve if necessary
caulking. to control the number of blows.
6.6.2.1 Work method The chisel cutting edge should be shaped as
shown in Fig. 173 and hardened.
Caulking is done after completion of a weld pass.
Note that a weld pass can consist of several
welding beads. It is not allowed to caulk the bead
of a pass individually.
The temperature of the weld must be below 100°C
(195°F) during the caulking process. All the weld
passes are to be caulked, except for the root and
cover passes. Remove slag and splatter from the
weld before caulking. Fix inadmissible excessive Fig. 173
curvature, notches and pores. Move the caulking
chisel two to three times over the same area of
the weld at a speed of around 100 cm/minute.
Make sure that no sharp notches, furrows, or
overlaps are produced during caulking. The
surface of the weld pass should be uniformly
treated.
Chisel hammers Chisel

Number of Piston Stroke Air con- Pres- Impact Cutting Tensile yield
blows diameter sumption sure force*) edge width strength of the
(mm)
weld metal
(per min- (mm) (l/min.) (bar) (N) b (mm)
ute) (N/mm2)
1680 - 45 - 6.5 -
20 - 28.5 420 - 650 ≈ 317 - 1913 16 - 25 460 - 690
3000 102 7.5
Data for chisel hammers and chisels that can be used with reference to the tensile yield strength of the weld
metal.
66
3 842 954.000 en
6.7 Treatment of welding fillers within approximately 8 hours (1 shift) after open-
ing the pack. Hydrogen content < 5 ml/100 g weld
Welding fillers, such as rod electrodes, welding metal.
wire coils, powder and welding rods need to be
stored in a place where they cannot deteriorate. Therefore, a carton (packet) contains several
This is only possible in rooms heated to approxi- individual packs to meet a welder’s needs. The
mately 30°C (90°F) and with a maximum atmos- rod electrodes, vacuum-sealed in foil, are tightly
pheric humidity of 50%. packed. Individual rods cannot move if the pack is
intact. Before the pack is opened, the temperature
Packaging must remain sealed until usage. Re- has to be equalized with the ambient temperature
pack and return unused welding fillers to the in the work place. Wet rod electrodes need to be
storage room. destroyed. They cannot be used, even if they are
Why is that necessary? re-dried.
 The coatings used for rod electrodes or the  Wet welding wires or welding rods rust. The
powder for submerged arc welding are hygro- copper coating offers only a limited corrosion
scopic, i.e. they absorb moisture from the en- protection time.
vironment. If they are left unprotected, these Rust is a chemical iron and oxygen compound
substances become damp or even wet. Dur- that introduces undesirable oxygen into the weld
ing the welding process, the hydrogen and metal. The material becomes brittle.
oxygen separated from the water penetrate in-
to the weld metal and embrittle it. Rusty welding wire contaminates the wire guides,
making them wear prematurely.
Rod electrodes from newly opened packages or
packages already started have to be dried again Rusted welding wires and rods must therefore be
and kept in a heated container until they are used. destroyed.
Manufacturers of rod electrodes provide informa- 6.8 Monitoring the temperature
tion on drying.
The following may be used to monitor the tem-
Guide values for electrodes with coating type B, perature of heat treatment processes:
according to the Böhler welding method.
 Electric temperature sensors:
Intermediate These are easy to use and indicate the exact
Minimum Drying storage temperature as an analog or digital value im-
tensile yield time in in heated con- mediately.
Temp. hours
strength of tainer
the base
°C (minimum)  Adhesive thermometer:
material Temp. Time Thermometer with an analog display that ad-
C° days heres to the component by means of mag-
nets.
≤ 355
250°C 2 150-200 ≤ 14  Temperature pens:
N/mm²
A mark is made with the pen on the compo-
> 355 300 – 150 - nent to be heated. When the desired tempera-
2 ≤ 14
N/mm² 350°C 200 ture range is reached, the color of the mark
changes. The process is very simple in princi-
However, the re-drying process should not exceed ple. However, experience is needed with the
a total re-drying time of 10 hours. pens.
This inconvenient but necessary process is often
not performed.
The manufacturers of rod electrodes are now
providing help.
The rod electrodes are supplied in a special site-
resistant, moisture-impermeable package (vac-
uum-packed electrodes).
It is no longer necessary to re-dry the rod elec-
trodes and keep them warm, if they are used
67
3 842 954.000 en
7. Cold forming of plates They depend on the plate thickness and the
rolling direction. The minimum radii of curvature
Plates can be cold formed. transverse to the rolling direction are more favor-
able than those longitudinal to the rolling direction.
However, minimum radii of curvature must be
observed in order to avoid cracks in the outer The welding aptitude in the area of the curve is
areas of the curve. also important for the minimum radius of curva-
ture. Due to the grain coarsening and the associ-
Details of the radii of curvature are given in the
ated embrittlement during heating after excessive
relevant standards for the various plate materials.
cold forming, the minimum radii of curvature
according to DIN 18800 Part 4 have to be ob-
served.
68
3 842 954.000 en
8. Hardfacing
Hardfacing has diverse uses. It is an important aid
for repair practice.
8.1 Supplementation of missing/worn
out materials
It may be necessary to supplement material as
the result of wear, deformation, or distortion, or as
the result of machining errors.
Hardfacing also requires expert planning and
careful execution.
The mechanical properties of the weld metal have
to match the requirements of the base material.
8.1.1 Hardfacing of bolt holes
Before carrying out the hardfacing process, the
worn bolt hole has to be enlarged by machining
on a boring machine or by grinding the diameter Fig. 175
manually by approximately 4 mm (2 mm cut
depth). This is necessary, so that after hardfacing
and machining, the new bolt hole surface lies in
homogenous weld metal and not in the relatively
hard heat affected zone.
Hardfacing must be done in adequate thickness
so that the bolt hole surface becomes “clean.”
Fig. 176
For small diameters, beads in the longitudinal

direction of the bolt hole are usual. For large bolt
holes, the weld metal can be applied as a con-
tinuous spiral bead.
Fig. 174
The individual work steps are shown in Fig. 174:

1 Worn bolt hole
2 Bolt hole drilled open
3 Tack-welded plate rings as run-off tab
4 Hardfacing
5 Run-off tabs removed, bolt hole machined to
final dimension.
69
3 842 954.000 en
Fig. 177 shows the recommended welding se- 8.1.2 Hardfacing of worn thread (Fig. 178)
quence using a practical example. Bolt hole (B) of
a bucket handle is to be hardfaced with longitudi-
nal beads. The shank is turned after the bottom
half of the bolt hole has been hardfaced.
Fig. 178
Before hardfacing, the worn or damaged thread

has to be machined on a lathe. The diameter of
Fig. 177 the trunnion should be approximately 4 mm
smaller than the core diameter.
Run-off grooves should also be gouged so that
the new contours lie in the homogenous weld
metal.
The threaded pin is extended with a pool backing
ring. The individual welding beads should end on
the ring.
The hardfacing should be done on a rotation
fixture for the component if possible.
The threaded pin can be made by machining.
70
3 842 954.000 en
8.2 Correcting component shapes to 8.3 Hardfacing for wear protection

improve the force path Component surfaces exposed to significant wear
Shape-related notches found on steel compo- can be protected by welding on wear-resistant
nents can be corrected by hardfacing. materials. See section 9 “Wear Protection” for
details.
The work is to be done particularly carefully when
eliminating shape notches in order to avoid metal-
lurgical notches, which are even more damaging
for the component.
Example:
Flattening between thick and thinner plate in the
edge area of the component (Fig. 179).
Fig. 179
The surfaces have to be ground very cleanly; all

grinding marks must be parallel to the force direc-
tion.
71
3 842 954.000 en
9. Wear protection (armoring) 9.2 Hardfacing of wear protection lay-

9.1 Basic principles ers
Wear-resistant weld metal is applied to those
Component surfaces exposed to significant wear
areas where there is a risk of wear.
can be protected by welding on wear-resistant
materials. Depending on the operating conditions, a very
tough, impact-resistant weld metal or one with a
The need for wear protection needs to be ascer-
greater surface hardness can be used.
tained before the machine is commissioned.
Suitability for welding in fixed positions has to be
If the component is to be armored after commis-
considered, too.
sioning, apply the wear protection promptly,
before the base is worn. A component with worn A metal which contains chromium, tungsten, and
load-bearing parts can no longer be effectively niobium carbides in a tough matrix and which
protected against wear. provides good resistance against frictional wear
and adequate impact resistance has proved to be
The wear protection is not permanent; it is also
an excellent weld metal.
subject to wear. However, the rate of wear is
greatly reduced by the special metallurgical prop- This weld metal has a total hardness of approxi-
erties of the wear protection materials. mately 59-61 HRC. If better impact sensitivity is
expected, it is possible to drop to a hardness of
The wear protection system has to be checked
approximately 54-56 HRC by using a different
regularly and carefully maintained.
weld metal.
Therefore, it is recommended that maintenance is
As the result of surface stresses, the hard and
scheduled during the machine down times or that
less tough weld metal breaks down at the surface
worn components are replaced promptly.
to create a fine network (Fig. 180).
Worn parts can then be dealt with in a workshop,
where more time is available for preparation.
Well trained, attentive repair personnel can make
a significant contribution to the level of operational
availability of a machine.
Several wear protection systems are presented
here. The specific operating conditions will dictate
which of these systems is to be used. The advan-
tages and disadvantages of the systems have to
be balanced and assessed.
Fig. 180
To prevent these cracks from penetrating the

material of the base, in the case of components
exposed to changing or pulsating stresses, a so-
called buffer layer has to be welded between the
base material and the facing material.
72
3 842 954.000 en
Component areas particularly at risk, such as the The direction of flow of the wear medium has to
side wings of excavator buckets, should even be be considered when arranging the dots (Fig. 184).
protected by 2 buffer layers (Fig. 181).
Fig. 184
Fig. 181
If the dots are not arranged correctly, furrows will
The hardfacing weld must always lie exactly on form between the rows of dots.
the buffer layer. Otherwise there is a risk that the
base will crack (Fig. 182). Diamond patterns - use these on smaller surfaces
exposed to high wear.
In the case of diamond patterns, a soft medium
may be deposited in the interstices and thus
provide additional wear protection for the base
(Fig. 185).
Fig. 182
9.2.1 Types of hardfacing

Dot patterns - use these on large areas where
there is a relatively small risk of wear (Fig. 183).
Fig. 185
Fig. 183
73
3 842 954.000 en
Full surface hardfacing 9.3.2 For armoring layers

Relatively small areas exposed to very high wear For gravity position only, e.g. first armoring proc-
are armored over the entire surface. This guaran- ess in the workshop:
tees protection of the base material without gaps
Wire electrodes
(Fig. 186).
DIN 8555: MF 10 - GF - 60 - RT
Flux-cored wire, diameter 2 mm
Reference analysis:
C Cr Nb Si Mn
5.0 22.0 7.0 0.5 0.7 %
Rod electrodes
DIN 8555: E 10 - UM - 60 GRZ
Diameter 5 mm x 450 mm
Reference analysis:
C Cr Nb V Mo W
Fig. 186
5.0 22.0 8.0 1.5 8.0 2.5 %
9.2.2 NB:
For fixed position welding, e.g. re-armoring on
 Before hardfacing, preheat the base materials site:
according to their quality. Rod electrodes
 Keep the interpass temperature below 250°C DIN 8555 - E 6 - UM - 60 P
(480°F) maximum, when welding.
Basic coating
 Only base materials up to a hardness of
approximately 300 HB should be protected by Alloyed core wire
hardfacing. Reference analysis:
If base materials with a higher hardness are
hardfaced, the welding heat introduced causes C Cr Si Mn
structural changes in areas of the material close
to the surface. The hardness drops drastically. 0.5 6.0 1.3 1.3 %
Furthermore, high internal stresses are generated
Legend to symbols:
in the base material. Only tough base materials
are able to absorb these internal stresses. These R = rust resisting
are materials up to a maximum of 300 HB.
Z = heat-proof
9.3 Weld fillers P = impact resistant
9.3.1 For buffer layers UM = coated
Rod electrodes: MF = metal arc welding with cored wire
EN 499: E 38 2 RA 22, DIN EN ISO 2560-A: E 42 GF = filled
2 RA 53
T = creep resistant
AWS 5.1: E 6013, E 7024-1
G = abrasion-resistant
Wire electrodes:
EN 440: G 3 Si 1, DIN EN ISO 14231-A: G 42 2 M
G 3Si1
AWS 5.18: ER 70 S-6
74
3 842 954.000 en
9.4 Repairing the hardfacing Wear state 2 (Fig. 188)

If necessary, worn hardfacing must be renewed
by rewelding.
Rewelding should be done at the latest when
remains of the buffer layer are still visible.
Carry out a surface crack test (MT/PT) before
rewelding. Goug cracks in the base material or
buffer layer before welding. Do not overweld
cracks!
9.4.1 State of wear
Different measures may be necessary, depending
on the state of wear.
Wear state 1 (Fig. 187)
Fig. 188
 The armor layer is completely worn.

 The armor layer is almost worn.
Measure: 1 new buffer layer and 2 new armor
layers have to be welded.
Wear state 3 (Fig. 189)
Fig. 187
 The armoring layer is almost worn.

 The buffer layer is still completely intact.
Measure: 2 new armor layers have to be welded.
Fig. 189
 Armor layer and buffer layer worn down

completely level with the plate.
Measures: 1 new buffer layer and 2 new armor
layers have to be welded.
75
3 842 954.000 en
Wear state 4 (Fig. 189) 9.4.2 Identification of the buffer and armor
layers
How to identify the individual hardfacing layers:
Buffer layer residue can be revealed by grinding
(Fig. 191).
Fig. 190
 Armor layer and buffer layer partly worn or

broken out.
Measures: the remains of the armor layer have to
be removed by arc-air gouging (see section 3.1). Fig. 191
Grinding sparks produced by the armor layer are

dark red. They run in a straight line, practically
Never hammer off remains of the without any branching off.
armor layer. Flying splinters may If the buffer layer consists of an austenitic, i.e.
cause an accident! stainless weld metal, the grinding sparks will be
light in color.
The gouged area has to be ground clean. 1 new
If the buffer layer consists of a ferritic weld metal
buffer layer and 2 new armor layers are then to be
the grinding sparks are light red. They branch off
welded.
and scatter (Fig. 192).
Fig. 192
76
3 842 954.000 en
9.5 Repairing cracks in the area of Gouge the crack in the base according to the
hardfacing standard rules of the art (see section 3) and weld
(Fig. 195).
Damage pattern: the crack in the component lies
in the area of the hardfacing (Fig. 193).
Fig. 195
5 Run-off tabs
Fig. 193 Cover the repair area again by buffer welding and
1. Crack hardfacing (Fig. 196).
2. Armoring
3. Base
4. Crack area
First of all, remove the hardfacing in the area of
the crack completely (Fig. 194).
The hardfacing can only be melted off with the
ARC-AIR method.
Fig. 196
Fig. 194
77
3 842 954.000 en
9.6 Welding on plates or strips of To weld on to curved surfaces with a very big
wear-resistant steel plates radius of curvature, the strips should be approxi-
mately 100 mm x 400 mm and also be offset in
Wear-resistant plates or strips with a hardness of relation to each other (Fig. 198).
up to 500 HB can be welded on to the surfaces to
be protected.
9.6.1 Arrangement of the plates/strips
For welding on to flat surfaces, the wear plates
should measure approximately 200 mm x 300 mm
and be offset in relation to each other (Fig. 197).
Fig. 198
The strips must not be deformed. The gap occur-

ring on both sides of the curve should be the
same as much as possible (Fig. 199).
Fig. 197
The plates should closely abut the surfaces to be

protected – “0” air gap if possible.
If the plates are bigger than recommended and do
not abut correctly, they will be likely to crack or
fracture in the event of pressure loads or impact.
When fixing the plates, stresses occur at plate
level which can lead to cracking of the welds.
Partially worn areas can also be renewed more
easily if the recommended plate size is observed. Fig. 199
The distance between the plates or strips should

not be too big (Fig. 200).
The interstices between the plates should fill with
medium. This will protect the welds against wear.
78
3 842 954.000 en
For the distances between the plates and a func-

tion of the plate thickness, see Fig. 200.
Fig. 200
t a b
10 6 20
15 8 25
20 10 30
The welds in the direction of flow of the medium
wear considerably more quickly than transverse
welds (Fig. 201).
Fig. 202
The side wings of bucket leading edges and hoe

buckets can be protected by wear strips.
Use one-piece strips. They are supposed to end
in the area with low operating stresses (Fig. 203).
Fig. 201
Narrow surfaces, e.g. at the side walls (arrow, Fig.

201 and 202) of bucket leading edges and hoe
buckets should therefore be covered with inter-
rupted strips.
 Transverse grooves or slots fill with the me-
dium. The welds become self-protected.
 The sliding of the medium is interrupted by the
grooves or slots. The medium rolls. This re- Fig. 203
duces the wear. Create a long and slim-tapered hardfacing weld at
Do not use an arrangement of circular weld open- the ends of the wear strips.
ings, because experience has shown that the Ground transitions from the weld metal to the
openings do not fill. Large parts of the weld and base material until they are notch-free.
plate wear.
79
3 842 954.000 en
Arrange the welds in the longitudinal direction of 3. The welds have optimum protection. The
the strips in such a way they are protected. arrangement of the wear strips is recom-
mended (Fig. 206).
Possible arrangements:
1. The welds are highly prone to wear. This
arrangement is not recommended (Fig. 204).
Fig. 206
4. This arrangement is only recommended if the

side walls are also covered with wear plates.
Fig. 204 The welds are then protected against wear
(Fig. 207).
2. The welds are prone to wear when the bucket
reverses. The cutting edge is widened con-
siderably. The penetration resistance is in-
creased (Fig. 205).
Fig. 207
Fig. 205
80
3 842 954.000 en
The gaps between the plates of the 1st row have The welds for fixing the plates and strips consist
to be closed by hardfacing. of a soft weld metal that is not wear-resistant. This
is necessary because of the types of material of
If this is not done, the wear plates in the 2nd row
the base and the wear plates.
behind the gap may wear (be filled).
Therefore, the welds lying in the direction of flow
in particular should be protected by a “hard” cover
pass against extra-fast wear.
Fig. 208
Information on Fig. 208:

1. Direction of flow of the medium
2. Fillet welds
3. Armor layer
Fig. 209
Information on Fig. 209:

1. Plate, base material, e.g. S690QL
2. Wear plate, hardness approx. 500 HB
3. Wear plate, hard layer on soft substrate
4. Soft weld metal
5. Soft weld metal, buffer layer
6. Hard weld metal, armor layer
81
3 842 954.000 en
9.6.2 Bending strips 9.6.3 Working instructions

Strips from a material up to 400 HB maximum can  Plates with hardnesses from 300 HB upwards
still be cold formed and adapted to curved sur- must not be hot formed or hot straightened.
faces (Fig. 210).
 Plates and strips must not be welded on to
highly stressed edges on the component.
 The plates and strips should be welded on
with continuous fillet welds all round. Tack
welding points are not sufficient.
 “Soft” welding fillers are used for welding on;
also for welding in the cover pass of the fillet
weld.
 The base is to be heated according to its
quality, but at least to approximately 100°C
(210°F).
 For plate thicknesses up to 20 mm, the wear
plates must be preheated to at least 100°C
(210°F). For plate thicknesses of 40 mm, pre-
heat to 150°C (300°F).
 During whelding the interpass temperature
must not exceed 250°C (480°F).
Fig. 210 9.6.4 Weld fillers
However, bending has to be carried out on a Rod electrodes:
bending roller and not on a plate metal folder.
DIN EN ISO 2560-A: E42 5 B 32 H5
When forming by gradual folding, taking into
account the bending angle and resilience, cracks AWS 5.1: E 7018-1
would be created in the wear plate on the tension
Wire electrodes:
side.
DIN EN ISO 14241-A: G 46 4 M G4Si1
Always renew promptly worn plates and strips.
AWS 5.18: ER 70S-6
Wear plate residue can only be cut off by wedges
(Fig. 211) if the welds have been grooved by
grinding and given pre-determined fracture points.
The separation points must be ground clean and
crack-free.
Fig. 211
82
3 842 954.000 en
9.7 Welding on plates or strips with

wear-resistant coating
Plates or strips in S235JR/S355J2+N with a wear-
resistant layer with a hardness of up to 58 HRC
previously welded on may also be welded on to
the surfaces to be protected.
The plate thickness depends on the size of the
bucket. If the recommended plate thicknesses are
used, the distance between the plates should be
15 mm (Fig. 212).
Fig. 214
9.7.1 Working instructions

 The plates and strips should be welded on
Fig. 212
with continuous fillet welds of a = 6 mm thick-
Plate thicknesses: e.g. ness all round.
A B C  “Soft” welding fillers (see 9.6.4) are used for
13 8 5 welding on; also for welding in the cover pass
19 13 6 of the fillet weld.
25 19 6
 The strips may not be welded on to highly
The plates or strips should be approximately 100 stressed edges on the component.
mm x 400 mm and be offset in relation to each
other (Fig. 213).
(210°F).
 The strips are usually not preheated. Excep-
tions: Component and ambient temperature is
below 20°C (70°F) and the strips are damp.
 Taking into account the base, the interpass
temperature when welding must not exceed
250°C (480°F).
 Worn strips are to be replaced promptly. Strip
residue must not be cut off by wedges, unless
Fig. 213 the welds are grooved by grinding and have
pre-determined fracture points.
The strips must not be deformed. Nevertheless,
they can be welded on to curved surfaces with  The separation points must be ground clean.
large radii of curvature if they abut in the center They must be crack-free before new strips are
and the gap at the longitudinal sides is relatively welded on.
small and evenly distributed left and right (Fig.
214).  The pre-fabricated strips can be separated
with the plasma torch. If this is not possible,
the substrate can be separated by grinding or
gouging. The hard layer then has to be bro-
ken.
83
3 842 954.000 en
9.8 Welding on wear-resistant pin as- Description of the method (Fig. 215)
sembly  Mount pin assemblies with ceramic weld pool
Pin assemblies in wear-resistant materials can be backing on the welding fixture. The ceramic
welded on to the surfaces to be protected. ring forms the pool and protects it from exter-
nal influences.
Pin assemblies of different sizes, shapes and
hardnesses are available from the trade.  When the pin assembly is removed from the
component surface, an arc is struck. Parts of
Welding method: the pin assembly and of the base material are
Pin assembly welding with tip ignition then melted.
High output power sources are required for weld-  The pin assembly is pressed into the molten
ing. pool. After the pool has cooled, the pin as-
sembly is completely welded on.
9.8.1 Working instructions
Before welding, check whether the  The distances between the pin assemblies
re-working site has sufficient electric should be as small as possible. The distance
power available. is determined by the size of the ceramic ring.
With a small distance between pin assem-
blies, the acting forces are distributed more
evenly over as many pin assemblies as pos-
sible. Consequently, the risk of pin assembly
fractures is significantly reduced.
(210°F).
 The pin assemblies must not be welded onto
component edges or component radii.
It is recommended that specialist companies are
consulted regarding the use of the method and
also the pin assemblies and tools. The method is
used successfully around the world.
The re-welding of individual pin assemblies that
have broken out is not recommended. The break-
out point in the base cannot usually be planed
sufficiently well.
Fig. 215
84
3 842 954.000 en
9.9 Welding on cutting edges on exca-

vator buckets
Pre-fabricated cutting edges (1, Fig. 216) in high
strength tempered steel as the wear material with
a good cutting capability can be welded onto the
bucket (2).
Fig. 217
Fig. 216
9.9.1 Work sequence

Straighten the contour of the worn cutting edge
section by flame cutting. Use the values in the
following table for the flame cutting process. Grind
the cut edges until they are metallically bright.
Minimum preheating temperature for flame cutting
S690QL:
Plate < 20 < 50 < 100 ≥ 100

thickness
S690QL 25°C 50°C 100°C 150°C
Use a template to manufacture the replacement

piece. Material: Wear-resistant tempering steel;
pre-formed; to be sourced from Caterpillar Global
Mining HMS Spares Service, for example.
To cut out the contour and bevel the welding
grooves, preheat the material to the temperature
specified in the table. Grind the welding groove
surfaces until they are metallically bright.
Fit the replacement piece (Fig. 217).
85
3 842 954.000 en
To facilitate the assembly and welding work, the (hard) welding fillers for 1/3 of the weld
bucket should be set up with the blade vertical.
Rod electrodes
Preheat the cutting edge and spare part to 150°C
(300°F) to weld. DIN EN ISO 18275-A: E 69 5 Mn2NiCrMo B 42
H5
9.9.2 Welding sequence (Fig. 218) and welding
fillers for corner blades AWS A5.5: E 11018 - G
Wire electrodes
DIN EN ISO 16834-A: G 69 6 M Mn4NI1,5CrMo
AWS A5.28: ER 100 S-G
The weld run-offs at the transitions to the teeth
holders must be ground clean (arrows, Fig. 218).
Fig. 218
First weld the root and 1 interpass from one side

with soft welding fillers.
(soft) welding fillers for 2/3 of the weld
Rod electrodes
DIN EN ISO 2560-A: E 42 5 b 32 H5
AWS 5.1: E 7018-1 Fig. 219
Wire electrodes The entire welded area must cool slowly after the
DIN EN ISO 14341-A: G 46 4 M G4Si1 welding work has been completed. Cover the area
with glass wool. Never cool with water or com-
AWS 5.18: ER 70S-6 pressed air.
Then grind out the root pass from the opposite
side and weld 2 layers as on the opposite side.
Then complete the remaining weld with the fillers
suitable for the cutting edge material (see page
86). Weld string beads; interpass temperature
max. 250°C (480°F).
Change sides continuously to avoid distorting the
spare part.
86
3 842 954.000 en
10. Repairs by welding cast-iron

components
10.1 Spheroidal graphite cast-iron
(GGG)
2 methods with different levels of effort can be
used. Hot welding requires more effort, but usually
leads to the better result.
10.1.1 Hot welding
The same kind of welding fillers are used. Pro-
vided that the welding is executed properly, a
weld metal Quality Class A according to VDG
specification N 60 is achieved. The mechanical
properties of the weld are the same as those of
the unwelded material.
Preheating to 600°C (1100°F) is necessary for
welding. After welding, temper at 900°C (1650°F).
Due to these requirements this method can hardly
ever be used in repair practice.
In addition, the thermal loading of the component
is so high that the dimensional stability of ma-
chined surfaces can no longer be guaranteed.
A specialized company should be used for this
type of welding. Only they have the necessary
facilities for preheating, tempering, and handling
the hot components.
87
3 842 954.000 en
10.1.2 Cold welding 10.2 Gray cast iron (GG)

A different type of welding filler is used for this 2 methods with different levels of effort can be
process. Provided that the work is done properly, used here, too. Hot welding, which requires great-
the weld metal achieves Quality Class B accord- er effort, leads to better results.
ing to VDG specification N 60. The mechanical
properties of the weld (strength) differ from those 10.2.1 Hot welding
of the unwelded material, but usually satisfy the The same kind of welding fillers are used. Pro-
requirements for a specific purpose. The require- vided that the welding is executed properly, a
ments have to be defined in each individual case. weld metal is achieved whose mechanical proper-
Welding recommendations: ties are the same as those of the unwelded mate-
rial.
 Locate cracks accurately using a dye penetra-
tion test. To weld, the component must be heated com-
pletely or partly to 650°C (1200°F). Since the weld
 Gouge out the crack to an open tulip shape metal is very fluid, the actual welding spot has to
with broad rounded edges. be contained.
 Remove the casting skin in the area of the Therefore, the method is hardly ever used in
weld. repair practice.
 Remove residue by grinding, for example. In addition, the thermal loading of the component
is so high that the dimensional stability of ma-
 If the parts are highly oiled, the oil can be chined surfaces can no longer be guaranteed.
burnt off with an oxygen + acetylene flame by
heating slightly. A specialized company should be used for this
type of welding. They have the necessary facilities
 When welding, make sure that the first pass is for preheating, tempering, and handling the hot
free from pores. components.
 Keep the arc as short as possible. 10.2.2 Cold welding
 The welds should not be welded longer than A different type of welding filler is used for this
10 times the electrode diameter and their process. Provided the work is properly executed,
width should correspond to twice the core wire a dissimilar weld metal is produced that has
diameter at the most. different mechanical properties (strength) com-
 Hammer off each bead immediately while it is pared with the base material. A homogenous
still warm. fusion bond between the base material and the
welding filler is not possible.
 Always re-strike on the weld metal, not on the
base material.
 Remove slag residue with a brush.
 Choose the best possible welding sequence.
 In principle, weld from inside to outside in the
case of open cracks.
 Use the back-step and string bead method
 Rod electrodes:
DIN EN ISO 1071: E C NiFe-13
AWS 5.15: E NiFe - C1
Electrodes - diameter 3.20 mm
Tempering after welding is not necessary.
After grinding, check the welded area for cracks
using the dye penetration method.
Cold welding by inexperienced welders can lead
to poor results. Here, too, the help of specialist
companies is recommended.
88
3 842 954.000 en
Therefore, the component cannot be fully re- 10.2.3 Repairs using the "latch plate method"
created with all its original properties. Structural
Often, it is not possible to repair cast iron compo-
changes in the edge zones and high internal
nents by welding if forces have to flow via the
stresses are unavoidable. Due to the inevitably
repair area.
high hardnesses micro-cracks must be expected.
Consequently, a repair method has been devel-
Welding recommendations:
oped where cracks or fractures are “latched”. The
 Keep the welding current as low as possible repair is done exclusively with the aid of mechani-
so that as little heat as possible is introduced. cal tools. Welding is not required at any stage.
 The temperature in the component should not Nevertheless, this method is a useful addition to
exceed 70°C (160°F) next to the welding welding technology.
zone. Fragments can be joined together or, if necessary,
 Rod electrodes: also newly made spare parts from a different
material, e.g. casting steel or plate.
DIN 8573 - Type E NiFe - 1 BG 23
Description of the method
AWS 5.15: E NiFe - CI
 A series of bolt holes is produced in the area
Electrodes - diameter 2.5 mm. of the fracture on both sides of the separation
 Weld short string beads, always offset in (Fig. 220).
relation to each other.
 To reduce the shrinkage, and therefore the
internal stresses in the component, the beads
should be slightly stretched by hammering be-
fore cooling.
Cold welds on gray cast iron should only be made
in extreme emergencies. Specialist companies
should be used in this case, too.
Alternative recommendation
Another method for repairing gray cast iron com-
ponents is available, known as the “latch plate
method.”
Only specialist companies can operate this meth-
od.
See section 10.2.3 for details.
Fig. 220
89
3 842 954.000 en
The bolt holes are drilled using templates. The 11. Repairing paintwork in repair
webs between the bolt holes are chiseled out.
areas
 Thus, grooves are produced in which the so-
called latches are inserted (Fig. 221). Any damaged or partly removed coating of the
component must be repaired when the welding
has been completed. This applies to the areas:
- where the welding was done,
- which were reinforced by inserting or put-
ting on plates,
- where, as the result of thermal effects
(e.g. straightening, heating) or mechanical
effects (e.g. loading gear), coatings have
been damaged.
The damaged areas on the component have to be
cleaned mechanically, e.g. by brushing, grinding,
scraping.
Degree of cleanness: Level 3 according to DIN
Fig. 221 EN ISO 12944-4. The degree of cleanness can
These latches consist of a steel material, only be achieved by careful cleaning.
which can be shaped by hammering and then The repair area is then to be coated with a two-
solidifies. pack coating system, i.e. a primer and a finish
 The latches are inserted into the grooves in coat.
layers and hammered. The latches then fit the The primer is to cover the metal substrate with
groove contours exactly. The rear latch areas sufficient overlap. The finish must cover the
are therefore also involved in the support primer with sufficient overlap.
function.
 The equivalent cross-section, i.e. the number
of latches, can be calculated from the ratio of
the gray cast iron/steel material strengths.
90
3 842 954.000 en
Annex
Conversion from feet and inches into meters
1 in (inch) = 25.4 mm (exactly) 1 ft (foot) = 12 in = 304.8 mm Example: 4 ft 2 in = 1.27 m
in +0 +1 +2 +3 +4 +5 +6 +7 +8 +9 +10 +11
ft
m m m m m m m m m m m m
0 0.0254 0.0508 0.0762 0.1016 0.1270 0.1524 0.1778 0.2032 0.2286 0.2540 0.2794
1 0.3048 0.3302 0.3556 0.3810 0.4064 0.4318 0.4572 0.4826 0.5080 0.5334 0.5588 0.5842
2 0.6096 0.6350 0.6604 0.6858 0.7112 0.7366 0.7620 0.7874 0.8128 0.8382 0.8636 0.8890
3 0.9144 0.9398 0.9652 0.9906 1.0160 1.0414 1.0668 1.0922 1.1176 1.1430 1.1684 1.1938
4 1.2192 1.2446 1.2700 1.2954 1.3208 1.3462 1.3716 1.3970 1.4224 1.4478 1.4732 1.4986
5 1.5240 1.5494 1.5748 1.6002 1.6256 1.6510 1.6764 1.7018 1.7272 1.7526 1.7780 1.8034
6 1.8288 1.8542 1.8796 1.9050 1.9304 1.9558 1.9812 2.0066 2.0320 2.0574 2.0828 2.1082
7 2.1336 2.1590 2.1844 2.2098 2.2352 2.2606 2.2860 2.3114 2.3368 2.3622 2.3876 2.4130
8 2.4384 2.4638 2.4892 2.5146 2.5400 2.5654 2.5908 2.6162 2.6416 2.6670 2.6924 2.7178
9 2.7432 2.7686 2.7940 2.8194 2.8448 2.8702 2.8956 2.9210 2.9464 2.9718 2.9972 3.0226
10 3.0480 3.0734 3.0988 3.1242 3.1496 3.1750 3.2004 3.2258 3.2515 3.2766 3.3020 3.3274
11 3.3528 3.3782 3.4036 3.4290 3.4544 3.4798 3.5052 3.5306 3.5560 3.5814 3.6068 3.6322
12 3.6276 3.6830 3.70 3.7338 3.7592 3.7846 3.8100 3.8354 3.8608 3.8862 3.9116 3.9370
Conversion of length dimensions

Length UK
in ft yd mile cm m
N mile
1 inch 1 0.0833 0.0278 2.54 0.0254
1 foot 12 1 0.3333 0.00019 0.00016 30.48 0.3048
1 yard 36 3 1 0.00057 0.00049 91.44 0.9144
1 statute mile 63,360 5,280 1,760 1 0.86842 1609.3
1 UK nautical mile 72,960 6,080 2,026.7 1.15151 1 1,853.2
1 cm 0.3937 0.0328 0.0109 1 0.01

1m 39.370 3.2808 1.0936 0.00062 0.00054 100 1
91
3 842 954.000 en
Temperature units and conversion formulas

units Conversion to
name
abbreviation K °C °R °F
Symbol
Kelvin K 1 (K-273.16°) 4/5 (K- 9/5 (K-
273.16°) 273.16°)+32°
Celsius °C °C+273.16° 1 4/5 °C 9/5 °C+32°
Réaumur °R 5/4 °R+273.16° 5/4 °R 1 9/4 °R+32°
Fahrenheit °F 5/9 (°F-32o)+ 5/9 (°F-32°) 4/9 (°F -32°) 1
273.16°
Example: Conversion from °R to °C: °C = 4/5 °R
The basic temperature unit is Kelvin (K).
T is used as the formula symbol.
The absolute temperature degree Rankin, which is also used, is calculated as
°Rank = 9/5 K.
92
3 842 954.000 en
Hardness-strength comparison
Vickers Brinell Tensile Rockwell hardness Vickers Brinell Tensile Rockwell
hardness hardness strength hardness hardness strength hardness
HV HB HRB HRC HB
kp/mm2 kp/mm2 N/mm2 kp/mm2 kp/mm2 N/mm2 HRB HRC
80 80 270 36.4 360 359 1210 37.0
85 85 290 42.4 370 368 1240 38.0
90 90 310 47.4 380 376 1270 38.9
95 95 320 52.0 390 385 1290 39.8
100 100 340 56.4 400 392 1330 40.7
105 105 360 60.0 410 400 1360 41.5
110 110 380 63.4 420 408 1390 42.4
115 115 390 66.4 430 415 1410 43.2
120 120 410 69.4 440 423 1440 44.0
125 125 430 72.0 450 430 1470 44.8
130 130 440 74.4 460 45.5
135 135 460 76.4 470 46.3
140 140 480 78.4 480 47.0
145 145 490 80.4 490 47.7
150 150 500 82.2 500 48.3
155 155 520 83.8 510 49.0
160 160 540 85.4 520 49.6
165 165 550 86.8 530 50.3
170 170 570 88.2 540 50.9
175 175 590 89.6 550 51.5
180 180 610 90.8 560 52.1
185 185 620 91.8 570 52.7
190 190 640 93.0 580 53.3
195 195 660 94.0 590 53.8
200 200 680 95.0 600 54.5
205 205 690 95.8 610 54.9
210 210 710 96.6 620 55.4
215 215 730 97.6 630 55.9
220 220 750 98.2 640 56.4
225 225 760 99.0 650 56.9
230 230 770 19.2 660 57.4
235 235 790 20.2 670 57.9
240 240 810 21.2 680 58.4
245 245 830 22.1 690 58.9
250 250 840 23.0 700 59.3
255 255 850 23.8 720 60.2
260 260 870 24.6 740 61.1
265 265 880 25.4 760 61.9
270 270 900 26.2 780 62.7
275 275 920 26.9 800 63.5
280 280 940 27.6 820 64.3
285 285 960 28.3 840 65.0
290 290 980 29.0 860 65.7
295 295 990 29.6 880 66.3
300 300 1010 30.3 900 66.9
310 310 1050 31.5 920 67.5
320 320 1080 32.7 940 68.0
330 330 1120 33.8
340 340 1150 34.9
350 350 1180 36.0
93
3 842 954.000 en
94
© Copyright Unless expressly permitted, the transfer and reproduction of this manual/file and
Caterpillar Global the sale and disclosure of its content is prohibited. Contraventions are liable to
Mining HMS GmbH compensation. All rights reserved in the event of patent, utility model, or registered
2014 design registration.
3 847 003.00 en
March 2013
Service Manual for

Oil Samples and
Oil Analysis
6015 - 6090
3 847 003.00 en

Dept. Technical Documentation
Tel. 49 (0) 231 922-4340
Fax 49 (0) 231 922-5005
© Copyright Caterpillar Global Mining Hydraulic Shovels GmbH 2013. The reproduction, distribution and
utilization of this manual / file as well as the communication of its content to others without express
authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the
event of the grant of a patent, utility model or design.
Printed in Germany
3 847 003.00 en
CONTENTS
SAFETY INSTRUCTIONS _________________________________________________________ 1

NOTES ON THE SELECTION OF OILS AND GREASES _________________________________ 1
ORIGINAL BUCYRUS HEX OILS AND GREASES ______________________________________ 1
ALTERNATIVE OILS AND GREASES ________________________________________________ 1
WHY CARRY OUT OIL ANALYSES? ________________________________________________ 2
PREREQUISITES FOR VALID OIL SAMPLES _________________________________________ 3
Analyses-Sets _________________________________________________________________ 3
TAKING OIL SAMPLES ___________________________________________________________ 4
Sampling from assemblies equipped with sampling valve _______________________________ 4
Sampling from assemblies without sampling valve ____________________________________ 5
INTERPRETING THE RESULTS OF THE OIL ANALYSIS ________________________________ 6
A typical laboratory report ________________________________________________________ 6
Typical laboratory report _________________________________________________________ 7
TYPICAL WEAR LIMITS __________________________________________________________ 8
For hydraulic oil in the 6015, (RH70), 6018, 6030, 6040 machines ________________________ 9
For hydraulic oil in 6050, 6060, 6090 machines ______________________________________ 10
For oil in the pump transfer gearboxes of the 6015, (RH70), 6018, 6030 __________________ 11
For oil in the pump transfer gearboxes of the 6040, 6050, 6060 _________________________ 12
For oil in the pump transfer gearboxes of the 6090 ___________________________________ 13
For oil in the swing gearboxes of the 6015 - 6090 ____________________________________ 14
For oil in the travel gearboxes of the 6015, (RH70), 6018 ______________________________ 15
For oil in the travel gearboxes of the 6030, 6040, 6060 ________________________________ 16
For oil in the travel gearboxes of the 6050, 6090 _____________________________________ 17
NOTES _______________________________________________________________________ 18
3 847 003.00 en
3 847 003.00 en
Safety instructions Notes on the selection of oils and

greases
Risk of injury
Caterpillar Global Mining HMS
caused by rotating fan blades, run-
ning V-belts and engine exhaust oils and greases
gases. Besides regular and careful maintenance, the qual-
ity of the oils and greases used in the machine has
Keep away from rotating fan blades a decisive influence on high performance, reliability
and running V-belts in the engine com- and long service life of a machine and of its units
partment. and assemblies.
Leave the engine compartment with the
The lubricants tables in the Caterpillar Global Min-
running engine immediately after tak-
ing HMS Operating Instructions contain specifica-
ing the oil sample.
tions for the oils and greases that are approved for
Components and oils can be hot use in Caterpillar Global Mining HMS machines.
These oils and greases are especially adapted to
The surfaces of engines, gearboxes Caterpillar Global Mining HMS machines and their
and tanks are hot after operation. units and assemblies.
Oil samples must however be taken
shortly after engine stop when oils are Other oils and greases which do not fulfil the re-
still at their operating temperature. The quirements of the specifications can be the cause
of premature wear or of damage to and failures of
substances contained in the oil are
machine units and assemblies.
then still in suspension.
Wear firm working clothing and gloves For this reason, Caterpillar Global Mining HMS only
and be especially careful when taking approves the use of the specified oils and greases.
oil samples. All other qualities are not approved.
Prevent oil from getting into con-
tact with the skin and the eyes. Alternative oils and greases
Skin contact with oil can be a health The oils and greases filled into the machine must
hazard. Skin contact must therefore be meet at least the specifications mentioned in the
avoided. lubricants tables of the Caterpillar Global Mining
Wear protective gloves or apply a bar- HMS Operating Instructions.
rier cream on the skin before beginning
work.
In the event of damage to the machine or to its
Clean your hands carefully.
units and assemblies caused by the use of alterna-
Oil splashes can cause eye injury. It is tive oils and greases that are not compatible with
absolutely important to prevent oil Caterpillar Global Mining HMS specifications,
splashes from getting into your eyes. Caterpillar Global Mining HMS does not assume
Therefore, you must wear goggles. If any responsibility and does not accept any war-
oil has splashed into your eyes rinse ranty claims.
extensively with clear water and con-
sult a doctor.
Protect the environment
Even smaller amounts of escaped oil
can pollute the environment. Absorb
spilt oil carefully and dipose of it with-
out polluting the environment.
1
3 847 003.00 en
Why carry out oil analyses?
The regular analysis of hydraulic oil, gearbox oil

and engine oil serves the purpose of making opti-
mal use of the service life of these consumables.
The laboratory analysing the oil can determine in

how far the oil has lost its efficiency and say how
long it can presumably still be used until the next oil
change is due.
Moreover, the laboratory can make a statement on

imminent or already existing damage to compo-
nents or assemblies (e.g. based on the presence of
abraded metal particles in the engine, gearbox or
hydraulic oil samples). Fig. 1
Damage can thus be detected at an early date and
preventive measures be taken.
The present manual explains the basic procedure

of taking oil samples. It also provides information
on how to interpret the laboratory report. The in-
structions can be of help when it comes to making
a decision about the measures to be taken.
Contact your oil analysis laboratory and ask them

to provide you with more detailed information.
Laboratories often have info brochures with de-
tailed requirements and instructions or also com-
plete oil sampling sets for their customers.
Fig. 2
Oil samples are taken at the following places:

 Oil samples from the engine are taken on the
engine block as shown in Fig. 1.
 Hydraulic oil samples are taken near pumps
and pump transfer gearboxes in the area
shown in Fig. 2.
 Oil samples from the pump transfer gearbox
are taken at the point shown in Fig. 3.
The above-designated places are equipped with a

special sampling valve.
(The illustrations are only examples. Depending on
Fig. 3
the type of machine, the sampling valve environ-
ment may differ from that shown in the illustra-
tions).
In swing and travel gearboxes, the oil sample must

be taken form the oil level checking or drain plugs.
2
3 847 003.00 en
Prerequisites for valid oil sam-

ples
The oil sample is always representative, which
 The oil samples should be taken at fixed inter-
means that it represents the condition of the whole
vals and regularly (see maintenance schedules
amout of grease / consumables contained in the
in the operating instructions of the machine).
respective assembly.
Another important aspect for comparing analy-
If the regular oil analyses are to be useful and valid, sis results is that the oil must always be sam-
the oil samples must be taken with particular care. pled in the same way and at the same place.
Please observe the following instructions if the For this purpose, Caterpillar Global Mining
analysis results are to document the actual condi- HMS machines are equipped with special
tion of your oil and not the state of contamination in sampling valves (in components where it
the surroundings of the component / assembly makes sense from a technical point of view).
from which the sample is taken.
 Send the oil samples as soon as possible to
The following prerequistes must be fulfilled for a the laboratory carrying out the analysis. Do not
good and valid oil sample: keep the oil samples while waiting for other
 Cleanliness is of utmost importance. There- samples in order to make a "combined ship-
fore, clean the sampling point, its surroundings ment". The risk of contaminating, mixing up or
and the hose of the sampling pump (if used) even of discarding the oil samples is just too
carefully. big.
 Use an individual hose on the sampling pump  File the results of the oil analyses. This is the
hose for each oil sample. This is to ensure that only way of judging the condition of the oil and
the oil analysis result is not invalidated by the of the assemblies concerned over time.
presence of rests of other oils or by contamina-
tions.
 Do not use the sampling pump that has been Analyses-Sets
used beforehand for taking coolant samples for Complete sets for oil sampling can be supplied
taking oil samples. Glycol residues can spoil from the Caterpillar Global Mining HMS (CGM
the results of the oil analysis. HMS) Spare Parts Service. They include oil sam-
pling tubes, data sheets and envelopes.
 The sampling tube must be clean and dry.
Contaminations, rests of the old contents or of Analyses set for: CGM HMS
water will equally invalidate the result of the oil part number:
analysis. For this reason, only new and unused
sampling tubes from the analysis lab should be Engine oil, gearbox oil 1 465 078
used, if possible. They are especially suitable Hydraulic oil 1 465 077
for oil samples. Tubes made of inappropriate
plastic material can invalidate the analysis re- Bio-degradable 6 001 720
sult, for instance by dissolved substances. hydraulic oil
Oil sampling pump 1 465 079
 The oil must be brought to normal operating
temperature. It can then be removed more
easily than in a cold and viscous state.
 Take the sample in operation or only shortly
after standstill. Everything contained in the oil
(such as dirt, particles of abraded metal or also
water) is then still in suspension and has not
yet settled.
 Do not take the samples shortly after oil
changes or after adding large amounts of oil.
3
3 847 003.00 en
Taking oil samples

 Let about 100 ml (5.2 oz) of oil flow out of the
Risk of injury valve.
This measure serves the purpose of rinsing the
Components and oils can be hot screwed connections and the sampling valve
The surfaces of engines, gearboxes so that accumulated dirt is removed. This oil
and tanks are hot after operation. must be disposed of.
Oil samples must however be taken  Place the recipient for the oil sample under the
shortly after engine stop when oils are drain valve.
still at their operating temperature. The
substances contained in the oil are  Open the valve (2) as described.
then still in suspension. When the needed amount of oil has drained
Wear firm working clothing and gloves out, let the valve knob (2) go. The drain outlet
and be especially careful when taking closes automatically.
oil samples.  Refit the cap (1).
Rotating fan blades, running V-  Label the oil sample, fill in the accompanying
belts and engine exhaust gases form of the oil analysis laboratory completely,
pack up the oil sample carefully and send it to
Keep away from rotating fan blades
the oil laboratory.
and running V-belts in the engine com-
partment.  Please make sure the oil samples can be cor-
Leave the engine compartment with the rectly assigned in the case of assemblies of
running engine immediately after tak- which two or more units are installed in the
ing the oil sample. machine (engines, gearboxes).
Sampling from assemblies equipped

with sampling valve
 Shut off the engines.
 Protect the machine against unauthorized
starting.
 Exception: When taking a sample of the engine
oil, the engine must be running at idling speed.
 Be especially careful in this stituation. Stay
inside the engine compartment only as long as
absolutely necessary for taking the sample.
 Clean the surroundings of the sampling valve /
sampling point carefully. This precaution pre- Fig. 4
vents that dirt gets into the sample and invali-
dates the analysis results.
 Unscrew the cap of the drain opening (1, Fig.
4).
 Place a recipient for the used oil under the
drain valve.
 Open the valve by turning the knob counter-
clockwise and by holding it in this position
(against the spring pressure). The oil now
flows out of the outlet.
4
3 847 003.00 en
Sampling from assemblies without

sampling valve
Swing and travel gearboxes are not equipped with

sampling valves. In swing and travel gearboxes,
the oil sample must therefore be taken form the oil
level checking or drain plugs.
Caterpillar Global Mining HMS recommends a
sampling pump for this purpose (Fig. 5).
The pump can be supplied from the Caterpillar
Global Mining HMS (CGM HMS) Service (CGM
HMS part number: 1 465 079).
The method of just letting the oil flow out of the
bore and catch it in a recipient cannot be recom- Fig. 5
mended. The risk of contaminating the oil sample
is very big in this case.
 Shut off the engines.
 Protect the machine against unauthorized
starting.
 Clean the surroundings of the sampling point
and the hose of the sampling pump carefully.
This precaution prevents that dirt gets into the
sample and invalidates the analysis results.
 Screw out the plug in the sampling bore and
take an oil sample. Observe equally the in-
structions of the sampling pump manufacturer
and / or of the oil laboratory.
 Screw the plug back in place.
 Label the oil sample, fill in the accompanying
form of the oil analysis laboratory completely,
pack up the oil sample carefully and send it to
the laboratory.
Please make sure the oil samples can be cor-
rectly assigned in the case of assemblies of
which two or more units are installed in the
machine (engines, gearboxes).
5
3 847 003.00 en
Interpreting the results of the oil A typical laboratory report

analysis The laboratory report shown in Fig. 6 is composed
of three sections:
 - Statistical information concerning the
The results of the oil analysis will be documented in oil sample,
a detailed report (see also "Typical laboratory re-
ports, Specimen Form“). The report provides am-  - Diagnosis and general assessment,
ple information which not only describes the condi- - Results of the analysis.
tion of the analyzed oil, but which also permits
drawing conclusions as to the state of the machine Ad 1.
component. The header of the laboratory report contains statis-
It would nevertheless be premature to take an im- tical data concerning the sample as such, the ma-
mediate decision as to an oil change or to other chine from which the sample originates, the name
measures based on the analysis report alone. Only of the laboratory, etc.
in very rare cases is it necessary to take action
immediately. In this case, the laboratory report Ad 2.
clearly emphasizes the need for such immediate Section 2 contains a detailed general assessment
action. and a diagnosis of the oil sample together with
addtional information about possible damage and
As a rule, the recommendations of the oil labora- the causes of unusual analysis values.
tory can only be used as an important decision aid
if they are combined with your special knowledge of
Ad 3.
the working conditions of the machine.
In this case, the oil sample was tested for five pa-
As far as the operating conditions of your machine rameters: wear, contamination, oil condition, addi-
are concerned the following facts are of impor- tives and additional results. One of the columns
tance: lists these parameters, the analyzed constituents of
 Has the machine been used for other ap- the oil, the tested properties and the units of meas-
plications / load conditions than to date? urement.
The results of the oil analysis are presented in the
 When was oil added, how much was four remaining columns: The left column contains
added and wich oil grade was added (a the result of the actual oil sample whereas the
grade different from the one already in the other columns show the results of the previous oil
machine?) analyses for comparison. The symbols in the col-
 Have any unusual component / assembly umn header represent the overall rating of the oil
conditions such as vibrations, noise and sample. They have the following meaning:
heat been detected in operation?
 Have any repairs been carried out on the The values are normal, everything is
machine? OK. No further action required.
 Have other consumables been changed? Continue to carry out regular oil
analyses.
All these facts should be diligently and precisely
documented. They may be of great importance The oil analysis has yielded unusual
when it comes to making the right desicion. values. Read the explanatory text on
The decision on further measures should be taken your laboratory report.
after due and careful consideration Immediate action is required. Read
 of all available analysis results, the explanatory text on your labora-
tory report.
 of the evolution of the analysis values and
 of all known operating conditions
Taking the appropriate measures in time can pre-
sumably help to avoid costly and long-lasting re-
pairs which are also always accompanied by the
corresponding downtimes during which the ma-
chine cannot be used.
For queries please contact your oil laboratory or the
Caterpillar Global Mining HMS Service.
6
3 847 003.00 en
Typical laboratory report
Fig. 6
7
3 847 003.00 en
Typical wear limits

The tables on the following pages provide you with The left column gives the parameters generally
benchmark values. They help you to properly analyzed in the case of oil samples.
judge the values of your laboratory report. wear, contamination, oil condition, additives and
These benchmark values are average values from supplementary tests.
oil analyses in a large number of Global Mining For each of these parameters the analyzed con-
HMS machines over several years and of the stituents of the oil, the tested properties and the
measures taken on the basis of these results. For units of measurement are set out in detail.
this reason, the values listed can be considered as
"wear limit values". Three columns are provided for the reference limit
The adoption of these values as wear limits pre- values. For better orientation, they are marked
supposes, however, that the condtions under with symbols. The symbols have the following
which the oil samples were taken in your ma- meaning:
chines and analyzed are the same as those men-
tioned in the table header. If the values in your laboratory report
correspond to those in this column or if
they are lower, no further action is
required. Everything is OK.
Continue to carry out regular oil analy-
ses.
If the values in your laboratory report
are above those in the "green" column
and reach at maximum those in this
column, caution is required. Read the ex-
planatory text on your laboratory report.
If the values in your laboratory report
are above those in the "orange" col-
umn and reaching the values in this
column, immediate action is required.
Read the explanatory text on your
laboratory report.
8
3 847 003.00 en
For hydraulic oil in the 6015, 6018, 6030, 6040 machines

The values are only valid  Caterpillar Global Mining HMS 6015 / 6018 / 6030 / 6040 hydraulic
for following conditions: (Tank sampling)
 Oil type: DIN 51 524 II HVLP 46 Long Term Hydraulic Fluid HSS
 Oil analysis every 500 operating hours
 Not more than 5.000 operating hours or 3 years oil usage
Analysis Parameter
Unit
Monitor Caution Action
Wear Metals
Iron Fe mg/kg 10 12 15
Chromium Cr mg/kg 1 2 4
Tin Sn mg/kg 1 2 3
Aluminium Al mg/kg 2 3 5
Nickel Ni mg/kg 1 2 3
Copper Cu mg/kg 8 10 18
Lead Pb mg/kg 3 5 7
Molybdenum Mo mg/kg 2 4 6
PQ-Index - - O.K. 32 45
Contamination
Silicium Si mg/kg fresh oil value +6 fresh oil value +8 fresh oil value +10
Potassium K mg/kg 6 8 10
Sodium Na mg/kg fresh oil value +16 fresh oil value +19 fresh oil value +24
Lithium Li mg/kg 5 11 14
Water H2O W% < 0.1 0.11 0.13
Oil Condition
Viscosity at 40 °C mm²/s min 42 – max 49 min 40.5 – max 50.0 min 39 – max 51.0
Viscosity at 100 °C mm²/s min 8.5 – max 9.5 min 7.9 – max 9.8 min 7.5 – max 10.5
Viscosity Index VI - min 150 – max 190 min 135 – max 192 min 120 – max 195
Oxidation A/cm 5 10 13
Additive Metals
Calcium Ca mg/kg
Magnesium Mg mg/kg
Boron B mg/kg ± 10 % ± 15 % ± 20 %
Zinc Zn mg/kg of fresh-oil of fresh-oil of fresh-oil
values values values
Phosphorus P mg/kg
Barium Ba mg/kg
Sulphur S mg/kg
Additional Results
Cleanliness Class ISO 4406 19/16/13 20/17/14 22/18/15
TAN mgKOH/g fresh oil value -0.2 / +0.3 fresh oil value -0.2 / +0.4 fresh oil value -0.2 / +0.5
© WEARCHECK GmbH Issued: 05/2006
Test Standard
Wear Metals, Contamination and Additives by ICP DIN 51 396-1, DIN 51391-3
Viscosity DIN 51 562
Oxidation by FT-IR DIN 51 453
Water by FT-IR DIN 51 451
TAN DIN 51 558
9
3 847 003.00 en
For hydraulic oil in 6050, 6060, 6090 machines

The values are only valid  Caterpillar Global Mining HMS 6050 / 6060 / 6090 hydraulic (Tank
for following conditions: sampling)
 Oil type: DIN 51 524 II HVLP 46 Long Term Hydraulic Fluid HSS
Not more than 5.000 operating hours or 3 years oil usage
Analysis Parameter
Unit
Wear Metals
Tin Sn mg/kg 1 2 3
Lead Pb mg/kg 2 3 4
PQ-Index - - O.K. 30 39
Contamination
Silicium Si mg/kg fresh oil value +6 fresh oil value +8 fresh oil value +10
Potassium K mg/kg 6 8 10
Sodium Na mg/kg fresh oil value +16 fresh oil value +19 fresh oil value +24
Water H2O W% < 0.1 0.11 0.12
Oil Condition
Viscosity at 40 °C mm²/s min 42 – max 49 min 40.5 – max 50.0 min 39 – max 51.0
Additive Metals
Calcium Ca mg/kg
Magnesium Mg mg/kg
Boron B mg/kg ± 10 % ± 15 % ± 20 %
Phosphorus P mg/kg
Barium Ba mg/kg
Sulphur S mg/kg
Additional Results
Cleanliness Class ISO 4406 19/16/13 20/17/14 22/18/15
TAN mgKOH/g fresh oil value -0.2 / +0.3 fresh oil value -0.2 / +0.4 fresh oil value -0.2 / +0.5
Test Standard
TAN DIN 51 558
10
3 847 003.00 en
For oil in the pump transfer gearboxes of the 6015, 6018, 6030
The values are only valid  Caterpillar Global Mining HMS 6015 / 6018 / 6030 Pump Gearbox
for following conditions:  Oil types: CLP HC DIN 51 517-3, ISO VG 100 / 220*
 Not more than 1.000 operating hours
Analysis Parameter
Unit
Wear Metals
Tin Sn mg/kg 1 2 4
Lead Pb mg/kg 5 7 13
PQ-Index - - 98 112 151
Contamination
Silicium Si mg/kg 26 38 47
Potassium K mg/kg
fresh oil value +20 fresh oil value +25 fresh oil value +35
Sodium Na mg/kg
Water H2O W% < 0.1 0.12 0.2
Oil Condition (Values marked with (*) valid only for Oils meeting the ISO VG 220)
Viscosity at 40 °C mm²/s min 92 – max 108 min 90 – max 110 min 85 – max 115
Viscosity at 40 °C* mm²/s min 204 – max 238 min 198 – max 242 min 187 – max 253
Viscosity at 100 °C mm²/s ±8% ± 10 % ± 15 %
Viscosity at 100 °C* mm²/s of fresh-oil of fresh-oil of fresh-oil
Viscosity Index VI -
Additive Metals
Calcium Ca mg/kg
Magnesium Mg mg/kg
Boron B mg/kg ± 10 % ± 15 % ± 20 %
Phosphorus P mg/kg
Barium Ba mg/kg
Sulphur S mg/kg
Additional Results
TAN mgKOH/g fresh oil value -0.2 /+0.6 fresh oil value -0.2 / +0.8 fresh oil value -0.2 / +1.2
Test Standard
TAN DIN 51 558
11
3 847 003.00 en
For oil in the pump transfer gearboxes of the 6040, 6050, 6060
The values are only valid  Global Mining HMS 6040 / 6050 / 6060 Pump Gearbox
Analysis Parameter
Unit
Wear Metals
Tin Sn mg/kg 1 2 3
Lead Pb mg/kg 3 5 8
PQ-Index - - 55 70 110
Contamination
Potassium K mg/kg
Sodium Na mg/kg
Water H2O W% < 0.1 0.12 0.18
Additive Metals
Calcium Ca mg/kg
Magnesium Mg mg/kg
Boron B mg/kg ± 10 % ± 15 % ± 20 %
Phosphorus P mg/kg
Barium Ba mg/kg
Sulphur S mg/kg
Additional Results
Test Standard
TAN DIN 51 558
12
3 847 003.00 en
For oil in the pump transfer gearboxes of the 6090

The values are only valid  Caterpillar Global Mining HMS 6090 Pump Gearbox
Analysis Parameter
Unit
Wear Metals
Tin Sn mg/kg 1 2 4
Lead Pb mg/kg 2 3 6
PQ-Index - - 39 55 101
Contamination
Potassium K mg/kg
Sodium Na mg/kg
Water H2O W% < 0.1 0.11 0.16
Additive Metals
Calcium Ca mg/kg
Magnesium Mg mg/kg
Boron B mg/kg ± 10 % ± 15 % ± 20 %
Phosphorus P mg/kg
Barium Ba mg/kg
Sulphur S mg/kg
Additional Results
Test Standard
TAN DIN 51 558
13
3 847 003.00 en
For oil in the swing gearboxes of the 6015 - 6090

The values are only valid  Caterpillar Global Mining HMS 6015 - 6090 Swing Gearbox
for following conditions:  Oil types: CLP HC DIN 51 517-3, ISO VG 220 / 320
Analysis Parameter
Unit
Wear Metals
Tin Sn mg/kg 1 2 3
Lead Pb mg/kg 2 4 9
PQ-Index - - 49 71 116
Contamination
Potassium K mg/kg
Sodium Na mg/kg
Water H2O W% < 0.1 0.11 0.16
Oil Condition (Values marked with (*) valid for Renolin Unisyn CLP 320)
Viscosity at 100 °C* mm²/s min 28.7 – max 33.2* min 27.9 – max 33.9* min 27.0 – max 34.6*
Viscosity Index VI* - min 125 – max 139* min 121 – max 144* min 117 – max 149*
Additive Elements
Calcium Ca mg/kg
Magnesium Mg mg/kg
Boron B mg/kg ± 10 % ± 15 % ± 20 %
Phosphorus P mg/kg
Barium Ba mg/kg
Sulphur S mg/kg
Additional Results

Test Standard
TAN DIN 51 558
14
3 847 003.00 en
For oil in the travel gearboxes of the 6015, 6018

The values are only valid  Caterpillar Global Mining HMS 6015 / 6018 Travel Gearbox
for following conditions:  Oil type: CLP HC DIN 51 517-3, ISO VG 220
 Travel Gearboxes include wet brakes
Analysis Parameter
Unit
Wear Metals
Tin Sn mg/kg 2 6 9
Aluminium* Al mg/kg 15* 28* 45*
Lead Pb mg/kg 4 9 12
PQ-Index - - 92 128 188
Contamination
Potassium K mg/kg
Sodium Na mg/kg
Water H2O W% < 0.1 0.12 0.14
Oil Condition
Viscosity at 40 °C mm²/s min 130 – max 147 min 125 – max 149 min 122 – max 159.5
Additive Elements
Calcium Ca mg/kg
Magnesium Mg mg/kg
Boron B mg/kg ± 10 % ± 15 % ± 20 %
Phosphorus P mg/kg
Barium Ba mg/kg
Sulphur S mg/kg
Additional Results
* values depend on the material of wet brakes
Test Standard
TAN DIN 51 558
15
3 847 003.00 en
For oil in the travel gearboxes of the 6030, 6040, 6060
The values are only valid  Caterpillar Global Mining HMS 6030 / 6040 / 6060 Travel Gearbox
for following conditions:  Oil type: CLP HC DIN 51 517-3, ISO VG 220
Analysis Parameter
Unit
Wear Metals
Tin Sn mg/kg 2 5 7
Lead Pb mg/kg 3 7 9
PQ-Index - - 59 98 154
Contamination
Potassium K mg/kg
Sodium Na mg/kg
Water H2O W% < 0.1 0.12 0.14
Oil Condition
Additive Elements
Calcium Ca mg/kg
Magnesium Mg mg/kg
Boron B mg/kg ± 10 % ± 15 % ± 20 %
Phosphorus P mg/kg
Barium Ba mg/kg
Sulphur S mg/kg
Additional Results
TAN mgKOH/g fresh oil value -0,2 /+0.5 fresh oil value -0,2 / +0.7 fresh oil value -0,2 / +1.0
Test Standard
TAN DIN 51 558
16
3 847 003.00 en
For oil in the travel gearboxes of the 6050, 6090

The values are only valid  Caterpillar Global Mining HMS 6050 / 6090 Travel Gearbox
for following conditions  Oil type: CLP HC DIN 51 517-3, ISO VG 220
Analysis Parameter
Unit
Wear Metals
Tin Sn mg/kg 2 5 7
Lead Pb mg/kg 3 6 8
PQ-Index - - 53 96 144
Contamination
Potassium K mg/kg
Sodium Na mg/kg
Water H2O W% < 0.1 0.12 0.14
Oil Condition
Additive Elements
Calcium Ca mg/kg
Magnesium Mg mg/kg
Boron B mg/kg ± 10 % ± 15 % ± 20 %
Phosphorus P mg/kg
Barium Ba mg/kg
Sulphur S mg/kg
Additional Results
Test Standard
TAN DIN 51 558
17
3 847 003.00 en
Notes
18
3 847 003.00 en
19
Printed in Germany
© Copyright Caterpillar Global Mining HMS GmbH 2018. The reproduction, distribution and utilization
of this manual / file as well as the communication of its content to others without express
authorization is prohibited. Offenders will be held liable for the payment of damages. All rights
reserved in the event of the grant of a patent, utility model or design.
Printed in Germany

Service Manual-DHJ40169-6040(RH170169) EM028957-0_en-us

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Service Manual-DHJ40169-6040(RH170169) EM028957-0_en-us

Uploaded by

Copyright:

Available Formats

EM028957-0 (en-us)

Caterpillar: Confidential Green

Caterpillar: Confidential Green

11. Central lubrication system

3720200en – (01) Page 1

15. Service Manual for fundamental principles of electricity

16. Service Manual for handling circuit diagrams

17. Service Manual for general information, conversion cal-

18. Service Manual for sealing, protective, testing and clean-

19. Service Manual for fittings, tube assemblies and hose

20. Repair welding manual

21. Service Manual for oil samples and oil analysis

Page 2 3720200en – (01)

Caterpillar: Confidential Green

1.1 Introduction ...................................................................................... 1.1 - 1

1.1.1 Service Manual ................................................................. 1.1 - 1

1.1.2 How to use the Service Manual ......................................... 1.1 - 1

1.1.3 Servicing and repair ........................................................... 1.1 - 2

1.1.4 Important hints ................................................................... 1.1 - 2

1.2 Safety instructions ........................................................................... 1.2 - 1

1.2.1 Risks of disregarding safety instructions ........................... 1.2 - 1

1.2.2 Safety regulations .............................................................. 1.2 - 1

1.2.3 Modification of the machine ............................................... 1.2 - 4

1.2.4 Re-commissioning ............................................................. 1.2 - 4

1.3 General .............................................................................................. 1.3 - 1

3720201en – (02) Page 1 - 1

Page 1 - 2 3720201en – (02)

1.1 Introduction Most tables referring to the drawings contain the

Using the Service Manual allows the experienced

Splines coated with mineral

To make it easier to understand the content, some

3849221en - (00) Page 1.1 - 1

 Check all mechanical connections and

Page 1.1 - 2 3849221en - (00)

1.2 Safety instructions

However, operating the machine if Follow the accident prevention

2440539en – (01) Page 1.2 - 1

Personnel Tools and devices

Page 1.2 - 2 2440539en – (01)

2440539en – (01) Page 1.2 - 3

1.2.3 Modifications of the machine 1.2.4 Re-commissioning

Unauthorized conversions or modi- Before re-commissioning:

Page 1.2 - 4 2440539en – (01)

All sketches and drawings show general principles.

Special equipment is normally not considered.

Technical modifications, which are introduced after

2440540en – (02) Page 1.3 - 1

Page 1.3 - 2 2440540en – (02)

Caterpillar: Confidential Green

2.1 Introduction ......................................................................................... 2 - 1

2.1.1 Foreword .............................................................................. 2 - 1

2.1.2 Safety ................................................................................... 2 - 1

2.1.3 General ................................................................................. 2 - 1

2.2 Engine / Motor ..................................................................................... 2 - 3

2.3 Hydraulic system ................................................................................. 2 - 4

2.3.1 Main pump ............................................................................ 2 - 4

2.3.2 Swing system ....................................................................... 2 - 5

2.3.3 Auxiliary pressure pump / Gear oil pump .............................. 2 - 6

2.3.4 Servo- and swing charge pump ............................................ 2 - 6

2.3.5 Cooling system hydraulic oil / water ..................................... 2 - 7

2.3.6 Travel motor ......................................................................... 2 - 9

2.3.7 Control block......................................................................... 2 - 9

2.3.8 Filter elements for hydraulic system ..................................... 2 - 9

2.4 Pressure setting ................................................................................ 2 - 10