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Liebherr TL 435-13 Telescopic Handler Service Repair Manual

Liebherr TL 435-13 Telescopic Handler Service Repair Manual

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This is the Highly Detailed factory service repair manual for theLIEBHERR TL 435-13 TELESCOPIC HANDLER, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.LIEBHERR TL 435-13 TELESCOPIC HANDLER Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

Service Repair Manual Covers:
General
Tools and Work Instructions
Technical Data and Maintenance Guidelines
Engine
Coupling, Splitterbox
Travel Hydraulic
Steering Hydraulic
Brake Hydraulic
Hydraulic Components
Electrical System – Diagrams and Components
Electrical System – Description
Axles / Tires and Gear Shafts
Main Frame – Installations
Tank Arrangements
Operator Cab, Heater, Air Conditioning System
Telescopic Boom
Working Attachments
Special Installations
Additional Documentation
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader

NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveLIEBHERR TL 435-13 TELESCOPIC HANDLER Service Repair Workshop Manual.

Looking for some other Service Repair Manual,please check:
https://www.aservicemanualpdf.com/

Thanks for visiting!






This is the Highly Detailed factory service repair manual for theLIEBHERR TL 435-13 TELESCOPIC HANDLER, this Service Manual has detailed illustrations as well as step by step instructions,It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic.LIEBHERR TL 435-13 TELESCOPIC HANDLER Service Repair Workshop Manual provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

Service Repair Manual Covers:
General
Tools and Work Instructions
Technical Data and Maintenance Guidelines
Engine
Coupling, Splitterbox
Travel Hydraulic
Steering Hydraulic
Brake Hydraulic
Hydraulic Components
Electrical System – Diagrams and Components
Electrical System – Description
Axles / Tires and Gear Shafts
Main Frame – Installations
Tank Arrangements
Operator Cab, Heater, Air Conditioning System
Telescopic Boom
Working Attachments
Special Installations
Additional Documentation
File Format: PDF
Compatible: All Versions of Windows & Mac
Language: English
Requirements: Adobe PDF Reader

NO waiting, Buy from responsible seller and get INSTANT DOWNLOAD, Without wasting your hard-owned money on uncertainty or surprise! All pages are is great to haveLIEBHERR TL 435-13 TELESCOPIC HANDLER Service Repair Workshop Manual.

Looking for some other Service Repair Manual,please check:
https://www.aservicemanualpdf.com/

Thanks for visiting!

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  1. 1.                                                                                              
  2. 2. Service Manual Table of contents TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 0.1.000 - 1 / 4 0.1.000 Table of contents Page No. Title Date of issue 0.1.000 Table of contents 03.2010 1.0.000 Sub group index "General" 05.2007 1.1.000 Foreword and explanations 10.2007 1.2.000 Safety guidelines 02.2008 1.3.001 Tightening torques 02.2010 1.3.002 Conversion charts 01.2009 1.3.003 Tapping holes 05.2007 1.4.000 Conservation guidelines 02.2010 1.5.000 Material weights 01.2010 2.0.000 Sub group index "Tools and work instructions" 08.2007 2.1.000 Special tools 03.2010 2.2.000 Repair welding 08.2007 2.3.000 Assembly instructions 01.2009 3.0.000 Sub group index "Technical data and Maintenance guidelines" 10.2007 3.1.000 Technical data 01.2010 3.1.001 Technical data 01.2010 3.2.000 Maintenance and inspection schedule 02.2009 3.2.001 Maintenance and inspection schedule 01.2010 3.3.000 Maintenance and inspection guidelines 01.2010 3.4.000 Adjustment check list 01.2010 3.5.000 Inspection and adjustment tasks 01.2010 4.0.000 Sub group index "Engine" 01.2009 4.1.000 Data page 01.2010 4.1.001 Data page 01.2010 4.2.000 Fan and cylinder arrangement 01.2010 4.3.000 Installation kit Liebherr- Diesel particle filter 01.2009 4.4.000 Installation and check list for Diesel particle filter 01.2009 5.0.000 Sub group index "Coupling, splitterbox" 03.2007 5.1.000 Data page 01.2010 5.2.000 Coupling 06.2007 5.3.000 Splitterbox 10.2007 6.0.000 Sub group index "Travel hydraulic" 10.2007 6.1.000 Data page 01.2010 6.2.000 Design 10.2007 6.2.001 Design 02.2010 6.3.000 Function 02.2010 6.3.001 Function 02.2010 6.4.000 Repair work and troubleshooting 10.2007 6.5.000 Component arrangement 08.2007 6.5.001 Component arrangement 05.2007 copyright by
  3. 3. Service Manual Table of contents TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 0.1.000 - 2 / 4 Mjfcifss! TL 442-13 F/N xxx-6000 Page No. Title Date of issue 7.0.000 Sub group index "Working hydraulic" 10.2007 7.1.000 Data page 01.2010 7.2.000 Design 10.2007 7.2.001 Design 03.2009 7.3.000 Function 03.2009 7.3.001 Function 03.2009 7.4.000 Repair work and troubleshooting 10.2007 7.5.000 Component arrangement 10.2007 8.0.000 Sub group index "Steering hydraulic" 10.2007 8.1.000 Data page 01.2010 8.2.000 Design 08.2007 8.3.000 Function 03.2009 8.3.001 Function 03.2009 8.4.000 Repair work and troubleshooting 10.2007 8.5.000 Component arrangement 08.2007 9.0.000 Sub group index "Brake hydraulic" 10.2007 9.1.000 Data page 01.2010 9.2.000 Design 08.2007 9.2.001 Design 01.2010 9.3.000 Function 03.2009 9.3.001 Function 01.2010 9.4.000 Repair work and troubleshooting 10.2007 9.5.000 Component arrangement 05.2007 9.5.001 Component arrangement 01.2010 10.0.000 Sub group index "Hydraulic components" 05.2007 10.1.000 Var. displacement pump / Travel pump – Travel hydraulic 03.2007 10.2.000 Var. displacement motor/ Travel motor - Travel hydraulic 03.2007 10.3.000 Regulating pump - Working hydraulic 06.2007 10.3.001 Regulating pump - Working hydraulic 01.2009 10.4.000 Fixed displacement pump 05.2007 10.5.000 Gear motor – fan drive 10.2007 10.6.000 Steering aggregate 05.2007 10.7.000 Proportional control valve block 03.2007 10.8.000 Black / white control valve block 02.2010 10.8.001 Black / white control valve block 02.2010 10.9.000 Brake cylinder 02.2010 10.10.000 Valves 02.2009 10.11.000 Cylinders 02.2009 11.0.000 Sub group index "Electrical system – Diagrams and components" 05.2007 11.1.000 Component description 01.2010 11.1.001 Component description 01.2010 11.2.000 Function list 01.2010 11.2.001 Function list 01.2010 11.3.000 Fuses, notes 01.2009 11.4.000 Circuit diagram 01.2009 11.4.001 Circuit diagram 01.2009 11.5.000 Component arrangement 01.2009 11.5.001 Component arrangement 03.2009 11.6.000 Control lever 01.2009 11.7.000 Calibration of the electronic load display 06.2007 11.7.001 Calibration of the electronic load display 10.2007 11.8.000 DMS Sensor installation 10.2007 copyright by
  4. 4. Service Manual Table of contents TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 0.1.000 - 3 / 4 Page No. Title Date of issue 12.0.000 Sub group index "Electrical system - Descriptions" 01.2009 12.1.000 Evaluation software Travel hydraulic LinDiag 01.2010 12.1.001 Evaluation software Travel hydraulic LinDiag 01.2010 12.2.000 Software Working hydraulic control Bodem 01.2010 12.2.001 Software Working hydraulic control Bodem 02.2010 12.3.000 Service-Code list 02.2010 12.4.000 Software PDL – Diesel particle filter 01.2010 13.0.000 Sub group index "Axles / tires and gear shafts" 10.2007 13.1.000 Data page 01.2010 13.2.000 Design 01.2010 13.3.000 Disk brake 01.2010 13.4.000 Differential 04.2007 13.5.000 Wheel hub and steering axle 02.2009 13.6.000 Gear shafts 06.2007 14.0.000 Sub group index "Main frame installations" 03.2007 14.1.000 Level regulation 03.2009 14.1.001 Level regulation 02.2010 14.1.002 Level regulation 02.2010 14.2.130 Stabilizer / side offset 03.2009 14.2.131 Stabilizer / side offset 02.2010 14.2.132 Stabilizer / side offset 02.2010 14.3.000 Cooler arrangement 05.2007 14.3.001 Cooler arrangement 05.2007 14.4.000 Engine mount 08.2007 14.5.000 Battery installation 03.2007 15.0.000 Sub group index "Tank arrangements" 03.2007 15.1.000 Hydraulic tank 10.2007 15.1.001 Hydraulic tank 03.2009 15.2.000 Fuel tank 08.2007 16.0.000 Sub group index "Operator’s cab, heater, air conditioning system" 03.2007 16.1.000 Operator’s cab 08.2007 16.2.000 Heater and blower 08.2007 16.3.000 Air conditioning system 01.2009 17.0.000 Sub group index "Telescopic boom" 06.2007 17.1.100 Design and function 10.2007 17.1.101 Design and function 06.2007 17.1.130 Design and function 06.2007 17.1.131 Design and function 06.2007 17.2.100 Repair instructions 02.2008 17.2.101 Repair instructions 02.2008 17.2.130 Repair instructions 03.2010 17.2.131 Repair instructions 03.2010 18.0.000 Sub group index "Working attachment" 10.2007 18.1.000 Tool coupler 01.2009 18.2.000 Forklift 08.2007 18.3.000 Bucket 03.2010 18.4.100 Aerial work platform 02.2010 18.4.130 Aerial work platform 02.2010 18.4.131 Aerial work platform 02.2010 copyright by
  5. 5. Service Manual Table of contents TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 0.1.000 - 4 / 4 Mjfcifss! TL 442-13 F/N xxx-6000 Page No. Title Date of issue 19.0.000 Sub group index "Special equipment" 03.2010 19.1.000 Industrial control 03.2009 19.1.001 Industrial control 03.2009 19.2.000 Rear axle steering 06.2007 19.4.000 Quick coupler 04.2007 19.5.000 Reversible fan 03.2009 19.6.000 Towing hitch device 01.2010 19.7.000 Telescope - Leak oil line 03.2010 20.0.00 Sub group index "Additional documentation" 10.2007 6.3.000 Schematic Travel hydraulic 02.2010 6.3.001 Schematic Travel hydraulic 02.2010 7.3.000 Schematic Working hydraulic 03.2009 7.3.001 Schematic Working hydraulic 03.2009 8.3.000 Schematic Steering hydraulic 03.2009 8.3.001 Schematic Steering hydraulic 03.2009 9.3.000 Schematic Brake hydraulic 03.2009 9.3.001 Schematic Brake hydraulic 01.2010 11.4.000 Circuit diagram 01.2009 11.4.001 Circuit diagram 01.2009 14.1.000 Schematic Level regulation 03.2009 14.1.001 Schematic Level regulation 02.2010 14.1.002 Schematic Level regulation 02.2010 14.2.130 Schematic Stabilizers and side offset 02.2010 14.2.131 Schematic Stabilizers and side offset 02.2010 14.2.132 Schematic Stabilizers and side offset 02.2010 18.4.100 Schematic Aerial work platform 02.2010 18.4.130 Schematic Aerial work platform 01.2009 18.4.131 Schematic Aerial work platform 03.2009 19.1.000 Schematic Industrial control 03.2009 19.1.001 Schematic Industrial control 03.2009 copyright by
  6. 6. Service Manual General Sub group index - General 1 General 1.0.000 Sub group index - General Foreword and explanations .............................................................................. 1.1 Safety guidelines ............................................................................................... 1.2 Charts ................................................................................................................. 1.3 Tightening torques..........................................................................................................1.3.001 Conversion charts...........................................................................................................1.3.002 Tapping holes .................................................................................................................1.3.003 Conservation guidelines ................................................................................... 1.4 Material weights................................................................................................. 1.5 TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 Mjfcifss! 1.0.000 - 1 / 2 copyright by
  7. 7. Service Manual General Foreword and explanations TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 1.1.000 - 1 / 2 1.1.000 Foreword and explanations 1 For information This manual contains technical data, design and functional descriptions, work and adjustment instructions as well as numerous drawings, functional views and illustrations for the LIEBHERR – Telescopic loader. This manual should simplify competent customer service of our products. However, it does not replace expert and qualified user training and attendance of our factory training classes. Generally valid basic information is not listed. Refer to separate documentation for operational and spare parts information. The manual will be updated and expanded as necessary when changes occur in series. Note! This symbol is used in the manual for very important notes. For all tasks on the machine, accident prevention guidelines and safety guidelines must be strictly observed. Note! This manual is solely for the own use of the registered owner and may not be duplicated or copied, complete or in part, nor passed on to a third person and remains the property of LIEBHERR-Werk Telfs GmbH. All rights reserved - Printed in Austria. We reserve the right to make changes of technical details on the machine in comparison to the information and illustrations in this manual. Written and published by LIEBHERR-Werk Telfs GmbH., Technical Documentation Dept. 2 Explanation of layout To make it easier to find certain information and to simplify filing of updates, the following structure was developed: 6.3.130 - 1/2 Main group Sub group Type group Page No. Components (item) groups acc. to index Structure of main group according to sub group index Continuous running number and complete pages within the model group Structure based on telescopic boom type (13) and updates (0) copyright by
  8. 8. General Service Manual Foreword and explanations TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 1.1.000 - 2 / 2 Mjfcifss! TL 442-13 F/N xxx-6000 For the 3-digit type group number, the last number provides information regarding updates, whereby the two other numbers provide information about the type of machine, for example 000 and no additional machine serial number limitation means that the document is valid for all TL machine. for example 100/130 and no additional machine serial number limitation means that this document is valid for a TL 10 meter boom / TL 13 meter boom. for example 001/101/131 is a supplement which is valid from a certain machine serial number. Changes are issued with the same number, but with a later date. Updates have new numbers. If a page is valid only for a certain machine group, then this is noted in the header. 3 Itemization variations This symbol denotes a standard listing. This symbol means:“ The prerequisite must be met“. The maintenance personnel must first fulfill the described prerequisites, for example, to bring the machine in working position, to be able to carry out the steps described thereafter. This symbol denotes an activity step. The maintenance personnel is to become active on this point and carry out the described activity. This symbol denotes a result. The maintenance personal is alerted that there is a result after an activity step, for example after pressing the test button, the LED lights up. 4 General This note shows that a detail view of an illustration is shown rotated by a given angle, as compared to the actual installation position (in this case 180°). We hope that with the enclosed information we have taken yet another step to improve the service on the LIEBHERR telescopic handlers, crawler dozers, crawler loaders and pipe layers. LIEBHERR-Werk Telfs GmbH. Technical Documentation copyright by
  9. 9. Service Manual General Safety guidelines TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 1.2.000 - 1 / 4 1.2.000 Safety guidelines 1 Introduction Prior to and during the performance of tests, inspections and repairs, the following safety guidelines must be observed: Any type of work may only be carried out by qualified expert personnel or under their guidance and supervision. Qualified expert personnel are persons, who, based on their specialized training and experience, have sufficient knowledge in the area of telescopic handlers and the specific technology of our machines in particular and who are familiar with all applicable laws and general work protection regulations, accident prevention guidelines, regulations, guidelines and generally approved rules concerning technology so that they are able to evaluate if the earthmoving equipment is safe to operate and if the necessary work can be performed without endangering themselves or third persons. Always adhere to the adjustment values noted in the LIEBHERR documentation when performing adjustment work. At the delivery of a machine, the operating personnel must be trained using the current operating instructions. The safety guidelines noted in the instructions must be particularly observed. These safety guidelines must also be observed during inspection, adjustment or repair work. However, there are special repair and / or inspection work which require qualified personnel to follow another procedure than that noted in the safety guidelines. In such cases, qualified personnel or individuals performing the work under the supervision of such personnel should assure that additional safety precautions necessary to insure the safety of those involved in the repair and/ or third persons are taken. Such items of repair and/ or inspection work include, but are not limited to the following: - Opening the engine compartment doors while the engine running to carry out tests and / or adjustments. In these cases, it should be ensured that the cab door is properly secured during the entire duration of the work to prevent it from closing unexpectedly and / or inadvertently. Care should be exercised to assure that there will be no inadvertent or unintended contact of any part of the body with any moving and / or heated components. Wear only tightly fitted clothing (no scarves, no tie, no wide sleeves, etc.). copyright by
  10. 10. General Service Manual Safety guidelines TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 1.2.000 - 2 / 4 Mjfcifss! TL 442-13 F/N xxx-6000 Danger notes in this manual In the description of work, which can cause dangers for man or machine, the required safety measures are described in this manual. They are denoted with the following notes: Danger! Warns that certain working procedures without appropriate precautionary measures can result in fatal injuries. Warning! Warns that certain working procedures without appropriate precautionary measures can result in severe bodily injuries. Caution! Warns that certain working procedures without appropriate precautionary measures can result in bodily injuries or damage to the machine. Following these notes does not relieve you from observation of additional regulations and guidelines! The following must also be observed: - the safety regulations valid for the jobsite. - those issued by the legislature "Traffic regulations“. - the guidelines issued by trade associations. copyright by
  11. 11. Service Manual General Safety guidelines TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 1.2.000 - 3 / 4 Safety guidelines in these Operating instructions The detailed descriptions of the following safety guidelines are in the Operating instructions of the machine and must be strictly observed. 1 Introduction 2 Destined use 3 Signs on the machine 4 Safety guidelines 4.1 General safety guidelines 4.2 Crushing and burn prevention 4.3 Fire and explosion prevention 4.4 Machine start up safety 4.5 Engine start up safety 4.6 Machine operating safety 4.7 Machine parking safety 4.8 Machine transporting safety 4.9 Machine towing safety 4.10 Machine maintenance safety 4.11 Safety guidelines for welding work on the machine 4.12 Safety guidelines for working on the attachment 4.13 Safety guidelines when loading the machine with a crane 4.14 Safe maintenance of hydraulic hoses and hose lines 4.15 Safety guidelines for maintenance work on machines with hydro accumulators 4.16 Roll over protection (ROPS) and falling object protection (FOPS) 4.17 Attachment and components 4.18 Safe operation for material handling 4.19 Protection from vibration 4.20 Safety guidelines for operation with quick coupler adapter (optional) copyright by
  12. 12. Service Manual General Tightening torques TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 1.3.001 - 1 / 4 1.3.001 Tightening torques The preload values and tightening torques noted in the chart have been taken from the VDI guidelines 2230 of July 1986. Installation preload values FM and tightening torques MA for shoulder studs with standard metric or fine thread per DIN ISO 262 and DIN ISO 965 T2 (replacement for DIN 13 part 13) and wrench sizes for hex head screws with shaft DIN EN 24014 (replacement for DIN 931 part 1) or socket head screws DIN EN ISO 4762 (replacement for DIN 912) - The chart values are valid for screws with black or phosphated, zinc plated and DACROMET 500. Screws and nuts with black, phosphated or zinc plated, lightly lubricated. Medium friction value G = 0,12. Note! Any tightening torque values and/ or tightening procedures noted in drawings / parts lists, instructions or component descriptions must be adhered to and given preference over factory standards. Beginning with grade 10.9, the use of lock washers does no longer provide any safety action. Always use correctly sized torque wrenches – the torque value according to the chart should be within the upper third of the existing range. When using impact wrenches, care must be taken so that the torque values are not exceeded. Check before and intermediately with a torque wrench. copyright by
  13. 13. General Service Manual Tightening torques TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 1.3.001 - 2 / 4 Mjfcifss! TL 442-13 F/N xxx-6000 1 Preload values and tightening torques with standard metric thread according to factory standard WN 4037 I Wrench size, (x) = according to DIN931, forPreload values FM based on grades in N Tightening torques MA based on grades in Nm Hex head screw Socket head screw Metric standard thread 8.8 10.9 12.9 8.8 10.9 12.9 mm Inch mm Inch M 4 x 0,7 4 050 6 000 7 000 2,8 4,1 4,8 7 9/32 3 -- M 5 x 0,8 6 600 9 700 11 400 5,5 8,1 9,5 8 5/16 4 5/32 M 6 x 1 9 400 13 700 16 100 9,5 14,0 16,5 10 -- 5 -- M 7 x 1 13 700 20 100 23 500 15,5 23,0 27,0 11 -- -- -- M 8 x 1,25 17 200 25 000 29 500 23 34 40 13 1/2 6 -- M 10 x 1,5 27 500 40 000 47 000 46 68 79 (17) 16 (11/16) -- 8 5/16 M 12 x 1,75 40 000 59 000 69 000 79 117 135 (19) 18 (3/4) -- 10 -- M 14 x 2 55 000 80 000 94 000 125 185 215 (22) 21 (7/8) -- 12 -- M 16 x 2 75 000 111 000 130 000 195 280 330 24 -- 14 9/16 M 18 x 2,5 94 000 135 000 157 000 280 390 460 27 1-1/16 14 9/16 M 20 x 2,5 121 000 173 000 202 000 390 560 650 30 1-3/16 17 -- M 22 x 2,5 152 000 216 000 250 000 530 750 880 (32) 34 -- 17 -- M 24 x 3 175 000 249 000 290 000 670 960 1120 36 1-7/16 19 3/4 M 27 x 3 230 000 330 000 385 000 1000 1400 1650 41 1-5/8 19 3/4 M 30 x 3,5 280 000 400 000 465 000 1350 1900 2250 46 1-13/16 22 7/8 M 33 x 3,5 350 000 495 000 580 000 1850 2600 3000 50 2 24 -- M 36 x 4 410 000 580 000 680 000 2350 3300 3900 55 2-3/16 27 1-1/16 M 39 x 4 490 000 700 000 820 000 3000 4300 5100 60 2-3/8 27 1-1/16 copyright by
  14. 14. Service Manual General Tightening torques TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 1.3.001 - 3 / 4 2 Preload values and tightening torques with fine metric thread according to factory standard WN 4037 I Wrench size, (x) = according to DIN931, forPreload values FM based on grades in N Tightening torques MA based on grades in Nm Hex head screw Socket head screw Metric fine thread 8.8 10.9 12.9 8.8 10.9 12.9 mm Inch mm Inch M 8 x 1 18 800 27 500 32 500 24,5 36 43 13 1/2 6 -- M 9 x 1 24 800 36 500 42 500 36 53 62 -- -- -- -- M 10 x 1 31 500 46 500 54 000 52 76 89 17 11/16 8 5/16 M 10 x 1,25 29 500 43 000 51 000 49 72 84 17 11/16 8 5/16 M 12 x 1,25 45 000 66 000 77 000 87 125 150 19 3/4 10 -- M 12 x 1,5 42 500 62 000 73 000 83 122 145 19 3/4 10 -- M 14 x 1,5 61 000 89 000 104 000 135 200 235 22 7/8 12 -- M 16 x 1,5 82 000 121 000 141 000 205 300 360 24 -- 14 9/16 M 18 x 1,5 110 000 157 000 184 000 310 440 520 27 1-1/16 14 9/16 M 18 x 2 102 000 146 000 170 000 290 420 490 27 1-1/16 14 9/16 M 20 x 1,5 139 000 199 000 232 000 430 620 720 30 1-3/16 17 -- M 22 x 1,5 171 000 245 000 285 000 580 820 960 32 -- 17 -- M 24 x 1,5 207 000 295 000 346 000 760 1090 1270 36 1-7/16 19 3/4 M 24 x 2 196 000 280 000 325 000 730 1040 1220 36 1-7/16 19 3/4 M 27 x 1,5 267 000 381 000 445 000 1110 1580 1850 41 1-5/8 19 3/4 M 27 x 2 255 000 365 000 425 000 1070 1500 1800 41 1-5/8 19 3/4 M 30 x 1,5 335 000 477 000 558 000 1540 2190 2560 46 1-13/16 22 7/8 M 30 x 2 321 000 457 000 534 000 1490 2120 2480 46 1-13/16 22 7/8 M 33 x 1,5 410 000 584 000 683 000 2050 2920 3420 50 2 24 -- M 33 x 2 395 000 560 000 660 000 2000 2800 3300 50 2 24 -- M 36 x 1,5 492 000 701 000 820 000 2680 3820 4470 55 2-3/16 27 1-1/16 M 36 x 3 440 000 630 000 740 000 2500 3500 4100 55 2-3/16 27 1-1/16 M 39 x 1,5 582 000 830 000 971 000 3430 4890 5720 60 2-3/8 27 1-1/16 M 39 x 3 530 000 750 000 880 000 3200 4600 5300 60 2-3/8 27 1-1/16 copyright by
  15. 15. General Service Manual Tightening torques TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 1.3.001 - 4 / 4 Mjfcifss! TL 442-13 F/N xxx-6000 3 Tightening torque for screws to mount SAE flange (not part of factory standard WN 4037 I) Listing according to LFR – Quality service 2QA 6 051 00 as of Oct. 2001 3.1 Flanges and half flanges for high pressure (Norm 62) 3.2 Half flange for low pressure (Norm 61) 3.3 Tightening torque for oil drain plugs on travel gear (40 km/h) (not part of the factory standard WN 4037 I) Plug Thread size Tightening torques in Nm M 26x1,5 40+10 Tightening torques in Nm for screw grade 10.9 Flange nominal size Screw size Half flange Flat flange without reinforcement rim Flange with reinforcement rim ½" M 8 31 -- -- ¾" M 10 62 45 65 1" M 12 108 70 110 1 ¼" M 14 172 120 180 1 ½" M 16 264 170 250 2" M 20 350 250 450 Tightening torques in Nm for Flange nominal size Screw size Screw grade 8.8 Screw grade 10.9 ½" M 8 22 31 ¾" M 10 44 62 1" M 10 44 62 1 ¼" M 10 44 62 1 ½" M 12 76 108 2" M 12 76 108 2 ½" M 12 76 108 3" M 14 122 172 3 ½" M 16 187 264 4" M 16 187 264 5" M 16 187 264 copyright by
  16. 16. Service Manual General Conversion charts TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 1.3.002 - 1 / 2 1.3.002 Conversion charts Unit of measure Multiply by To obtain - Multiply by To obtain Length mm 0,039 inch 25,4 mm m 3,281 feet 0,305 m m 1,093 yard 0,914 m km 0,621 mile 1,609 km Area cm² 0,155 sq. inch 6,452 cm² m² 10,764 sq. feet 0,093 m² m² 1,196 sq. yard 0,8361 m² km² 0,386 sq. mile 2,59 km² Volume cm³ 0,061 cu. inch 16,387 cm³ m³ 35,314 cu. feet 0,028 m³ m³ 1,308 cu. yard 0,764 m³ l 61,025 cu. inch 0,016 l l 0,035 cu. feet 28,316 l l 0,264 gallon 3,785 l l 1,057 quart 0,946 l Weight g 0,035 oz. 28,349 g kg 2,204 lbs. 0,453 kg t 1,102 short t 0,907 t Force N 0,225 lbs. 4,449 N kN 224,732 lbs. 0,0044 kN Torque Nm 0,737 ft. lbs. 1,356 Nm Power kW 1,342 HP 0,745 kW PS 0,736 kW 1,358 PS PS 0,986 HP 1,014 PS Pressure bar 14,5 PSI 0,069 bar (hydraulic) kpa 0,145 PSI 6,896 kpa Ground pressure kg/cm² 14,223 lbs. sq. inch 0,0703 kg/cm² kg/m² 0,205 lbs. sq. ft. 4,878 kg/m² Compression g/cm³ 0,036 lbs. cu. inch 27,78 g/cm³ kg/m³ 0,062 lbs. cu. ft. 16,13 kg/m³ Speed km/h 0,621 mph 1,609 km/h m/min 3,281 ft. / min 0,305 m/min Temperature °C (°Cx1,8) + 32 °F (°F-32)/1,8 °C °C °C+273 °K °K-273 °C copyright by
  17. 17. Service Manual General Tapping holes 1.3.003 Tapping holes 1 Tapping holes for metric ISO standard threads Thread size Thread size Ø Diameter limits max. min. Drill bit Ø M 1 0,785 0,729 0,75 M 1,1 0,885 0,829 0,85 M 1,2 0,985 0,929 0,95 M 1,4 1,160 1,075 1,1 M 1,6 1,321 1,221 1,25 M 1,7 1,346 1,258 1,30 M 1,8 1,521 1,421 1,45 M 2 1,679 1,567 1,6 M 2,2 1,838 1,713 1,75 M 2,3 1,920 1,795 1,9 M 2,5 2,138 2,013 2,05 M 2,6 2,176 2,036 2,10 M 3 2,599 2,459 2,5 M 3,5 3,010 2,850 2,9 M 4 3,422 3,242 3,3 M 4,5 3,878 3,688 3,7 M 5 4,334 4,134 4,2 M 6 5,153 4,917 5 M 7 6,153 5,917 6 M 8 6,912 6,647 6,8 M 9 7,912 7,647 7,8 M 10 8,676 8,376 8,5 M 11 9,676 9,376 9,6 M 12 10,441 10,106 10,2 M 14 12,210 11,835 12 M 16 14,210 13,835 14 M 18 15,744 15,294 15,5 M 20 17,744 17,294 17,5 M 22 19,744 19,294 19,5 M 24 21,252 20,752 21 M 27 24,252 23,752 24 M 30 26,771 26,211 26,5 M 33 29,771 29,211 29,5 M 36 32,270 31,650 32 M 39 35,270 34,670 35 M 42 37,799 39,129 37,5 M 45 40,799 40,129 40,5 M 48 43,297 42,587 43,0 M 52 47,297 46,587 47,0 M 56 50,796 50,046 50,5 M 60 54,796 54,046 54,1 M 64 58,305 57,505 57,6 M 68 62,305 61,505 61,6 TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 1.3.003 - 1 / 2 copyright by
  18. 18. General Service Manual Tapping holes TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 1.3.003 - 2 / 2 Mjfcifss! TL 442-13 F/N xxx-6000 2 Tapping holes for metric ISO fine threads Thread size Hole Ø Diameter limits max. min. Drill bit Ø M 1 x 0,2 0,821 0,783 0,8 M 1,1 x 0,2 0,921 0,833 0,9 M 1,2 x 0,2 1,021 0,983 1 M 1,4 x 0,2 1,221 1,183 1,2 M 1,4 x 0,25 1,185 1,129 1,15 M 1,6 x 0,2 1,421 1,383 1,4 M 1,8 x 0,2 1,621 1,583 1,6 M 2 x 0,25 1,785 1,729 1,75 M 2,2 x 0,25 1,985 1,929 1,95 M 2,5 x 0,35 2,201 1,121 2,15 M 3 x 0,35 2,721 2,621 2,65 M 3,5 x 0,35 3,221 3,121 3,15 M 4 x 0,5 3,599 3,459 3,5 M 4,5 x 0,5 4,099 3,959 4 M 5 x 0,5 4,599 4,459 4,5 M 5,5 x 0,5 5,099 4,959 5 M 6 x 0,75 5,378 5,188 5,2 M 7 x 0,75 6,378 6,188 6,2 M 8 x 0,75 7,378 7,188 7,2 M 8 x 1 7,153 6,917 7 M 9 x 0,75 8,378 8,188 8,2 M 9 x 1 8,153 7,917 8 M 10 x 0,75 9,378 9,188 9,2 M 10 x 1 9,153 8,917 9 M 10 x 1,25 8,912 8,647 8,8 M 11 x 0,75 10,378 10,188 10,2 M 11 x 1 10,153 9,917 10 M 12 x 1 11,153 10,917 11,1 M 12 x 1,25 10,912 10,647 10,8 M 12 x 1,5 10,676 10,376 10,5 M 14 x 1 13,153 12,917 13 M 14 x 1,25 12,912 112,647 12,8 M 14 x 1,5 12,676 12,376 12,5 M 15 x 1 14,153 13,917 14 M 15 x 1,5 13,676 13,376 13,5 M 16 x 1 15,153 14,917 15 M 16 x 1,5 14,676 14,376 14,5 M 17 x 1 16,153 15,917 16 M 17 x 1,5 15,676 15,376 15,5 M 18 x 1 17,153 16,917 17 M 18 x 1,5 16,676 16,376 16,5 M 18 x 2 16,210 15,835 16 M 20 x 1 19,153 18,917 19 M 20 x 1,5 18,676 18,376 18,5 M 20 x 2 18,210 17,835 18 M 22 x 1 21,153 20,917 21 M 22 x 1,5 20,676 20,376 20,5 M 22 x 2 20,210 19,835 20 M 24 x 1 23,153 22,917 23 M 24 x 1,5 22,676 22,376 22,5 Thread size Hole Ø Diameter limits max. min. Drill bit Ø M 24 x 2 22,210 21,835 22 M 25 x 1 24,153 23,917 24 M 25 x 1,5 23,676 23,376 23,5 M 25 x 2 23,210 22,835 23 M 26 x 1,5 24,676 24,376 24,5 M 27 x 1 26,153 25,917 26 M 27 x 1,5 25,676 25,376 25,5 M 27 x 2 25,210 24,835 25 M 28 x 1 27,153 26,917 27 M 28 x 1,5 26,676 26,376 26,5 M 28 x 2 26,210 25,835 26 M 30 x 1 29,153 28,917 29 M 30 x 1,5 28,676 28,376 28,5 M 30 x 2 28,210 27,835 28 M 30 x 3 27,252 26,752 27 M 32 x 1,5 30,676 30,376 30,5 M 32 x 2 30,210 29,835 30 M 33 x 1,5 31,676 31,376 31,5 M 33 x 2 31,210 30,835 31 M 33 x 3 30,252 29,752 30 M 35 x 1,5 33,676 33,376 33,5 M 36 x 1,5 34,676 34,376 34,5 M 36 x 2 34,210 33,835 34 M 36 x 3 33,252 32,752 33 M 38 x 1,5 36,676 36,376 36,5 M 39 x 1,5 37,676 37,376 37,5 M 39 x 2 37,210 36,835 37 M 39 x 3 36,252 35,752 36 M 40 x 1,5 38,676 38,376 38,5 M 40 x 2 38,210 37,835 38 M 40 x 3 37,252 36,752 37 M 42 x 1,5 40,676 40,376 40,5 M 42 x 2 40,210 39,835 40 M 42 x 3 39,252 38,752 39 M 42 x 4 38,270 37,670 38 M 45 x 1,5 43,676 43,376 43,5 M 43 x 2 43,210 42,835 43 M 45 x 3 42,252 41,752 42 M 45 x 4 41,270 40,670 41 M 48 x 1,5 46,676 46,376 46,5 M 48 x 2 46,210 45,835 46 M 48 x 3 45,252 44,752 45 M 48 x 4 44,270 43,670 44 M 50 x 1,5 48,676 48,376 48,5 M 50 x 2 48,210 47,835 48 M 50 x 3 47,252 46,752 47 M 52 x 1,5 50,676 50,376 50,5 M 52 x 2 50,210 49,835 50 M 52 x 3 49,252 48,752 49 M 52 x 4 48,270 47,670 48 copyright by
  19. 19. Service Manual General Conservation guidelines TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 1.4.000 - 1 / 6 1.4.000 Conservation guidelines 1 General All parts of a construction machine are exposed to corrosion, especially when the machine is taken out of service. Corrosion can be compared to wear. However, the effects of corrosion can greatly exceed that of mechanical wear and shorten the service life of the affected parts significantly. For that reason, for longer shut down, the machines and its components must be preserved according to certain guidelines. In general, these guidelines are tiered according to the following times: Taking the machine out of service – for an unknown duration Shut down of the machine Shut down for up to 2 months Shut down for up to 12 months Shut down for longer than 12 months Return to operation The required measures are graduated depending on the different time frames. The conservation measures cannot be strictly standardized and they must be shorted or lengthened depending on the assessment of necessity (such as environmental influences). Such influences are, for example: Placement location of machine (for example in unprotected surrounding, in closed areas, protected by a roof, temperate surrounding) Type of climate (for example extreme temperatures, location in water / near the coast, etc.) Note! For conservation for sea transport, special guidelines must be observed, which are not included in these instructions. Refer to the special operating instructions. 2 Taking the machine out of service – for an unknown duration If a machine is taken out of service for a longer period of time without conservation, then it must be operated in intervals not to exceed 14 days, to prevent abnormal corrosion and its effects. Before putting the machine back into service, check all oil levels and correct them, if necessary. Always carry out the specified daily maintenance work before putting the machine back into service. In addition, carry out the time limited maintenance work according to the inspection schedule and additional Diesel engine Operating instructions no later than the specified intervals. Put the machine into operation according to the Operating instructions and operate it until the Diesel engine and the hydraulic system has reached the specified operating temperature in the hydraulic tank and in the coolant circuit. Actuate all functions of the travel, working hydraulic as well as functions of additionally installed hydraulic components and alternately operate them over a period of approx. 20 minutes. The hydraulic cylinders must be extended and retracted over their full stroke length. When turning the machine off, retract all hydraulic cylinders fully, if possible, and fill the fuel tank. If the machine is parked on soft ground, park the machine on wooden planks or similar and secure it to prevent it from rolling off. Check the batteries and remove them and recharge them, if necessary. Check the electrical contact points and grease them, if necessary. copyright by
  20. 20. General Service Manual Conservation guidelines TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 1.4.000 - 2 / 6 Mjfcifss! TL 442-13 F/N xxx-6000 3 Shut down of the machine Preparations for shut down Park the machine on horizontal, dry and solid ground and secure it to prevent it from rolling off. Lower the working attachment to the ground level so that there is no longer any residual pressure of the hydraulic. Clean the machine diligently according to the procedure outlined in the Operating instructions. The machine must be completely dry before starting the conservation measures. Dry electronic components and damp areas on the machine with pressurized air. If freezing temperatures are expected for the intended duration of shut down, then the fuel tank must be filled with winter fuel. Then start the Diesel engine and let it run for some time to bring the winter fuel into the fuel circuit. Then add enough fuel to the fuel tank until it is full. Note! When a conserved machine is moved for loading or transport, then the conservation protection on the piston rods of the cylinders will most often be removed by the scraper ring. For that reason, if the machine is transported, the conservation of the piston rods must be rechecked after loading and carried out again, if necessary. Note! Despite completed conservations measures, the machine must still be inspected in certain intervals and touched up, if necessary. This is within left to the discretion of the operator, but these inspections should be carried out regularly (monthly), especially in aggravated conditions (cold, heat, near the coast, etc.). 3.1 Shut down for up to 2 months Required tools / Service items Description Id. No. Description Display Optical charge tester See section 2.1 To check the battery condition and the antifreeze in the coolant WAXOYL 120-4 Anti corrosion wax 8504472 Spray can 500ml Long term protection for up to 2 years Ballistol Spray Corrosion protection 10025514 Application area: Door locks Dehumidification capsule 10013313 Prevents infiltration of moisture over an extended period of time Check the entire machine for damage and remedy, if necessary. Check the machine for paint damage and remedy, if necessary. Take care of any maintenance work which would fall within the timeframe of the planned shut down. Due to the UV exposure of the components, synthetic materials, such as plastic parts, hoses, rubber etc. must be covered with suitable aids. Electrical components, contact points and plug connections which are not sealed must be sealed with conservation wax „Waxoyl 120-4“. copyright by
  21. 21. Service Manual General Conservation guidelines TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 1.4.000 - 3 / 6 Apply a thick layer of conservation wax „Waxoyl 120-4“ to cover ball joints, hinges, blank parts and exposed piston rods. (Do not protect ball bearings with Waxoyl!) Place a dehumidification capsule into the central electric box. Protect all door and container locks with „Ballistol Spray“. Set the battery master switch (if present) to position „0“ and then remove the batteries. Check the battery acid level and add distilled water, if necessary. Always store the batteries in a cool and dry area. Check the load current regularly every 6 weeks and recharge, if necessary. Close the exhaust outlet with an air and watertight cover. Pay attention to any additional guidelines for special components or special local conditions. 3.2 Shut down for up to 12 months Carry out all measures according to paragraph 3.1. In addition, the following is required: Clean the Diesel engine externally. Drain water from the fuel tank or condensation of the Diesel engine prefilter (see Operating instructions). Add commercially available Diesel fuel to the fuel tank until it is completely full. If the shut down is during the cold time of the year, fill the fuel dank with winter Diesel fuel (Winter Diesel fuel is suitable up to a temperature of -22°C / -7.6°F). Then start the Diesel engine and let it run for some time to bring the winter fuel into the fuel circuit. Then add enough fuel to the fuel tank until it is full. Check the coolant to ensure it has sufficient corrosion and antifreeze protection - at least 50% corrosion inhibitor antifreeze fluid (for guidelines refer to the Operating instructions). Seal the entire machine (Diesel engine, hydraulic aggregates, main frame, tank, travel gear / axles, equalizer bar, working attachments, etc.) with preservation wax „Waxoyl 120-4“. (Amount of preservative agent: An area of approx. 5m² can be treated with one liter Waxoyl) Note! The following points must be observed when applying the corrosion inhibitor wax: Observe a drying time of 3 hours. Ambient temperature at least +15°C / 59°F. Use protective equipment (breathing protection, safety glasses, respirator, etc.). The solvents of the anti corrosion wax are flammable! (Do not smoke and avoid open flames!) Cold resistant to a temperature of -40°C / -40°F. Release the chain tension by relieving the tension cylinder (see Operating instructions). Check the machine monthly and reapply conservation protective measures if necessary. copyright by
  22. 22. General Service Manual Conservation guidelines TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 1.4.000 - 4 / 6 Mjfcifss! TL 442-13 F/N xxx-6000 3.3 Shut down for longer than 12 months Carry out all measures according to paragraph 3.1 and 3.2. In addition, the following is required: Note! If a shut down for longer than 12 months is scheduled, then contact the Service Dept. of the Diesel engine manufacturer. Close off all openings, such as air filter, exhaust pipe, vent openings on components, etc. airtight. The vent for the fuel tank (if present) must remain open for safety reasons! Rub the rubber seal of the cab and containers with talcum powder, close the doors. If the cab is not installed, cover the operator’s platform properly. If necessary, remove the operator’s seat. Cover the instrument panel and protect it. 4 Return to operation 4.1 After a shut down of 2 months Remove the dehumidification capsule from the electronic box. Check the fill levels and lubricate the machine according to the Operating instructions. Install the batteries and clean / grease the battery terminals. Open the exhaust outlet. Drain water from the fuel tank or drain any condensation of the Diesel engine prefilter (see Operating instructions). Clean anti corrosion wax from ball joints, hinges, blank parts and exposed piston rods. Put the machine back into service as outlined in the Operating instructions. Before working with the machine, check all functions of the machine and remedy and defects immediately. Carry out a thorough visual inspection on the machine. Actuate all functions of the travel, working hydraulic as well as functions of additionally installed hydraulic components and alternately operate them over a period of approx. 20 minutes. The hydraulic cylinders must be extended and retracted over their full stroke length. Observe any additional guidelines for special components or special local conditions. 4.2 After a shut down of 12 months Carry out the items according to paragraph 4.1. Take an oil sample of the hydraulic oil and send it in for analysis. Carry out the scheduled maintenance and inspection work on the machine before putting it back into service. On the Diesel engine, mechanically actuate the AGR flap (exhaust return) and the engine brake flap and check for easy movement. Grease the V-belts! Use a high pressure cleaner with steam (at least 120°C) as well as 5% additive of solvent (such as petroleum) to clean the anti corrosion wax from the machine and aggregates. (Caution when walking on surfaces, there is a danger of slipping due to the wax residue.) Check the V-belt of the Diesel engine and replace it if necessary. Carry out a Diesel engine test run: Increase the Diesel engine rpm only slowly to ¾ of the high idle rpm until the operating temperature is reached. Check the oil pressure display immediately after starting the Diesel engine. Check the vacuum display of the air filter. Adjust the chain tension to suit the application (see Operating instructions). copyright by
  23. 23. Service Manual General Conservation guidelines TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 1.4.000 - 5 / 6 4.3 After shut down of longer than 12 months Complete all items outlined in paragraph 4.2 and 4.1. Note! After a scheduled shut down of longer than 12 months contact the Service Dept. of the Diesel engine manufacturer. Remove all covers and closures, which were installed for conservation measures. Turn the Diesel engine manually a few turns (use the turning device - flywheel – see Special tools). Start the machine and bring it to operating temperature. After the machine was brought to operating temperature, change all lube and service fluids as well as filters according to the Operating instructions Check the entire machine for function and for leaks. If necessary, carry out any time limited maintenance work at this time. copyright by
  24. 24. Service Manual General Material weights TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 1.5.000 - 1 / 2 1.5.000 Material weights Material spec. weight 1) kg/m3 fest Loosening in % Loosening factor spec. weight kg/m3 loose Anthracite coal - raw 1600 35 0,74 1190 - washed - 35 0,74 1100 Ash bituminous coal 590 - 890 8 0,93 550 - 830 Basalt 2970 52 0,66 1960 Bauxite, Kaolin 1900 33 0,75 1420 Bituminous coal - raw 1280 35 0,74 950 - washed - 35 0,74 830 Carnotite, Uranium ore 2200 35 0,74 1630 Soil - dry hardened 1900 26 0,79 1510 - wet loosened 2020 26 0,79 1600 - clay 1540 23 0,81 1250 Gypsum - broken 3170 75 0,57 1810 - ground 2790 75 0,57 1660 Granite - broken 2730 64 0,61 1660 Hematite, iron ore 2130 - 2900 18 0,85 1810 - 2450 Limestone - broken 2610 69 0,59 1540 - ground - - - 1540 Gravel - damp 2170 12 0,89 1930 - dry 1690 12 0,89 1510 - dry 6-50mm 1900 12 0,89 1690 - wet 6-50mm 2260 12 0,89 2020 Coke 860 54 0,65 1560 Loam, clay - seasoned 2020 22 0,82 1660 - dry 1840 24 0,80 1480 - wet 2080 24 0,80 1660 Clay with gravel - dry 1660 17 0,86 1420 - wet 1840 19 0,84 2540 Magnetite, iron ore 3260 17 0,86 2790 Topsoil 1370 44 0,69 950 Natural stone - ground 2670 67 0,60 1600 Pyrite, iron ore 3030 18 0,85 2580 Sand - dry, lose 1600 12 0,89 1420 - damp 1900 12 0,89 1690 - wet 2080 13 0,88 1840 Sand with clay - lose 2020 26 0,79 1600 - compressed - - - 2400 Sand with gravel - dry 1930 12 0,89 1720 - wet 2230 10 0,91 2020 Sandstone 2520 67 0,60 1510 Slate 1660 33 0,75 1250 Slag - broken 2940 68 0,59 1750 Snow - dry - - - 130 Sand with clay - lose - - - 520 Trapp rock - broken 2610 49 0,67 1750 Weathered rock 75% rock, 25% soil 2790 42 0,70 1960 Weathered rock 50% rock, 50% Soil 2280 33 0,75 1720 Weathered rock 25% rock, 75% Soil 1960 24 0,80 1570 1) The actual values depend on the moisture content, the grain size and the compression. Testing is required to determine more exact values. copyright by
  25. 25. Service Manual Tools and work instructions Sub group index – Tools and work instructions TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 2.0.000 - 1 / 2 2 Tools and work instructions 2.0.000 Sub group index – Tools and work instructions Special tools .................................................................................................. 2.1 Repair welding............................................................................................... 2.2 Assembly instructions.................................................................................. 2.3 copyright by
  26. 26. Service Manual Tools and work instructions Special tools TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 2.1.000 - 1 / 14 2.1.000 Special tools General The following section is divided into three sections: 1 Special tools - Maintenance 2 Special tools - Repairs 3 Special tools for in-house manufacture Special tools for maintenance are a must-have to carry out the maintenance and inspection schedule. In addition, some tools are necessary aids for troubleshooting. Special tools for repairs are only required in case of a repair of the affected components. Special tools for in-house manufacture can be made in-house as necessary. The drawings to make them are made available by the manufacturer. 1 Special tools Maintenance 1.1 Diesel engine Description Id. No. Remarks Illustration Turning device for flywheel JDE83 7090362 To adjust the valve clearance, install on the flywheel housing Adjustment pin JDG1571 7090360 Is required together with JDE 83 to adjust the valve clearance. To hold the flywheel TDC to adjust the injection pump. Digital rpm gauge „Shimpo“ 7364 284 Reflective tape 6140 632 01 To measure the rpm with reflective tape Test range: 6-8300 rpm Accuracy: 1 rpm Use with „Shimpo“ rpm gauge Optical charge tester 7408922 To check the battery charge condition and the antifreeze in the coolant V-belt test unit „Krikit2“ 8042829 To check the V-belt tension copyright by
  27. 27. Tools and work instructions Service Manual Special tools TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 2.1.000 - 2 / 14 Mjfcifss! TL 442-13 F/N xxx-6000 1.2 Hydraulic system Description Id. No. Remarks Illustration Vacuum pump 12V cpl. with accessories Consisting of: Vacuum pump with electrical cable, PVC hose inside diameter 5mm, Fitting 10355585 For faster bleeding of hydraulic system, by enclosing the PVC hose, a slight excess pressure can be produced. Temperature gauge 10024185 Accuracy: 2%/2° Test range: -18°C - +260°C Difference pressure test set 230V Consisting of: Test unit Multi-Handy 2045 2 pressure sensors 0-600 bar 2 Mini test connections 2 test cables 12m long KFZ connector cable Data cable Power unit 7025 376 To measure pressure, pressure peaks and pressure difference and suitable for data transfer to PC Scale pressure gauge 0-10 5002 865 0-25 7361 289 0-40 7361 288 0-60 5002 867 0-100 5602 903 0-160 7361 286 0-250 7361 285 0-400 7500 002 0-600 7361 294 0-1000 4601 115 Accuracy: 1% of the scale end value All pressure gauges are „glycerin filled“ copyright by
  28. 28. Service Manual Tools and work instructions Special tools TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 2.1.000 - 3 / 14 Description Id. No. Remarks Illustration Pressure gauge connection R ½ 7002 436 To seal at pressure tests, a square seal ring, Id.No. 7409 794 must be used. Test fitting, cpl. R 6 L 7409 916 R 10 L 7406 864 R 12 L 7409 918 Union nut and compression ring are affixed on the test fitting. Screw coupling M 8x1 7615 321 M 10x1 5608 462 M 12x1.5 7407 071 M 14x1.5 7406 865 R ¼ 7409 720 To connect to additional test points in the machines Screw coupling M 16x2 7407 070 To connect shorter test lines or for connection between test connection and pressure sensor Test hose NW 2 1000 mm 7002437 1500 mm 7002475 4000 mm 7009134 5000 mm 7363732 To keep loss of pressure during tests to a minimum, shorter test hoses are preferable Hook wrench 45 – 50 mm 7403366 58 – 62 mm 7900282 To loosen / counter when adjusting the pump regulating range Use with socket wrench HPV copyright by
  29. 29. Tools and work instructions Service Manual Special tools TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 2.1.000 - 4 / 14 Mjfcifss! TL 442-13 F/N xxx-6000 Description Id. No. Remarks Illustration Socket wrench for grooved nut HPV 9792711 To loosen / counter when adjusting the pump end stop Use with hook wrench Groove – ø 45.5 +0.5mm Socket wrench for 0- position grooved nut HPV 9749025 To loosen / counter when adjusting the hydraulic zero position Groove – ø 32 +0.5 mm Angle screwdriver Size 22 8000989 For cap – hydraulic tank Test plates For SAE flange 1/2 10355369 A 90mm B 32mm C, r 5mm For SAE flange 3/4 7370092 A 90mm B 40mm C,r 5mm For SAE flange 1 7370093 A 90mm B 44mm C,r 5mm Or to be made in-house To close off high pressure connections Material: Ground spring steel Round off end of the plate (simplifies installation, avoids damage to the seal ring) copyright by
  30. 30. Service Manual Tools and work instructions Special tools TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 2.1.000 - 5 / 14 1.3 Electrical system Description Id. No. Remarks Illustration LinDiag Diagnostics Consisting of: Data carrier with latest software version 10467309 Dongle for LinDiag 7 9124.01.750 10297212 Adapter cable for LH-ECU-UP/CR 10035410 To adjust the travel hydraulic, read out the Service Codes and for troubleshooting on machines in exhaust stage Tier2 and Tier3 USB - Adapter 693190714 Intermediate adapter from serial to USB Is only required for notebooks without serial connection Bodem Software with copy protection plug for USB connection 10285174 To adjust the working hydraulic, read out the Service Codes and for troubleshooting on machines Bodem Data cable 6905910 To adjust the working hydraulic Flash tool Working hydraulic controller (is not required for adjustments 10412388 To transfer updates to the working hydraulic control Digital multi meter cpl. with cable and bag 10018500 for Voltage (V)- Amperage (A)- Resistance ( )- and Frequency (Hz)- tests copyright by
  31. 31. Tools and work instructions Service Manual Special tools TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 2.1.000 - 6 / 14 Mjfcifss! TL 442-13 F/N xxx-6000 Description Id. No. Remarks Illustration Optical charge tester see Pt. 1.1 Diesel engine To check the battery condition and the antifreeze in the coolant LMB Magnet 10354217 For calibration mode of electronic load display Already included on tool box. 1.4 Mechanical component groups Description Id. No. Remarks Illustration Feeler gauge 8145535 To measure the wear on the brake disks (service brake)) 2 Special tools - Repair 2.1 Diesel engine Note! The special tools for Diesel engine repair are listed in the Diesel engine workshop manual. copyright by
  32. 32. Service Manual Tools and work instructions Special tools TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 2.1.000 - 7 / 14 2.2 Hydraulic system Description Id. No. Remarks Illustration Socket wrench Valve sleeve 10430260 For repair of variable motor HMV To remove and install the valve sleeve of the directional valve See section 10.2 Position 73 Mandrel thrust ring HPV 75 10472251 HMV 210 10472261 For repair of var. pump HPV or var. motor HMV For the installation of the hot thrust ring on the drive shaft. See chapter 10.1 or 8.2. Position 11 Mandrel [1] and protective sleeve [2] for shaft seal ring HPV 75 1 10472271 HPV 75 2 10472273 HMV 210 1 10472317 HMV 210 2 10410295 For repair of var. pump HPV or var. motor HMV For pressing in the radial shaft seal ring to push over the drive shaft (in connection with the corresponding protective sleeve) See section 10.1 or 10.2 Position 12 copyright by
  33. 33. Tools and work instructions Service Manual Special tools TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 2.1.000 - 8 / 14 Mjfcifss! TL 442-13 F/N xxx-6000 Description Id. No. Remarks Illustration Installation aid for seal ring on oil guide pipes Pos.1 HMV 210 10472322 Pos.2 HPV 75 10472321 For repair of var. pump HPV or var. motor HMV The tool is used to install the O-rings on the oil guide pipes See Section 10.1 Position 46 or section 10.2. Position 45 Spindle device for swash plate mount 10324938 For repair of var. pump HPV or var. motor HMV With this device, the swash plate mount can be lowered targeted onto the pump housing at installation. Centering pins for swash plate mount M12 HPV 75 10324939 M14 HMV 210 10472320 For repair of var. pump HPV or var. motor HMV The guide pins are used to guide the swash plate mount at assembly with the pump housing. minimum 2 each maximum 4 each required copyright by
  34. 34. Service Manual Tools and work instructions Special tools TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 2.1.000 - 9 / 14 Description Id. No. Remarks Illustration Centering device for swash plate mount 10324937 For repair of var. pump HPV or var. motor HMV Device to affix the oil guide pipes at installation of swash plate mount 2 each required Note! The special tools for cylinder repair are listed in the spare parts list. 2.3 Electrical system Description Id. No. Remarks Illustration Crimper for MATE-N-LOK Crimp contacts For 1,5 mm² 7367025 For 2,5 mm² 7366314 To make proper crimp connection on MATE-N-LOK plug connections Removal tool AMP for MATE-N-LOK Crimp contacts 7366655 Spare insert 7015180 To remove crimp contacts from plug connector Installation tool AMP for MATE-N-LOK Crimp contacts 8145432 To insert the pin and bushing contacts in MATE-N-LOK plug connectors Hand Crimper for „Deutsch“ plug connector 8503647 To make proper crimp connections copyright by
  35. 35. Tools and work instructions Service Manual Special tools TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 2.1.000 - 10 / 14 Mjfcifss! TL 442-13 F/N xxx-6000 Description Id. No. Remarks Illustration Removal tool Cannon for „Deutsch“ crimp contacts AWG 4 8503633 AWG 8 8503632 AWG 12 10114733 AWG 16 885563714 AWG 20 10114732 To remove pin and bushing contacts in „Deutsch“ plug connectors Removal tool Cannon for „Deutsch“ crimp contacts (alternate) AWG 12 8145674 AWG 16 8145673 AWG 20 8503630 To remove pin and bushing contacts in „Deutsch“ plug connectors (alternate) Crimper AMP AMP Certi-Lock 7415333 To crimp the „JUNIOR POWER TIMER“ contacts Removal tool AMP AMP 726 503-1 7026266 To remove contacts from the „JUNIOR POWER TIMER“ housing Crimper ESA 0760 7409781 CRB 0560 7409782 To crimp insulated 0.5 -6.0 mm² cable shoes, for example cable connectors CRB 0560 also windshield wiper motor Insulating pliers, cpl. Type 5011-26 7409777 Spare cutter: 1.5-6.00 qmm 7409788 0.15-2.5 qmm 7409789 To insulate the 0.75 mm² electric cable copyright by
  36. 36. Service Manual Tools and work instructions Special tools TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 2.1.000 - 11 / 14 Description Id. No. Remarks Illustration Removal tool METRI-PACK wide 7091022 narrow 7091023 To remove connector clamps on central plug of engine electronic ECU 2.4 Mechanical component group Description Id. No. Remarks Illustration Eyebolt 4000785 To install and remove the operator’s cab to gain access to the hydraulic tank Screw swirl 10490498 To install and remove the 1350kg ballast weight. 2 each required See section 2.3 Installation instructions. Installation aid Ballast weight see Pt. 3 Tools for in-house manufacture To remove and install the 625kg ballast weight to equalize the center of gravity 2 each required See section 2.3 Installation instructions. This tool can also be used as an alternate for the screw swirl 10490498. copyright by
  37. 37. Tools and work instructions Service Manual Special tools TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 2.1.000 - 12 / 14 Mjfcifss! TL 442-13 F/N xxx-6000 2.5 Telescopic boom Description Id. No. Remarks Illustration Spacer for the telescopic cylinder (13m) 9410926 Device to keep two cylinders of the 13m telescope apart for repair Eyebolt 9417658 To install and remove tilt cylinder Open ended box wrench 8122204 The wrench is ground at the opening to be able to install hoses on the solenoid valves 10306272Pin puller Or to be made in-house To pull the two pins from the cylinder bearing – telescopic cylinder 1 of 13 m telescope External bleeding of telescopic cylinder Hydraulic hose 9412239 (TL 4xx-13 F/N xxx- 6000 9500) Flange half SAE 3/4“ 10286359 2 each required Hex head screw M10x35 10.9 4001246 4 each required Hose fitting 10815208 (TL 4xx-13 F/N xxx-9501 ) can also be carried out with the aid of the already installed hose by using the fitting Pulling device 10306606 To replace the hose on the 13m telescopes from TL 4xx-13 F/N xxx- 9501 copyright by
  38. 38. Service Manual Tools and work instructions Special tools TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 2.1.000 - 13 / 14 3 Special tools for in-house manufacture Note! The following dimensions are given in millimeters [mm]. 3.1 Pin puller To pull the two pins from the cylinder bearing – telescopic cylinder 1 of the 13 m telescope. See also section 17.2 Repair instructions. Fig. 1 Pin puller Note! Affix the hex nut Pos.5 with three weld points. 1 Guide rod 5 Hex nut M20 2 Hex fitting 6 Washer ISO 8738 20 3 Impact sleeve 7 2x Washer DIN 433 8,4 4 Allen screw M8x30 8.8 copyright by
  39. 39. Tools and work instructions Service Manual Special tools TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 2.1.000 - 14 / 14 Mjfcifss! TL 442-13 F/N xxx-6000 3.2 Installation aid for ballast weight To remove and install the 625kg ballast weight. Is used to equalize the center of gravity, since it is not located in the center. The angle equalized the distance, so that the ballast weight can be installed / remove without jamming. Fig. 2 Installation aid for ballast weight copyright by
  40. 40. Service Manual Tools and work instructions Repair welding TL 435-10 F/N xxx-6600 TL 445-10 F/N xxx-6600 TL 435-13 F/N xxx-6600 TL 442-13 F/N xxx-6600 MJFCIFSS! 2.2.000 - 1 / 6 2.2.000 Repair welding Caution! In principle, prior to beginning any welding work on the telescopic handler, disconnect the electronic boxes and various electronic components (see Operating instructions). In addition, the ground terminal of the welding unit must be connected directly to the blank work piece, which is to be welded. 1 Preparation of cracked part Clean the cracked area to remove paint, grease and any dirt. To prevent the crack from extending during the preparation and welding process, the end of the cracks should be drilled out with a drill (at least 8 mm Ø). Then the crack should be ground, chiseled, or arched out to an angle of approx. 60° . Be certain that the edges are clean and extend through the full cross section of the material, without exceeding the space of 1 mm in the lower part. On larger grooves, a welding safety should be installed. Fig. 1-1 Ground out / drilled out crack Certain materials must be preheated to approx. 150°C Special preparations are necessary when preparing a crack in manganese steel. This material cannot be prepared with a chisel or planing machine, due to its hardness and peen hardening. We suggest that the crack is prepared with a slow running and water-cooled grinding wheel to prevent overheating. Note! Another possibility to prepare cracks and remove high alloy welding seams is the use of cutting electrodes of the type UTP 82 AS. 2 Preparation of a weld The area to be welded must be fee of grease, paint, oil, moisture and dirt. During rain, the area to be welded must be covered sufficiently. Materials with a thickness above 15 mm and high carbon steel (carbon content more than 0.22 %) and difficult to weld steel, the material must be preheated to approx. 80°- 200°C. Preheating is also necessary when the component temperature at the start of the welding work is below +5°C and when the construction of the repair part prevents the welding stress to be released. copyright by
  41. 41. Tools and work instructions Service Manual Repair welding TL 435-10 F/N xxx-6600 TL 445-10 F/N xxx-6600 TL 435-13 F/N xxx-6600 2.2.000 - 2 / 6 Mjfcifss! TL 442-13 F/N xxx-6600 3 Treatment of electrodes Use only dry electrodes for welding. Electrodes with damaged coating and rusted electrodes may not be used any longer. Electrodes must be stored in a dry room with a minimum temperature of 15°C. Open electrode packages must be carefully closed and stored after the welding work is complete. 4 Welding technique The welding of material with the required electrodes (see chart under paragraph 7) is carried out according to DIN 1912. The adjustment of the welding current – dictated by the different thicknesses of the electrodes – can be taken from the chart of the electrode package. Beginning with material thickness of 8 mm, butt welds must be made in several layers. The weld is applied in several beads. Wide butt welds are filled with several side by side beads, with the last layer covering the center. The electrode should meld evenly without creating burrs and peaks. The valley or crater, which is created when changing electrodes must be filled in and overlapped with the next electrode. To prevent cracks in those craters, care must be taken that they are properly filled in. If the crack extends towards the outer edge of the material, slap may be trapped or burn holes may be created. To prevent this, the following aid may be used: tack apiece of sheet metal to the outer edge of the material. The welding seam begins now at the sheet metal in the direction of the arrow. After the welding is completed, the sheet metal is removed and the edge of the material is ground smooth. The welding seam must be cooled off slowly and should therefore be protected from rain and wind. Fig. 4-1 Crack running to the outer edge of the material / Prepared crack copyright by
  42. 42. Service Manual Tools and work instructions Repair welding TL 435-10 F/N xxx-6600 TL 445-10 F/N xxx-6600 TL 435-13 F/N xxx-6600 TL 442-13 F/N xxx-6600 MJFCIFSS! 2.2.000 - 3 / 6 5 Reinforcement of welding seam If the crack of the material is due to on overload or abuse, a reinforcement plate should be welded over the crack. The selection of the correct reinforcement plate is based on the construction and load factors of the component to be repaired. For that reason, only general recommendations can be made as to the size and shape of the reinforcement plates. 5.1 Shape of plate The crossover or connection between the reinforced and not reinforced part should be as gradual as possible, this means that the size of the plate should be selected in such a way that new or unacceptable high stress in the repaired part is avoided. Plates with sharp corners (such as a rectangular plate) may not be used. Fig. 5-1 Reinforcement plate against clean pulling / bending and alternating loads 5.2 Plate thickness The thickness of the reinforcement plate should be up to 2/3 of the thickness of the material to be reinforced. 5.3 Material quality of the plate The material properties (yield and tensile strength, etc.) of the reinforcement plate should be equal to the material to be reinforced. 5.4 Installation of the reinforcement plate The welded area of the crack should be ground so it is smooth and level. The size of the plate must be selected in such a way that the longer sides of the plate extend into the connecting construction of the material to be reinforced. The plate should also overlap the crack on each side by at least 20 mm. The correct position and fit of the reinforcement plate is achieved by clamping and spot welding. 5.5 Welding the reinforcement plate The reinforcement plate should be welded on by running a welding bead alternately on both sides. The welding should always start in the middle of the plate and run towards the outside. Be certain to observe that each welding seam has proper run out. copyright by
  43. 43. Tools and work instructions Service Manual Repair welding TL 435-10 F/N xxx-6600 TL 445-10 F/N xxx-6600 TL 435-13 F/N xxx-6600 2.2.000 - 4 / 6 Mjfcifss! TL 442-13 F/N xxx-6600 Welding direction Fig. 5-2 Welding directions The size of the welding run "a" is figured out in reference to the thickness "k" of the repair plate. Use formula: a=0.5 k Up to a welding run "a" of approx. 3 mm, a single run can be made, however, as a general rule, a double run should be preferred. Above a welding run "a" = 3 mm, the first run provides excellent penetration between the reinforcement plate and the basic material. Subsequent runs are added on top of the first run. Fig. 5-3 3- or 1- layer welding seam After the welding is completed, clean the welding seam as necessary and grind out the run between the reinforcement plate and the basic material. 6 Selection of correct welding electrodes For repair welding, only lime based (Kb) electrodes should be used, and as a rule, the electrodes (additional material) should be "softer" than the basic material. Exceptions to this ruse should be observed. Note! To reach the theoretical welding quality, the work must not only be performed in a professional manner, the electrode manufacturer’s guidelines must be strictly observed as well. Caution! Welding of vertical-down welds is not permitted for steel components! copyright by
  44. 44. Service Manual Tools and work instructions Repair welding TL 435-10 F/N xxx-6600 TL 445-10 F/N xxx-6600 TL 435-13 F/N xxx-6600 TL 442-13 F/N xxx-6600 MJFCIFSS! 2.2.000 - 5 / 6 6.1 Steel chart Item Description Analysis HARDOX 400 Weldable, low alloy special steel with high wear resistance, a tensile strength of 1250 N/mm² and a yield strength limit of 1000 N/mm² C 0,27% Si 0,7% Mn 1,6% Cr 1,4% Mo 0,6% Q St E 380 N Fine grain structural steel poured at special low turbulence with a guaranteed minimum tensile strength of 500 - 640 N/mm² and minimum yield strength limit of 380 N/mm² C 0,18% Si 0,5% Mn 1,6% Special steel Highly abrasion resistant steel with a tensile strength of 1720 N/mm²² C = 0,3% Mn = 0,7% Si = 0,5% Cu = 0,65% Mo = 0,3% V = 0,05% St 52 - 3 S355J2G3 Structural steel poured at low turbulence with a guaranteed minimum tensile strength of 510 N/mm² C 0,22% LH 690 Tempered fine grade structural steel with a tensile strength 770 - 940 N/mm² and a yield strength limit of 690 N/mm² C 0,18% Si 0,50% Mn 1,5% Mo 0,5 % Ni 1,5 % Lightly alloyed with V, AI and Cu 6.2 Welding chart for arc welding Item Description Analysis values in % / Application per EN 499: E42 5 B 4 2 H5 For example: Böhler FOX EV 50 E = Arc welding 42 = 500-640 N/mm² tensile strength 5 = Value for notch impact strength B = basic shielded 4 = Value for run out and type of current 2 = Value for welding positions H5 = maximum hydrogen content C = 0,07, Si = 0,5, Mn = 1,1 For connection and applied welds, especially for steels with low purity and higher carbon content. Weldable with DC current, Electrode on Plus terminal (+). No vertical seams. per EN 757: E 69 6 Mn2NiCrMo B 4 2 H5 for example: Böhler FOX EV 85 E = Arc welding 69 = 760-960 N/mm² tensile strength 6 = Value for notch impact strength Mn2NiCrMo = Chemical composition B = basic shielded 4 = Value for run out and type of current 2 = Value for welding positions H5 = maximum hydrogen content C = 0,05, Si = 0,4, Mn = 1,5, Cr = 0,4, Ni = 2,0, Mo = 0,5 For welds, which require high tenacity and crack resistance, use for highly alloyed fine grain steel. Very low hydrogen content in welding material. Weldable with DC current, Electrode on Plus terminal (+). No vertical seams. per EN 1600: E 18 8 Mn B 2 2 For example: Böhler FOX A 7 E = Arc welding 18 = 620-770 N/mm² tensile strength 8 = Value for notch impact strength Mn = Chemical composition B = basic shielded 2 = Value for run out and type of current 2 = Value for welding positions C = 0,1, Si = 0,7, Mn = 6,5, Cr = 18,8, Ni = 8,8 For connections between different alloyed and difficult to weld steel Weldable with DC current, Electrode on Plus terminal (+). No vertical seams copyright by
  45. 45. Tools and work instructions Service Manual Repair welding TL 435-10 F/N xxx-6600 TL 445-10 F/N xxx-6600 TL 435-13 F/N xxx-6600 2.2.000 - 6 / 6 Mjfcifss! TL 442-13 F/N xxx-6600 6.3 Welding chart for metal inert gas weld with solid wire electrodes Item Description Analysis values in % / Application per EN 440: G4Si1 For example: Böhler EMK 8 G = G = Metal inert gas weld with solid wire electrodes 4 = 500-640 N/mm² tensile strength Si = Chemical properties 1 = Value for run out and type of current C = 0,1, Si = 1,0, Mn = 1,7 For connection and applied welds, especially for steels with low purity and higher carbon content. Weldable with DC current, Electrode on Plus terminal (+). Shielding gas: Argon + 15-20% CO2 or 100% CO2 No vertical seams Per EN 12534: G3CrNi1Mo For example: Böhler X 70 - IG G = Metal inert gas weld with solid wire electrodes 3 = 900 N/mm² tensile strength CrNi1Mo = Chemical composition C = 0,1, Si = 0,6, Mn = 1,6, Cr = 0,25, Ni = 1,3, Mo = 0,25, V = 0,1 For welds, which require high tenacity and crack resistance, use for highly alloyed fine grain steel. Weldable with DC current, Electrode on Plus terminal (+). Shielding gas: Argon + 15-20% CO2 or 100% CO2 No vertical seams per EN 12072: G 18 8 Mn For example: Böhler A7 IG G = Metal inert gas weld with solid wire electrodes 18 = 580-730 N/mm² tensile strength 8 = Value for notch impact strength Mn = Chemical composition C = 0,08, Si = 0,9, Mn = 7,0, Cr = 19,2, Ni = 9,0 For connections between different alloyed and difficult to weld steel Weldable with DC current, Electrode on Plus terminal (+). Shielding gas: Argon + max. 2,5% CO2 copyright by
  46. 46. Service Manual Tools and work instructions Installation guidelines TL 435-10 F/N xxx-6600 TL 445-10 F/N xxx-6600 TL 435-13 F/N xxx-6600 TL 442-13 F/N xxx-6600 MJFCIFSS! 2.3.000 - 1 / 4 2.3.000 Installation guidelines 1 General Described in this section are installation notes for various components, which must be observed at reinstallation in case of a repair. 2 Installation notes 2.1 Equipment The threaded bores required to take on the 625 kg ballast weight are located outside the center of gravity of the weight. For that reason, the weight can get stuck at removal. To avoid this, the installation aids X (see section 2.1 Special tools) must be used. Because there is a risk of damage to the machine, the chains must be spread with the assistance of a suitable aid. Fig. 2-1 Removal – Ballast weight 625kg copyright by
  47. 47. Tools and work instructions Service Manual Installation guidelines TL 435-10 F/N xxx-6600 TL 445-10 F/N xxx-6600 TL 435-13 F/N xxx-6600 2.3.000 - 2 / 4 Mjfcifss! TL 442-13 F/N xxx-6600 2.2 Travel hydraulic 1.1.1 Variable displacement pump Since the installation notes refer to the positions in the sectional drawing, they are described in section 10.1 „Variable displacement pump – Travel hydraulic“. 1.1.2 Variable displacement motor Since the installation notes refer to the positions in the sectional drawing, they are described in section 10.2 „Variable displacement motor – Travel hydraulic“. 1.1.3 Gear pump The double gear pump is accessible via the cover on the inside of the main frame. Raise the telescope and secure it with the aid of the hoist support. Remove the cover plate At installation of the fixed displacement pump – double gear pump, the following must be observed: Clean and grease the sealing surfaces on motor and pump. Seal the sealing surfaces with liquid seal. Fig. 2-2 Double gear pump In addition, it must be observed that the distance between flange and gear is at least 0.5 mm. 2.2.1 Collector block When removing or replacing the pressure filter, pay attention to the flow direction (marked on the filters) at installation. When removing or replacing the check valve (cold start valve) 57, pay attention to the opening direction at installation. The correct flow direction is marked on the valve. copyright by
  48. 48. Service Manual Tools and work instructions Installation guidelines TL 435-10 F/N xxx-6600 TL 445-10 F/N xxx-6600 TL 435-13 F/N xxx-6600 TL 442-13 F/N xxx-6600 MJFCIFSS! 2.3.000 - 3 / 4 Fig. 2-3 Installation of the pressure filter on the collector block 2.3 Working hydraulic 2.3.1 Telescope Since the installation notes refer to the positions in the sectional drawing, they are described in section 17.1 „Design and function“ or 17.2 „Repair instructions“. 2.3.2 Industrial control - Boom suspension Warning! Before starting any maintenance and repair work on the stabilizing module of the emergency down screw 252 (covered by a plug) back it out by 2-3 turns to relieve the pretension of the pressure accumulator 256 to the tank (connection T). Before putting it back into service, adhere the screw with Loctite. Fig. 2-4 Pressure accumulator The pretension of the pressure accumulator is reestablished when the telescope is raised. 2.4 Electrical system 2.4.1 DMS Sensor – rear axle See section 11.8 „DMS Sensor installation“. copyright by
  49. 49. Tools and work instructions Service Manual Installation guidelines TL 435-10 F/N xxx-6600 TL 445-10 F/N xxx-6600 TL 435-13 F/N xxx-6600 2.3.000 - 4 / 4 Mjfcifss! TL 442-13 F/N xxx-6600 2.5 Main frame 2.5.1 Variable motor mount Observe the correct arrangement of the components at installation. Tighten the hex head screws 5 with a tightening torque of 350 Nm. Fig. 2-5 Variable motor mount and installation of RPM sensor B2 Installation of RPM sensor Tighten the impulse sensor with 30Nm. Secure the sensor with Loctite to prevent it from twisting. With the aid of shims, adjust the distance between the RPM sensor B2 and the perforated plate 10. 2.5.2 Cab mount See section 16.1 „Operator’s cab“. 2.5.3 Stabilizers Secure the screws 24 at installation with Loctite. Fig 2-6 Installation of stabilizers for 13m telescopic loader copyright by
  50. 50. Service Manual Technical data and Maintenance guidelines Sub group index – Technical data and Maintenance guidelines TL 435-10 F/N xxx-6000 TL 445-10 F/N xxx-6000 TL 435-13 F/N xxx-6000 TL 442-13 F/N xxx-6000 MJFCIFSS! 3.0.000 - 1 / 2 3 Technical data and Maintenance guidelines 3.0.000 Sub group index – Technical data and Maintenance guidelines Technical data................................................................................................ 3.1 Maintenance and inspection schedule........................................................ 3.2 Maintenance and inspection guidelines...................................................... 3.3 Adjustment check list ................................................................................... 3.4 Inspection and adjustment tasks................................................................. 3.5 copyright by
  51. 51. Service Manual Technical data and maintenance guidelines Technical data TL 435-10 F/N xxx-6000 9500 TL 445-10 F/N xxx-6000 9500 TL 435-13 F/N xxx-6000 9500 TL 442-13 F/N xxx-6000 9500 MJFCIFSS! 3.1.000 - 1 / 4 3.1.000 Technical data TL435- 10 TL445- 10 TL435- 13 TL442- 13 Diesel engine Type D504 T Version 4 cyl. In-line, water cooled, turbocharged Rating according to ISO 9249 kW 80 (109 PS) Nominal RPM RPM 2400 Low idle RPM RPM 1050 (with working hydraulic on) 850 (with working hydraulic off) High idle RPM RPM 2450 Displacement l 4.5 Oil quantity incl. filter l 12 Oil quality / viscosity See operating instructions Max. permissible machine incline – all directions 30° Firing order 1 – 3 – 4 – 2 Coolant / DCA 80 L See operating instructions Fuel tank capacity l 125 Fuel usage approx. l/h 5 - 15 Splitterbox Type 4519.02 Version Spur gear – 1-stage Ratio i 0,8974 Oil quantity l 1,7 Oil quality / viscosity See operating instructions Hydraulic system Variable pumps – Travel hydraulic Type HPV75 - 02 Max. flow - Qmax l/min 203 Operating pressure (M1 / M2) pmax bar 420 Tandem gear pumps – replenishing - Cooling circuit / fan drive Size 28/ 11 Max. flow replenishing - Qmax l/min 65 Operating pressure (SP) pmax bar 20 Max. flow - fan drive - Qmax l/min 26 Operating pressure (electronically regulated) - pmax bar 180 Gear motor – fan drive Size 8 Operating RPM RPM presently 2000 / 2600 Variable motor – Travel hydraulic Type HMV 210 (25 km/h) Regulating pump – Working hydraulic Type A10V 045 Max. flow - Qmax l/min 120 Stand-by pressure (HD) bar 35 Operating pressure (HD) pmax bar 300 Hydraulic tank capacity l 95 Circuit, additionally l 95 Oil quality / viscosity See operating instructions copyright by
  52. 52. Technical data and maintenance guidelines Service Manual Technical data TL 435-10 F/N xxx-6000 9500 TL 445-10 F/N xxx-6000 9500 TL 435-13 F/N xxx-6000 9500 3.1.000 - 2 / 4 Mjfcifss! TL 442-13 F/N xxx-6000 9500 TL435- 10 TL445- 10 TL435- 13 TL442- 13 Electrical system Operating voltage V 12 Batteries Ah 170 Alternator 12 V,65 A Starter kW 4,2 Central fuse A 125 Individual fuses See operating instructions Front axle (45% Self locking differential) Front axle Type 212 / 415 …/ 709 Planetary gear (axles) i 1:6 Axle ratio, total 1:26.25 Oil quantity in axle casing - front axle See Operating instructions Oil quantity in wheel head – front axle See Operating instructions Oil quality / viscosity and oil change intervals See Operating instructions Service brake / parking brake – front axle Type Disk brake Tires See section 3.4 Rear axle (0% Self locking differential) Rear axle Type 212 / 416 …/ 710 Planetary gear (axles) i 1:6 Axle ratio, total 1:26.25 Oil quantity in axle casing – rear axle See Operating instructions Oil quantity in wheel head – rear axle See Operating instructions Oil quality / viscosity and oil change intervals See Operating instructions Rear axle No brake Tires See section 3.4 Steering Regulating pump Type A10V 045 Max. flow l/min 120 Steering / Servostat Type LAGU 250/ 125 Steering cylinder Type Synchronous cylinder Priority valve LPS 160 Brake system Supply via regulating pump – working pump copyright by
  53. 53. Service Manual Technical data and maintenance guidelines Technical data TL 435-10 F/N xxx-6000 9500 TL 445-10 F/N xxx-6000 9500 TL 435-13 F/N xxx-6000 9500 TL 442-13 F/N xxx-6000 9500 MJFCIFSS! 3.1.000 - 3 / 4 TL435- 10 TL445- 10 TL435- 13 TL442- 13 General Travel speed Normal range – III km/h 0 25 Reduced range – II km/h 0 16 Reduced range – I km/h 0 8 Max. traction Depending on ground conditions kN 56 Basic machine Overall height (without beacon) mm 2500 Overall length to front carrier mm 5810 Overall width via standard tires mm 2364 Height over rear mm 1710 Wheel base mm 2950 Rear overhang mm 1130 Track width mm 1970 Ground clearance (center of vehicle) mm 440 Width over supported stabilizers mm 3150 Turning radius via tips of forklift prongs mm 5150 Turning radius via tires mm 3850 Operating weight Basic machine kg 8593 9129 9559 10565 Basic machine with standard forklift kg 8857 9424 9839 10866 Basic machine with standard bucket kg 8941 9477 9929 10913 Standard forklift „LH“ (various fork prongs) Fork prongs dimensions mm 100x50 x1100 125x50 x1100 100x50 x1100 100x50 x1100 Max. prong distance mm 955 955 955 955 Operating weight kg 266 295 266 301 Load carrying capacity (depends on prongs) kg 3500 4500 3500 4200 Standard bucket „LH“ Bucket width mm 2450 2450 2450 2450 Bucket capacity m³ 1 1 1 1 Operating weight kg 347 347 347 347 Load capacity kg 1800 1800 1800 1800 copyright by
  54. 54. Service Manual Technical data and Maintenance guidelines Technical data TL 435-10 F/N xxx-9501 TL 445-10 F/N xxx-9501 TL 435-13 F/N xxx-9501 TL 442-13 F/N xxx-9501 MJFCIFSS! 3.1.001 - 1 / 4 3.1.001 Technical data TL435- 10 TL445- 10 TL435- 13 TL442- 13 Diesel engine Type TL 4xx-xx F/N xxx-9501 10999 D 504 TI TL 4xx-xx F/N xxx-11000 CD 4045 HF 287 Version 4 cyl. In-line, water cooled, turbocharged Rating according to ISO 9249 kW 84 (114 PS) Nominal RPM RPM 2400 Low idle RPM RPM 1050 High idle RPM RPM 2430 Displacement l 4,5 Oil quantity incl. filter See operating instructions Oil quality / viscosity See operating instructions Max. permissible machine incline – all directions 30° Firing order 1 – 3 – 4 – 2 Coolant / DCA 80 L See operating instructions Fuel tank capacity l 125 Fuel usage approx. l/h 5 - 15 Splitterbox Type 4519.02 Version Spur gear – 1-stage Ratio i 0,8974 Oil quantity See operating instructions Oil quality / viscosity See operating instructions Hydraulic system Variable pumps – Travel hydraulic Type HPV75 - 02 Max. flow - Qmax l/min 203 Operating pressure (M1 / M2) pmax bar 420 Tandem gear pumps – replenishing - Cooling circuit / fan drive Size 28/ 11 Max. flow replenishing - Qmax l/min 65 Operating pressure (SP) pmax bar 20 Max. flow - fan drive - Qmax l/min 26 Operating pressure (electronically regulated) - pmax bar 180 Gear motor – fan drive Size 8 Operating RPM RPM 2000 Variable motor – Travel hydraulic TL 20-25 km/h Type HMV 210 TL 40 km/h Type ICVD GT-S1N-233V-094 Regulating pump – Working hydraulic Type A10V 045 Max. flow - Qmax l/min 120 Stand-by pressure (HD) bar 35 Operating pressure (HD) pmax bar 300 Hydraulic tank capacity l 95 Circuit, additionally l 95 Oil quality / viscosity See operating instructions copyright by
  55. 55. Technical data and Maintenance guidelines Service Manual Technical data TL 435-10 F/N xxx-9501 TL 445-10 F/N xxx-9501 TL 435-13 F/N xxx-9501 3.1.001 - 2 / 4 Mjfcifss! TL 442-13 F/N xxx-9501 TL435- 10 TL445- 10 TL435- 13 TL442- 13 Electrical system Operating voltage V 12 Batteries Ah 170 Alternator 12 V,75 A Starter kW 4,2 Central fuse A 125 Individual fuses A See operating instructions Front axle (45% Self locking differential) Front axle (20-25 km/h) Type 212 / 415 …/ 709 Front axle (40 km/h) Type 212 / 797 Planetary gear (axles) i 1:6 Axle ratio, total (20-25 km/h) i 1:26,25 Axle ratio, total (40 km/h) i 1:17,50 Oil quantity in axle casing - front axle See Operating instructions Oil quantity in wheel head – front axle See Operating instructions Oil quality / viscosity and oil change intervals See Operating instructions Service brake / parking brake – front axle Type Disk brake Tires See section 3.4 Rear axle (0% Self locking differential) Rear axle (20-25 km/h) Type 212 / 416 …/ 710 Rear axle (40 km/h) Type 212 / 798 Planetary gear (axles) i 1:6 Axle ratio, total (20-25 km/h) i 1:26,25 Axle ratio, total (40 km/h) i 1:17,50 Oil quantity in axle casing - rear axle See Operating instructions Oil quantity in wheel head – rear axle See Operating instructions Oil quality / viscosity and oil change intervals See Operating instructions Service brake – rear axle (20-25 km/h) No brake Service brake – rear axle (40 km/h) Type Disk brake Tires See section 3.4 Steering Regulating pump Type A10V 045 Max. flow l/min 120 Steering / Servostat Type LAGU 250/ 125 Steering cylinder Type Synchronous cylinder Priority valve LPS 160 Brake system Supply via regulating pump – working hydraulic copyright by
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