Operating Instructions

Mobile Excavator
HML 42

AUSGABE • EDITION

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

004200/0099 > 0218

SCHAEFF-TEREX GmbH & CO. KG • D-74595 LANGENBURG
Hauptverwaltung/Verkauf Kundendienst Ersatzteile
Direction générale/Vente Service après-vente Pièces de rechange
Headquarters / Sales Service department Spare parts
Schaeff-Terex GmbH & Co KG Schaeff-Terex GmbH & Co KG Schaeff-Terex Ersatzteile-Service
GmbH & Co KG
Postfach 61 • D-74595 Langenburg Postfach 12 64 • D-91534 Rothenburg Postfach 12 64 • D-91534 Rothenburg
Schaeffstr. 8 • D-74595 Langenburg Erlbacher Str. 115 • D-91541 Rothenburg Erlbacher Str. 115 • D-91541 Rothenburg
Phone +49 (0) 7905/58-0 Phone +49 (0) 9861/972-451 Phone +49 (0) 9861/972-0
Fax +49 (0) 7905/58-114 Fax +49 (0) 9861/972-460 Fax + 49 (0) 9861/972-410

Order no.: 5 780 140 012

 Table of Contents

1 Introduction.....................................................................................................................1
1.1 General.................................................................................................................................. 1
1.2 Warranty and Maintenance .................................................................................................... 2
1.3 Notes on using the instruction book ....................................................................................... 2
1.4 Environmental requirements .................................................................................................. 3
1.5 Pictograms............................................................................................................................. 3
1.6 Copyright ............................................................................................................................... 5
2 Safety and Prevention of Accidents..............................................................................7
2.1 Introductory remarks .............................................................................................................. 7
2.2 Proper use ............................................................................................................................. 7
2.3 General safety notes.............................................................................................................. 8
2.4 Operation............................................................................................................................... 8
2.5 Danger zone .......................................................................................................................... 9
2.6 Transport of persons.............................................................................................................. 9
2.7 Stability .................................................................................................................................. 9
2.8 Travel operation................................................................................................................... 10
2.9 Operation............................................................................................................................. 10
2.10 Guides ............................................................................................................................... 11
2.11 Danger of falling objects..................................................................................................... 11
2.12 Working in the vicinity of underground power lines............................................................. 11
2.13 Working in the vicinity of overhead power lines.................................................................. 12
2.14 Operation in closed rooms ................................................................................................. 12
2.15 Work stoppages................................................................................................................. 12
2.16 Load hook applications ...................................................................................................... 13
2.17 Change of work attachments, maintenance, repair ............................................................ 13
2.18 Recovery, loading, transportation....................................................................................... 14
2.19 Monitoring and inspections ................................................................................................ 15
2.20 Fire protection.................................................................................................................... 15
2.21 Emergency exit .................................................................................................................. 15
2.22 Other dangers.................................................................................................................... 15
3 Technical Data ..............................................................................................................17
3.1 Views ................................................................................................................................... 17
3.2 Engine ................................................................................................................................. 20
3.3 Electrical system.................................................................................................................. 20
3.4 Travel drive .......................................................................................................................... 20
3.5 Brakes ................................................................................................................................. 21
3.6 Hydraulic system ................................................................................................................. 22
3.7 Axles.................................................................................................................................... 23
3.8 Tires .................................................................................................................................... 24
3.9 Lubricants ............................................................................................................................ 24
3.9.1 Filling quantities............................................................................................................. 24
3.9.2 Fuel, lubricant and coolant specifications....................................................................... 25
3.10 Permissible loads in accordance with local regulations ...................................................... 26
3.11 Sound level values, vibration ............................................................................................. 26
3.12 Dimensions and weights .................................................................................................... 26
3.13 Excavator installation ......................................................................................................... 27
3.14 Carrying capacity ............................................................................................................... 27
3.15 Work attachments .............................................................................................................. 28
3.16 Stabilizers / Support blade ................................................................................................. 29
3.17 Optional accessories.......................................................................................................... 29

HML 42
Table of Contents

4 Operation.......................................................................................................................30
4.1 Operator controls ................................................................................................................. 30
4.2 Engine ................................................................................................................................. 34
4.2.1 Starting the engine......................................................................................................... 34
4.2.2 Monitoring during operation ........................................................................................... 35
4.2.3 Switching off the engine................................................................................................. 36
4.3 Driver’s seat, height and tilt adjustment of steering wheel .................................................... 37
4.4 Heating / Ventilation / Air conditioning.................................................................................. 38
4.5 Light switch .......................................................................................................................... 39
4.6 Front window ....................................................................................................................... 39
4.7 Travel operation................................................................................................................... 40
4.7.1 Driving ........................................................................................................................... 40
4.7.2 Steering ......................................................................................................................... 42
4.7.3 Brakes ........................................................................................................................... 44
4.7.4 Driving on roads............................................................................................................. 44
4.8 Parking the machine ............................................................................................................ 46
5 Working Operation........................................................................................................47
5.1 General................................................................................................................................ 47
5.2 Moving the excavator at high engine speed ......................................................................... 48
5.3 Operation of work functions ................................................................................................. 49
5.3.1 Operation of work equipment ......................................................................................... 49
5.3.2 Operation — intermediate boom/ articulation ................................................................. 50
5.3.3 Operation — Stabilizers / Support blade ........................................................................ 50
5.3.4 Operation — Front dozer blade (option)......................................................................... 51
5.3.5 Operation — Additional control circuit ............................................................................ 52
5.3.6 Operation of oscillating axle lock.................................................................................... 52
5.4 Changing work attachments................................................................................................. 53
5.4.1 General.......................................................................................................................... 53
5.4.2 Assembly of work attachments ...................................................................................... 54
5.4.3 Clamshell grab............................................................................................................... 55
5.4.4 Hydraulic rock breaker ................................................................................................... 56
5.4.5 Using the machine for load hook applications ................................................................ 57
6 Towing and Transport of the Machine ........................................................................59
6.1 Towing the machine............................................................................................................. 59
6.2 Loading the machine using a crane ..................................................................................... 61
6.3 Transporting the machine .................................................................................................... 62
7 Maintenance and Service .............................................................................................63
7.1 General................................................................................................................................ 63
7.2 Intervals ............................................................................................................................... 63
7.3 Regular oil analyses............................................................................................................. 64
7.4 Warranty .............................................................................................................................. 64
7.5 Inspection parts and aids ..................................................................................................... 65
7.6 Care and cleaning................................................................................................................ 66
7.7 Notes for use in winter ......................................................................................................... 66
7.8 Checking, maintenance and inspection plans ...................................................................... 68
7.8.1 Initial inspection (delivery/ handing-over inspection) ...................................................... 68
7.8.2 Daily and weekly tasks................................................................................................... 70
7.8.3 Overview of lubricating points ........................................................................................ 72
7.8.4 Inspection plan .............................................................................................................. 74

HML 42
 Table of Contents

7.9 Inspection and maintenance work........................................................................................ 76

7.9.1 Engine oil....................................................................................................................... 76
7.9.2 Engine oil filter ............................................................................................................... 77
7.9.3 Cooling system — Combined hydraulic oil-water cooler................................................. 78
7.9.4 Fuel system ................................................................................................................... 80
7.9.5 Air filter, air intake .......................................................................................................... 82
7.9.6 V-belts ........................................................................................................................... 86
7.9.7 Checking the valve lash ................................................................................................. 87
7.9.8 Hydraulic oil tank ........................................................................................................... 88
7.9.9 Hydraulic oil return filter ................................................................................................. 89
7.9.10 Hydraulic oil suction filter ............................................................................................. 90
7.9.11 Hydraulic oil tank breather ........................................................................................... 91
7.9.12 Venting the plunger cylinders....................................................................................... 92
7.9.13 Line-rupture valves for stabilizers................................................................................. 92
7.9.14 Axles............................................................................................................................ 93
7.9.15 Brakes ......................................................................................................................... 97
7.9.16 Wheels ........................................................................................................................ 99
7.9.17 Swing gear................................................................................................................. 100
7.9.18 Swing bearing ............................................................................................................ 100
7.9.19 Cab ventilation dust filter............................................................................................ 102
7.9.20 Windshield washer system......................................................................................... 102
7.9.21 Electrical equipment................................................................................................... 103
7.10 Shutdown......................................................................................................................... 104
7.10.1 Preservation (temporary shutdown) ........................................................................... 104
7.10.2 During shutdown........................................................................................................ 104
7.10.3 After shutdown........................................................................................................... 104
8 Trouble-Shooting ........................................................................................................105
8.1 Generalities........................................................................................................................ 105
8.2 Engine ............................................................................................................................... 105
8.3 No steering movement....................................................................................................... 105
8.4 Insufficient performance of service brake........................................................................... 105
8.5 Parking brake without function ........................................................................................... 105
8.6 Insufficient braking power of swing brake........................................................................... 105
8.7 No zero position of travel direction ..................................................................................... 106
8.8 Hydraulic oil exceeds max. admissible temperature........................................................... 106
8.9 Sluggish acceleration and deceleration, too little propulsive power .................................... 106
8.10 Transmission works in one direction only......................................................................... 107
8.11 Transmission works in neither direction ........................................................................... 107
8.12 Excavator installation is not working................................................................................. 108
8.13 Decrease in machine’s performance ................................................................................ 108
8.14 Machine is working too slowly and hydraulic oil is becoming hot...................................... 108
8.15 Superstructure slews too far ............................................................................................ 109
8.16 Working cylinders are not working satisfactorily ............................................................... 109
8.17 Plunger cylinders fail to lock or lock insufficiently ............................................................. 109
8.18 Overload warning device malfunctions............................................................................. 109
8.19 Trouble in the electrical system........................................................................................ 110

HML 42
Table of Contents

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

HML 42
 Introduction 1

1 Introduction Please state the vehicle type and the vehicle

1.1 General identification number when making inquiries
or orders, and in all written correspondence.
You decided to buy the SCHAEFF-TEREX
HML 42 Mobile Excavator. The vehicle identification number of
the machine is stamped on the type
The confidence placed in this model will be label (1/1).
rewarded by the efficient and economical
performance of the machine.
These operating instructions contain all
information necessary for the correct use of
the machine. Please read them carefully
before putting the machine into operation and
make sure that they are kept at hand at all
times.
If you require additional information or if any
point is unclear, please contact your dealer
immediately. FH
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Special equipment and attachments are not

included in these operating instructions.
We reserve the right to make improvements
on the machine within the scope of impending 1
technical developments, without incurring any HM32-001

obligation to change these operating

instructions. Fig. 1 – Type label

Any modifications of SCHAEFF-

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

HML 42 1
1 Introduction

1.2 Warranty and Maintenance
The warranty period covers 1,000 operating
hours, not exceeding a maximum of twelve
months, whichever comes first, beginning
with the day the machine is handed over or
put into operation.
Safe working conditions and good working
order of the machine are prerequisites for
efficient work. Your SCHAEFF-TEREX
mobile excavator fulfills these requirements
when correctly handled and when serviced
and maintained as specified.
Careful observation of the machine whilst in
function and the use of the specified
lubricants will prevent malfunction.
Trained specialist personnel are responsible
for any servicing of the machine which
requires expert knowledge. Inspections and
repairs must therefore be carried out by your
dealer’s customer service.
In respect of possible claims for damages
during the warranty period, all work specified
in the maintenance and inspection plan must
be carried out at the specified intervals.
After the warranty period, too, regular
maintenance must be performed in order to
ensure that the machine is constantly in good
working order and enjoys a reasonable
service life.
Insist that only original SCHAEFF-TEREX
spare parts are used in the event of any
repair work. In this way, you will have a
product of lasting high quality, thereby
ensuring that your machine maintains its
original condition.
1.3 Notes on using the instruction book
References to pictures and items
The references to pictures and items
contained in the text, such as "Figure 12/4"
mean Figure 12, Item 4 (Fig. = Figure).
The figures shown in these operating
instructions partly contain additional
equipment.
“DANGER” symbol
This symbol is employed for a high
risk of injury to persons. It is essential
that the safety notes are observed.
“WARNING” symbol
This symbol is employed for
information whose non-compliance
may lead to severe material damage.
It is essential that the safety notes
are observed.
“ATTENTION” symbol
This symbol is employed for
information containing important
notes about the correct use and / or
how to proceed. Non-compliance
may lead to malfunction.

2 HML 42
 Introduction 1

1.4 Environmental requirements 1.5 Pictograms

Applicable environmental requirements must The following table explains the meaning of
be observed for all tasks performed on and the pictograms which may be attached to
with the machine. your machine.
During installation, repair and maintenance
tasks, particular care must be taken that
substances that would damage the Symbol Description
environment such as
• Lubricating grease and oil Danger
• Hydraulic oil
In Operating Instructions:
• Fuel Warning
• Coolants On machine:
Caution — Safety
• Cleaning fluids containing solvents
distance
are not allowed to come in contact with the
soil or the water system. Attention
These substances must be stored in suitable
containers and must be properly transported, Battery charge indicator
collected and disposed of.
If the substances listed above do reach the Pre-heating
soil, the leak or outlet must be stopped
immediately and the fluid must be cleaned up
with a suitable absorbent material. If Engine oil pressure
necessary, the soil involved must be
removed. Absorbent materials and removed Coolant temperature
soil must be disposed of properly. Applicable
environmental requirements must be
observed. Air filter

Fuel / Fuel level

Fan / Heater / Ventilation

Air conditioning

Windshield wash/ wipe

system

Horn

R Travel motion alarm

HML 42 3
1 Introduction

Symbol Description Symbol Description

!
Hydraulic oil / Hydraulic oil Brake accumulator
level pressure monitor

Hydraulic oil filter clogging Parking brake

indicator
Mode of operation Oscillating axle lock
Operating hours

Hazard warning system Dozer blade

Direction indicator, left/

Hydraulic rock breaker
right

Light, low beam Overload warning indicator

High beam indicator lamp Lashing points

Working floodlights Suspension points for

loading by crane

Rotating beacon First-aid kit

Rear fog lamp

Fire extinguisher
V
Travel, forward / reverse Danger of crushing
R

Travel speed, fast Danger of injury

Travel speed, slow Observe notes in

Operating Instructions
Accelerator pedal for
"Sensitive" travel Grease gun
Lubricating point
Steering change-over

Working hydraulics cut-off

Engine speed control

4 HML 42
 Introduction 1

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

HML 42 5
1 Introduction

6 HML 42
 Safety and Prevention of Accidents 2
2 Safety and Prevention of Accidents
2.1 Introductory remarks
Before putting the earth-moving machine into
operation, read these operating instructions
carefully and strictly observe the indicated
references for safe operation.
National safety regulations - e.g. the Accident
Prevention Regulations, “Earth-Moving
Machinery” (VBG 40) and “Vehicles” (VBG
12) in the Federal Republic of Germany -
must also be complied with when operating
the earth-moving machine.
In addition to the operating instructions, legal
regulations governing road traffic and road
safety measures must also be observed.
Such requirements could also apply in
respect of handling hazardous goods or the
wearing of personal safety gear, for example.
Furthermore, safety laws governing work in
particular locations (tunnels, adits, quarries,
pontoons, contaminated areas, etc.) must
likewise be observed.
HML 42
2.2 Proper use
The earth-moving machine with standard
bucket equipment is intended solely for work
which is suitable for the function of the
machine and its work implements.
Such work involves loosening, taking up,
transporting and dumping soil, rock or other
materials as well as loading these materials
on trucks, conveyor belts or other means of
transport.
The assembly of special work implements
such as clamshell grab, hydraulic rock
breaker, etc. allows the machine to perform
above mentioned work.
Any usage above and beyond that specified
here, e.g. the transport of persons or the
transport of loading material and any non-
compliance with the manufacturer’s
instructions is regarded as improper use. The
manufacturer shall not be liable for damage
resulting from improper use. This risk is borne
solely by the plant operator.
Compliance with the operating and
maintenance instructions, the performance of
maintenance work as specified and
adherence to replacement intervals all form
part of the concept of proper use.
7
2 Safety and Prevention of Accidents

2.3 General safety notes 2.4 Operation

It is important to refrain from any working Earth-moving machines are only to be
methods which impair safety. independently operated and serviced by
persons who
The earth-moving machine is only to be used
when it is in a safe, operational condition. • are physically and mentally suitable
The manufacturer’s instructions must be • have been instructed in the operation or
complied with for operation, maintenance, maintenance of earth-moving machines
repair, assembly and transportation. and have demonstrated this ability to the
The plant operator must provide additional plant operator
special safety instructions, wherever • can be expected to perform their allocated
necessary, for specific local conditions. duties reliably
The operating instructions and any All such persons must be of the legal
information pertaining to safety must be minimum age.
carefully kept in the operator’s cab.
They must be designated by the plant
The operating instructions and safety notes operator to operate or service the earth-
must be complete and fully readable. moving machine.
Safety devices on earth-moving machines are Operating equipment is only to be operated
not to be deactivated or removed. from the driver's seat.
Protective work clothing must be worn during The earth-moving machine is only to be
operation. Rings, scarves and unbuttoned ascended and entered using the entrances
jackets are to be avoided. Protective goggles, and surfaces intended for this purpose.
protective boots, helmets, gloves, reflecting
jackets, ear-muffs, etc. may be required. It is the driver’s responsibility to ensure that
the operator’s stand, entrances and other
Before commencing work, information must surfaces of the earth-moving machine which
be obtained on first aid and possible means have to be stepped on are free of dirt, grease,
of rescue (ambulance, fire brigade, oil, ice and snow.
helicopters).
A check must be carried out to ensure that
the first aid box is at hand and that its
contents comply with regulations.
Personnel must be aware of the location and
method of operation of the fire extinguishers
on the earth-moving machine as well as on-
site fire-warning and fire-fighting equipment.
Loose parts such as tools or other
accessories must be secured to the earth-
moving machine.
Open doors, windows, covers, flaps, etc.
must be closed or secured so that they
cannot slam shut.

8 HML 42
 Safety and Prevention of Accidents 2
2.5 Danger zone
• No one is to enter the danger zone of
earth-moving machines.
The danger zone encompasses the
area around the earth-moving
machine in which persons may be
injured by movements of the earth-
moving machine during operation, its
work implements and attachments, or
by swinging out or falling loads.
• The machine operator is only to work the
earth-moving machine when the danger
zone is free of personnel.
• The machine operator must give a
warning signal to persons who may be in
danger.
• The machine operator shall stop work
with the earth-moving machine if anyone
remains in the danger zone despite the
warning.
• To ensure no danger of crushing, a
sufficient safety distance (min. 0.5 m)
must be kept from solid objects, e.g.
buildings, excavation slopes, scaffolding,
other machines, etc.
• If the above safety distance cannot be
maintained, the area between solid
objects and the working zone of the earth-
moving machine must be blocked off.
• If conditions are such that the machine
operator’s view of the driving and working
zone is restricted, he must be guided or
the driving and working zone must be
marked by a solid barricade.
HML 42
2.6 Transport of persons
The transport of persons on the machine is
forbidden.
2.7 Stability
• The earth-moving machine must be used,
driven and operated in such a manner
that its stability against overturning is
ensured at all times.
• The machine operator must drive at
speeds which are suitable for local
conditions.
• The permitted payload of the earth-
moving machine is not to be exceeded.
• The earth-moving machine must remain
at a sufficient distance from the edges of
quarries, pits, mounds and slopes to
ensure there is no risk of falling.
• Earth-moving machines must be secured
so that they cannot roll or slip when in the
vicinity of excavations, shafts, ditches,
pits and slopes.
9
2 Safety and Prevention of Accidents
2.8 Travel operation
Before putting the earth-moving machine into
operation, the driver's seat, mirrors and
operator's controls must be adjusted so as to
ensure safe working.
A safety belt (seat belt), if installed, must
always be fastened.
The windows must be clean and free of ice.
Driving tracks must be designed so as to
ensure smooth, safe operation, i.e. they must
be sufficiently wide, on ground which has as
few slopes as possible and sufficient carrying
capacity.
Downhill tracks must be set out in such a way
that earth-moving machines can be safely
braked.
Before driving downhill, the appropriate gear
for the terrain must be selected and the gear
lever is not to be moved during downhill travel
(on-road or cross-country gear).
On steep drops and uphill gradients, the load
must be carried on the uphill side, if possible,
in order to increase stability.
The carrying capacity of bridges, cellar roofs,
vaults, etc. must be verified before the earth-
moving machine can drive over them.
The internal dimensions of constructions
must be noted before entering underground
passages, tunnels, etc.
It is the plant operator's responsibility to
ensure that equipment such as first-aid box,
warning triangle, hazard lights are kept with
the machine in compliance with the traffic
regulations valid in the user’s country (e.g. in
Germany "StVZO"), and that the driver has
the appropriate license as required by the
national traffic laws of the country in question.
Outside areas covered by general traffic
regulations, e.g. on construction sites, traffic
regulations should be applied in the proper
manner. This should also apply with regard to
drivers’ licenses.
10
2.9 Operation
Daily before commencing work and after
every change of work attachments, the
machine operator must check the correct
fastening of the work attachments as well as
the correct lock of the quick-mount hitch.
Work attachments are to be carefully moved
at low height. During this check no one is to
be in the danger zone of earth-moving
machines.
The machine operator is only to swing the
work equipment over occupied drivers' seats,
operator consoles and workplaces of other
machines when these are protected by
canopies (FOPS).
If a cab does not have the required
protection, the driver of this vehicle must
leave the operator’s stand when the work
equipment has to be slewed overhead.
The vehicles must be loaded in such a
manner as to ensure that there is no
overloading and no material can be lost
during travel. The vehicle must be loaded
from the lowest possible height.
At dumping points, earth-moving machines
are only to be operated when suitable
measures have been taken to prevent rolling
or falling.
HML 42
 Safety and Prevention of Accidents 2
2.10 Guides
Guides must be easily recognizable, e.g. by
means of reflective clothing. They must
remain within the machine operator’s field of
vision.
While guiding the machine, guides are not to
be given other jobs which may distract them
from their task.
2.11 Danger of falling objects
Earth-moving machines are only to be used
where there is a danger of falling objects
when the operator’s stand has a canopy
(FOPS). A front rock guard must be
employed if there is a risk of materials
breaking into the cab.
In front of walls e.g. of stacked materials,
earth-moving machines must be positioned
and operated in such a way that the driver's
seat and entry to the driver's seat are not
situated on the side facing the wall.
Demolition work is only to be performed by
earth-moving machines where there is no
danger to persons and if the machine is
equipped with canopy, front rock guard
mounted on cab and the appropriate work
implement.
See regulations book “Demolition work” (ZH
1/614) published by the Tiefbau-
Berufsgenossenschaft (the employer’s liability
insurance association).
HML 42
2.12 Working in the vicinity of
underground power lines
Before commencing excavating work using
earth-moving machines, it must be
determined whether any underground power
lines are present in the intended working
zone which may present a danger to persons.
If underground power lines are present, their
exact position and course must be
determined in consultation with the proprietor
or operator of the lines, and the necessary
safety precautions decided and implemented.
The course of power lines in the work area
must be clearly marked, under supervision,
before commencing any excavation work. If
the position of lines cannot be determined,
search ditches must be dug - manually, if
needed.
If underground power lines are encountered
unexpectedly or they or their protective
covers are damaged, the machine operator
must discontinue work immediately and notify
the supervisor.
11
2 Safety and Prevention of Accidents
2.13 Working in the vicinity of overhead
power lines
When the earth-moving machine is being
used in the vicinity of overhead power lines
and trolley wires, a safety distance which
varies depending upon the nominal voltage of
the overhead line must be maintained
between the lines and the earth-moving
machine and its work equipment, in order to
prevent current overspill.
This also applies to the distance between
these lines and attached implements or
loads.
The safety distances specified below must be
complied with:
Nominal voltage Safety distance
in Volt in meters
- 1000 V 1.0 m
over 1 kV - 110 kV 3.0 m
over 110 kV - 220 kV 4.0 m
over 220 kV - 380 kV 5.0 m
nom. voltage 5.0 m
unknown
In the observation of safety distances, all
working movements of earth-moving
machines, e.g. positions of the work
equipment and the dimensions of attached
loads must be taken into consideration.
Uneven ground which would cause the earth-
moving machine to be inclined and thus
nearer to overhead lines must also be taken
into account.
During work in windy conditions, both
overhead lines and work equipment may
swing out, thus reducing the safety distance.
If it is impossible to maintain sufficient
distance from overhead power lines and
trolley wires, the plant operator must consult
with the proprietor or operator of the
overhead lines to find other safety
precautions to prevent current overspill.
12
Such measures could be, e.g.
• Switching off the current
• Re-routing the overhead line
• Cabling, or
• Limiting the work zone of earth-moving
machines.
2.14 Operation in closed rooms
If earth-moving machines are to be used in
closed rooms, these areas must be
sufficiently ventilated and the special
regulations observed.
2.15 Work stoppages
Before rest periods and at the end of the
working day, the driver of the earth-moving
machine must park the machine on ground
which has sufficient carrying capacity and is
as level as possible, and must secure it
against unintended movement.
Before rest periods and at the end of the
working day, the driver must lower the work
equipment onto the ground or secure it so
that it cannot move.
The driver is not to leave the earth-moving
machine if the work equipment has not been
lowered to the ground or secured.
Earth-moving machines are only to be parked
in places where they do not present an
obstacle to others, e.g. on the construction
site or to plant traffic. Warning devices, e.g.
triangles, warning cordons, flashing or hazard
lights are to be used if necessary.
Before leaving the operator stand, the driver
must bring all operating equipment into home
position, switch off the working hydraulics and
apply the brakes.
If the driver is leaving the earth-moving
machine unattended, he must first turn off the
engine and ensure that it cannot be started
up by unauthorized persons (e.g. removing
ignition keys).
HML 42
 Safety and Prevention of Accidents 2
2.16 Load hook applications
Load hook applications are the hoisting,
transporting and lowering of loads with the
aid of a fixing device (rope, chain, etc.),
whereby the assistance of personnel is
required to attach and release the load. Such
work covers e.g. the lifting and lowering of
pipes, tubbing rings or containers.
Earth-moving machines are only to be used
for load hook applications if they are
equipped in the proper manner and if they
have the approval to this purpose.
For load hook applications, the earth-moving
machine must be equipped with the following
safety devices which have to be in proper
working condition:
• Secure attachment of loading implements
• Table of carrying capacity
• Overload warning device
• Line rupture valve in boom cylinder
When earth-moving machines are used for
load hook applications, personnel attaching
loads are only to approach the boom from the
side and with the machine operator’s
permission. The machine operator is only to
give his permission if the earth-moving
machine is standing still and the work
equipment is not in motion.
Personnel guiding the machine and attaching
loads are never to leave the machine
operator’s field of sight.
Do not use fixing devices (ropes, chains,
shackles) which are damaged or of
inadequate dimensions. Protective gloves
must always be worn when working with
fixing devices.
Only loads not exceeding the carrying
capacity of the machine and the hoisting
appliance are to be used.
Attach loads only at the load hook intended
for this purpose.
Loads must be attached in such a way that
they cannot slip or fall out.
Do not guide loads above persons.
The machine operator must carry loads as
close to the ground as possible and prevent
them from swinging.
HML 42
Earth-moving machines are only to travel with
an attached load if the path of travel is fairly
level and if there is sufficient overview of the
path of travel.
2.17 Change of work attachments,
maintenance, repair
Earth-moving machines are only to be
converted, maintained or serviced under the
guidance of a suitable person designated by
the plant operator and following the
manufacturer’s operating instructions.
After every change of work attachments, the
driver must convince himself that the quick-
mount hitch is correctly fastened and locked.
Work on e.g.
• braking,
• steering,
• hydraulic and
• electric systems
of the machine is only to be carried out by
expert personnel specially trained in these
areas.
Stability must be ensured during all type of
work on the machine at all times.
The work equipment must be secured against
movement by lowering it to the ground or
equivalent measures, e.g. cylinder supports,
trestles. With the engine running, the
unprotected articulation range of articulated
loaders is not to be entered.
When jacking up earth-moving machines,
jacking devices must be positioned so that
they cannot slip. Jacks must be positioned
and applied absolutely straight, without tilting.
Raised earth-moving machines must be
supported by suitable structures such as
crosswise stacks of planks, square timbers or
steel trusses.
Earth-moving machines which are raised with
work equipment must be stabilized by a
supporting structure immediately after lifting.
Work under machines which are only
supported by their hydraulics is forbidden.
13
2 Safety and Prevention of Accidents
The engine/motor must be turned off prior to
all maintenance and repair work. These
requirements are only to be ignored in the
case of maintenance or repair work which
cannot be performed without the
engine/motor running.
When performing maintenance and repair
work on the hydraulic system, the system
must be relieved of pressure. With the engine
turned off, lower the work equipment to the
ground and actuate all hydraulic control
levers until there is no pressure in the
hydraulic system.
Before working on the electrics or when
performing arc-welding on the machine, the
connection to the battery must be
disconnected.
When disconnecting the battery, first the
negative pole then the positive pole must be
disconnected. The battery must be re-
connected in reverse order.
During repair work around the battery, the
battery must be covered with insulating
material; tools should never be placed on or
near the battery.
Protective devices of moving machine parts
are only to be opened or removed when the
drive has been switched off and cannot be
switched on again by unauthorized persons.
Protective devices are e.g. engine/motor
covers, doors, protective grating, trim.
Upon completion of assembly, maintenance
or repair work, all protective devices must
once more be attached in the proper manner.
Load-bearing parts of loading machines are
only to be welded following consultation with
the manufacturer and in accordance with
recognized welding principles.
Protective structures (ROPS, FOPS) are not
to be welded or drilled in any way.
Alterations, such as welding of the hydraulic
system, are only to be undertaken with the
manufacturer’s permission.
Before commencing work on the hydraulic
system, the operating pressure, pilot
pressure, back pressure and pressure inside
the tank must be let off.
14
Swallowing lubricants, or long and repeated
skin contact, can be hazardous to health.
When used properly, there is no particular
danger to health. The safety specification
sheets from the mineral companies must be
observed.
Only the hoses specified by the manufacturer
are to be used.
Hydraulic hoses must be routed and
assembled by expert personnel.
In the vicinity of fuel or batteries, smoking and
naked flames are prohibited.
2.18 Recovery, loading, transportation
Earth-moving machines are only to be loaded
onto recovery vehicles when adequate towing
vehicles are used.
The tow fixing points specified by the
manufacturer must be employed.
For loading and transportation, earth-moving
machines and all necessary auxiliary
equipment must be secured against
unwanted movement.
The traveling gear and track-laying gear of
earth-moving machines must be sufficiently
cleaned of mud, snow and ice to ensure that
ramps can be driven up without risk of
slipping.
When transporting the earth-moving machine
on trucks, flatbed trailers, or by rail, it must be
sufficiently secured with chocks and by
attachment to the lashing points.
Before setting off, the route to be taken must
be examined to determine whether the roads
are wide enough, entrances and passages
under bridges are large enough and that
roads and bridges have sufficient carrying
capacity.
HML 42
 Safety and Prevention of Accidents 2

2.19 Monitoring and inspections The machine operator must advise the
supervisor immediately - and his
The machine must be submitted to a general
replacement, if there is a change of operator -
inspection in compliance with the existing
with regard to any shortcomings.
UVV-regulations (Accident Prevention
Regulations). This inspection must be carried In the event of shortcomings which jeopardize
out by an expert (e.g. machine engineer or the operating safety of the earth-moving
machine foreman): machine, it is not to be used until these have
been eliminated.
• before the machine is put into operation
for the first time and before the machine is
again put into operation after essential
modifications have been made
2.20 Fire protection
• at least once a year
The fire extinguisher must be kept
• in the meantime, in compliance with in the cab. The fire extinguisher
operating conditions and local symbol must be attached.
environments
The results of this inspection have to be MTK115002

recorded in writing and this record has to be

kept until the next inspection takes place.
Prior to every work shift, the machine
operator must check the earth-moving
machine in compliance with the inspection
and maintenance plan.
Hydraulic hoses must be replaced as soon as
the following damage is recognized:
• Damage to the outer layer which reaches
the intermediate layer
• Embrittled patches on the outer layer
• Deformations when under pressure or
without pressure which differ from the
original shape of the installed hose
• Leaks
• Damage or deformation to hose fittings or
to the connection between the fitting and
the hose
The coolant level is only to be checked after
the engine has cooled down; the cap must be
turned carefully in order to bleed excess
pressure.
Prior to operations, the machine operator
must check the function of the safety devices.
2.21 Emergency exit
The windshield acts as an emergency exit. If
a front rock guard is fitted or this exit can no
longer be used for any other reason, an
emergency hammer must be affixed in an
easily accessible place inside the operator’s
cab.
2.22 Other dangers
Failure of the hydraulic system
If the hydraulic system fails because the
diesel engine is not running, the hydraulic
pump is damaged or hydraulic oil has been
lost, only the EMERGENCY functions
• manual steering (without power
assistance) and
• lower work equipment (only if ignition is
switched on)
can be performed.

HML 42 15
2 Safety and Prevention of Accidents

16 HML 42
 Technical Data 3

3 Technical Data
3.1 Views
• Two-piece articulated boom "TPA" with dipperstick, 2,000 mm
3975
2990

HM42-003
0
1
2
3

8300
4
5
6
7
8
9
9

5
6040 3665
7140 4315
8240
2
3

8010 Ausladung Greifer

4
5
6
7
8
9
9

4980 5530
Fig. 3 Digging envelope

HML 42 17
3 Technical Data

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

5
8215

4
5843

3975
2891

2990
2

0
HM42-004
9 8 7 6 5 4 3 2 1 0

1
3498
4263

8145
Fig. 4 Digging envelope

18 HML 42
 Technical Data 3

3000
1600

HM42-008

Fig. 8 Slew circle

Slew circle
180° slew circle 1,600
360° slew circle 3,000
221
1030

2500
761
490

HM42-009

Fig. 9 Parallel side shift

HML 42 19
3 Technical Data

3.2 Engine
Make:.................................................... Deutz
Type: .................................................... BF 4 M 2012
Design: ................................................. Four-stroke diesel engine with direct injection,
turbocharger
Cooling: ................................................ Water-antifreeze mixture
Displacement: ....................................... 4,040 cm³
Power to DIN 70020:............................. 67 kW at n = 2,000 rpm
Max. torque:.......................................... 371 Nm at n = 1,500 rpm
Specific fuel consumption: .................... 208 g/kWh
Max. inclined position:........................... 30° on all sides
Heating: ................................................ Water-heat exchanger

3.3 Electrical system

Operating voltage: ................................ 12 V
Battery: ................................................. 12 V 135 Ah 600 A
Generator: ............................................ 14 V 70 A
Starter:.................................................. 3.1 kW
Starting aid: .......................................... Glow plugs
Lighting system:.................................... in compliance with German Motor Vehicle
Construction and Use Regulation (StVZO) and
Euronorm

3.4 Travel drive

Travel drive:.......................................... Variable displacement pump flanged directly onto the
diesel engine, two-stage variable displacement motor
with power shift on the front axle reduction gear.
Suction filter in the form of a fixed tank filter.
Travel speeds: .......................................... Forward - reverse
HML 42, HML 42 AL HML 42 S
(all-wheel steering) (high-speed)
Speed I Speed II
Driving mode 0 - 6 km/h 0 – 5.2 km/h 0 – 12 km/h
"Work":
Driving mode 0 - 20 km/h 0 – 15 km/h 0 - 36 km/h
"Road"

20 HML 42
 Technical Data 3

Power transmission:.............................. Hydrostatic travel drive with automatic adjustment of

Max. operating pressure "Travel": .........
propulsive force and speed over the entire driving
speed range through variable speed motor.
Twin-stage transmission with power shift and infinitely
variable speed control, forward and in reverse.
Operation using accelerator pedal, four-wheel drive
from front axle transmission over propeller shaft to
rear axle.
440 bar

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

HML 42 21
3 Technical Data

3.6 Hydraulic system

Hydraulic pumps
Hydraulic circuit 1: ................................ Work functions: Boom, dipperstick, bucket,
intermediate boom, rock breaker / additional
control circuit
Axial piston variable-capacity pump with flow
adjustment and pressure cut-off.
Flanged onto the flywheel side.
Max. capacity: 200 l/min
Max. pressure: 280 bar
Hydraulic circuit 2: ............................... Work functions: Slewing and all positioning
functions
Pumps sections 1, 2, and 3 of the triple gear pump
flanged onto the power take-off.
Twin-stage power switch at a system pressure of
110 bar.
Max. capacity: 39 + 26 + 11 l/min
Max. pressure: 230 bar
Servo control: ....................................... Pressure removal at travel drive variable
displacement pump
Pressure: approx. 35 bar
Braking system: ....................................... Pump section 3 of triple gear pump
Max. capacity: 11 l/min
Max. pressure: 150 bar
Priority valve: ........................................... Priority supply of hydraulic oil to steering
Actuation:................................................. Hydraulic pilot-operated excavator valves for all
functions.
Hydraulic cylinders:.................................. Double-acting working cylinders, partially with end
position damping.
Swing drive: ............................................. Hydrostatic with reduction gear and drive pinion on
internally toothed ring gear of swing bearing.
Slewing range: 360° unlimited
Slewing speed: 0 -10 rpm
Hydraulic oil filters:................................... Suction filter in tank for “Travel” hydraulic circuit.
Return filter in tank for "Working System" hydraulic
circuit.
Hydraulic oil cooler: ................................. Thermostatically controlled
Operating range 50 °C — 45 °C
Knickmatik® boom control: ....................... Bend mechanism for the lateral parallel adjustment
of the boom axle at total digging depth.
Lateral adjustment to the right: 1,030 mm
Lateral adjustment to the left: 760 mm

22 HML 42
 Technical Data 3

Steering, HML 42, HML 42 S: .................. Fully hydraulic proportional steering of front axle by
means of steering control unit and one steering
cylinder integrated in the axle.
Steering, HML 42 AL:............................... Electric preselection of steering mode
Fully hydraulic proportional steering of front and
rear axles by means of steering control unit and
one steering cylinder integrated in the axles.
Due to the two steerable axles the following
steering modes are possible:
standard steering standard steering for on-road and standard
operations — only front axle is moved
all-wheel steering "round": steering to reduce the turning radius. Counter-
rotating movement of the two axles.
all-wheel steering "crab": steering for diagonal-sideway displacement. The
two axles steer in the same direction.
Max. wheel lock: ...................................... 30°

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

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

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

HML 42 23
3 Technical Data

3.8 Tires
Tire size Type Profile Remark Tire pressure Tire pressure
front in bar rear in bar
9.00-20 14 PR cleat profile Twin tires 7.0 7.0
600/40-22.5 Special J 331 "Super" wide- 5.0 5.0
base tires

3.9 Lubricants
3.9.1 Filling quantities

Fuel:............................................................ approx. 240.0 l Diesel

Engine oil: ................................................... approx. 10.0 l HD-oil (first filling)
Hydraulic oil, tank and system:.................... approx. 190.0 l Hydraulic oil
Hydraulic oil tank:........................................ approx. 125.0 l Hydraulic oil (change
quantity)
Steering front axle, HML 42, HML 42 AL..... approx. 7.2 l Transmission oil
center housing: ...........................................
Steering front axle , HML 42 S .................... approx. 6.8 l Transmission oil
center housing: ...........................................
Steering front axle, HML 42, HML 42 AL..... approx. 0.9 l Transmission oil
transmission................................................
Steering front axle -, HML 42 S ................... approx. 1.9 l Transmission oil
transmission, shiftable ................................
Steering front axle, HML 42, HML 42 AL,.... each 0.8 l Transmission oil
HML 42 S, wheel hub.................................. approx.
Rear axle, HML 42, HML 42 S .................... approx. 8.0 l Transmission oil
center housing: ...........................................
Steering rear axle, HML 42 AL .................... approx. 7.3 l Transmission oil
center housing: ...........................................
Rear axle, HML 42, HML 42 S wheel hub ... each 2.1 l Transmission oil
approx.
Steering rear axle, HML 42 AL, wheel hub.. each 0.8 l Transmission oil
approx.
Swing gear:................................................. circulating lubrication supplied by
hydraulic system
Service brake:............................................. supplied by hydraulic system
Engine coolant: ........................................... approx. 12.0 l water with anti-
corrosion agent and
antifreeze
All values stated are approximate values.
The filling level indications should always be used as a guide.

24 HML 42
 Technical Data 3

3.9.2 Fuel, lubricant and coolant specifications

Prescribed fuels, lubricants and
coolants for Central Europe
Application Code designation Designation Specification, Remarks
to Bi
1) Standards, Quality
Engine -- Diesel fuel DIN 51601
ASTM D975 1-D / 2-D Before using RME-fuels
(rape oil methyl ester), it is
essential to consult your
responsible SCHAEFF-TEREX
dealer for further details.
Engine EO 1540 A Engine oil SAE 15W-40 See also engine manufacturer’s
API CF4 instructions
Cooling for engine SP-C Coolant Antifreeze based on See also engine manufacturer’s
ethylene glycol instructions
Hydraulic system HYD 1040 Hydraulic oil or HVLP D 68 The following viscosity limit
multi-grade or values must be kept (in
engine oil SAE 10W-40 compliance with ASTM 445)
2
at 100 °C min. 10 mm /s (cSt)
at minus 10 °C approx. 1,500 mm
2
/s (cSt)
BIO-E-HYD-HEES Biodegradable Filling in compliance The same viscosity specifications
hydraulic oil on with customer apply as for mineral hydraulic
synthetic ester specifications. oils.
base Brand label on
machine. When changing from
mineral to biodegradable
hydraulic oils, the tank and
Do not mix hydraulic system must be
biodegradable oils of completely drained, cleaned and
different suppliers. flushed.
For further details before
changing oils, please consult
your responsible SCHAEFF-
TEREX dealer.
Axles, GO 90 LS Transmission SAE 80W-90LS Alternative recommendations
Transmission (s) oil API-GL 5 SAE 90LS
SAE 85W-90LS
Lubricating points MPG-A Multi-purpose, K2K-30
lithium-soap DIN 51825
based grease
1)
In conformity with the regulation lubricants of the Main Association of the German Building Industry e.V.

Alternative recommendation for other temperature ranges

Engine oil Hydraulic oil

in compliance with API CG 4 or CF 4 and in compliance with DIN 51524.T3 HVLP
in compliance with ACEA E3 or E2

HML 42 25
3 Technical Data

3.10 Permissible loads in accordance with local regulations

(e.g. in Germany, StVZO - Regulations Authorizing the Use of Vehicles for Road Traffic)
Permissible gross weight ................................................ ðsee nameplate

Permissible axle load, front ............................................. or

Permissible axle load, rear.............................................. ð General Operating License

3.11 Sound level values, vibration

Sound level values in compliance with directive 2000/14/EC and EN 474

Guaranteed sound power level: ...................... LW(A) = 99 dB (A)
Sound pressure level: ..................................... LP(A) = 71 dB (A)

Vibration values in compliance with directive 98/37/EEC and EN 474

Weighted r.m.s. value of acceleration is below ............... 0.5 m/s2 for entire body
and ................................................................................. 2.5 m/s2 for upper limbs

3.12 Dimensions and weights

(with 9.00-20 14 PR twin tires)

Operating weight: approx. kg 10,990

Total width (at outside edge of tires): mm 2,500
Total length in travel position: mm 5,400
Total height in travel position: mm 3,980
Total height up to cab: mm 2,990
Uppercarriage tail swing: mm 1,600
Ground clearance 440
mm
beneath propeller shaft: approx.
Wheel base: mm 2,570
Tread width: mm 1,942
Smallest turning radius (at outside edge of tires) — HML 7,400
mm
42, HML 42 S, HML 42 AL-standard steering
Smallest turning radius (at outside edge of tires) — HML
mm 5,100
42 AL featuring all-wheel steering "Round"
All dimensions and weights refer to standard equipment.
Weight including 600-mm bucket, stabilizers (blade +100 kg), driver 75 kg, twin tires
(single tires – 440 kg)

26 HML 42
 Technical Data 3

3.13 Excavator installation

Dipperstick Dipperstick
2,000 mm 1,850 mm
Digging depth mm 4,315 4,263
Max. dumping height mm 6,040 5,843
Max. height of bucket hinge point mm 7,140 7,017
Max. reach mm 8,300 8,145
Bucket angle of rotation ° 187 quick-mounting directly attached
177.4 192.5
* Ripping force N 58,500 58,300
* Breakout force N 72,000 68,100
* Values are theoretical in compliance with DIN 24086

3.14 Carrying capacity

The carrying capacities indicated in tons (t) were determined in compliance with ISO 10567 and
include a stability factor of 1.33 or 87% of the hydraulic lifting capacity.
The weight of the work attachment must be deducted from the payload indicated (weight
see type label).

Table of carrying capacity, machine with the following equipment:

• without bucket
• 9.00-20 14 PR twin tires with intermediate rings
• full fuel tank, with driver
A = supported by blade V = traveling
Load radius from center of ring gear
Height 3m 4m 5m 6m 7m
of hook
along* across* along* across* along* across* along* across* along* across*

3.0 A - - 3.11 2.63 2.44 1.91 2.39 1.31 1.98 0.92

m V - - 2.56 2.40 1.76 1.71 1.28 1.18 0.92 0.83
1.5 A 4.91 3.87 3.11 2.51 2.72 1.79 2.71 1.25 1.94 0.89
m V 3.88 3.54 2.51 2.30 1.77 1.62 1.20 1.13 0.83 0.78
0 A 6.50 3.60 3.88 2.36 3.00 1.68 2.57 1.22 1.79 0.88
m V 3.65 3.31 2.35 2.21 1.65 1.54 1.18 1.12 0.84 0.79
-0.9 A 7.26 3.43 4.25 2.16 3.34 1.50 2.51 1.11 1.77 0.86
m V 3.43 3.25 2.27 2.04 1.59 1.43 1.15 1.03 0.87 0.81
* across / along undercarriage

HML 42 27
3 Technical Data

3.15 Work attachments

(based on 9,00-20 14PR twin tires)
for dipperstick, 2,000 mm for dipperstick, 1,850 mm
3)
Width (mm) Capacity (m Density Width (mm) Capacity m3 Density
(t/m3) (SW=quick- t/m3
mounting)
Buckets
Drainage buckets
350 ejector 0.145 1.8
300 0.200 1.8
450 ejector 0.200 1.8
300 SW 0.200 1.8
350 conical 0.130 1.8
400 0.285 1.8**
450 conical 0.175 1.8
Clay buckets
600 0.250 1.8
400 0.260 1.8
750 0.330 1.8
400 SW 0.260 1.8
900* 0.410 1.6
500 0.350 1.8**
Ditch-cleaning bucket
Rock buckets
1500* 0.300 1.8
500 0.230 1.8
Swing bucket
500 SW 0.230 1.8
1500* 0.260 1.8
600 0.300 1.8
Clamshell grabs type GS 3
Ditching buckets
325 0.135 1.8
1500* 0.260 1.8
400 0.170 1.8
1500 SW* 0.260 1.8**
500 0.220 1.8
Grab Type E15
600 0.260 1.8
300 0.170 1.8**
800 0.355 1.6
* = These attachments are not licensed for
* = These attachments are not licensed for
use on the road!
use on the road!
** = with additional rear weight

- Further work attachments available on request -

28 HML 42
 Technical Data 3

3.16 Stabilizers / Support blade

Rear stabilizers for attaching diverse support pads:

Support width:............................................... 2,320 mm - 2,400 mm

Distance below level surface:........................ 230 mm - 290 mm
Pad sizes for the different types: ................... flat 550 mm x 573 mm
rough terrain 550 mm x 570 mm
rubber 485 mm x 540 mm
Rear support blade:
Width: ........................................................... 2,500 mm
Distance below level surface:........................ 250 mm

3.17 Optional accessories

• Load hook, quick-mounting
• Load hook for bucket rod (bolted)
• Boom height limitation
• Adapter for rock breaker attachment
• Hydraulic rock breaker SMS 140
• Open return
• Supplementary heating
• Immobilizer
• Electrical refueling pump
• Air conditioning

- Further optional accessories available on request!-

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

HML 42 29
4 Operation

4 Operation
4.1 Operator controls

This picture contains non-standard equipment!

9 10 11 12 13 23

8
7
14
6
5 15
4
25
3
16
2

17

21
1
22
HM32-0101
18 010831

19
20

24

Fig. 10.1 Operation

30 HML 42
 Operation 4

Description of cab
1 Windshield washer tank
2 Stabilizer, left
3 Stabilizer, right
4 Door release
5 Control lever — excavator installation
6 Working hydraulics cut-off (raise panel)
7 Steering column — tilt and height adjustment
8 Turning indicator
9 Sensitive travel
10 Operation of intermediate boom / articulation
11 Excavator brake release
12 Service brake / excavator brake
13 Accelerator pedal
14 Control lever — excavator installation
15 Travel direction pre-selector — forward / neutral / reverse
16 Engine speed control (manual throttle)
17 Heater temperature control
18 Battery main switch
19 Socket
20 Refueling pump (option)
21 Superstructure slewing lock
22 Radio
23 Socket
24 Service ladder (cover)
25 Choice fresh air — re-circulating air

HML 42 31
4 Operation

26
27
28 40
29
30
31 41
32 , 42
33 !
0 4/4
43
P

35 37 39
68 34 36 38

69 44 45 46 47 48

49 50 51 52 53 54
HM42-0102-N 55
70 71 72 73
56
57
15

HML42AL
P

P
HML42
64 59 60 61 62 63
58 59 60 61 62 63
I HML42S
II P

58 59 65 66 67 62 63

Fig. 10.2 Instruments and operation

32 HML 42
 Operation 4

Description of instrument panel

15 Preselection of travel direction — 53 Rock breaker / additional control

Forward/Neutral/Reverse circuit

26 RED — battery charge indicator 54 Overload warning device ON/OFF

lamp 55 Operation of additional control
circuit I; e.g. grab rotation, rock breaker
27 YELLOW — pre-heating monitor
56 Horn
28 RED — engine oil pressure
57 Button — change-over intermediate
29 YELLOW — air filter indicator boom / articulation
30 RED — hydraulic oil return filter 58 Fast — slow
clogging indicator
59 Sensitive travel
31 RED — hydraulic oil level 60 Travel motion alarm cut-off
32 GREEN — turn signals 61 Front dozer blade
33 BLUE — high beam 62 Oscillating axle lock
34 GREEN — rear axle straight-ahead 63 Parking brake

35 GREEN — front axle straight-ahead 64 Travel speed and steering mode

switch
36 GREEN — travel direction, reverse
65 High-speed change-over switch
37 GREEN — travel direction, forward
Only press when machine is
38 RED — parking brake standing still and service brake is
39 RED — brake accumulator pressure applied!
indicator If the red indicator lamp in the
40 Overload warning device switch lights up, no gear is engaged
(idle-running position). The manual
41 Coolant temperature transmission is in an intermediate
position. The machine is not ready
42 Operating hour meter for operation! This can be
43 Fuel gauge remedied by brief steering
movements to be performed until
44 Light switch the transmission engages.
45 Rotating beacon 66 Indicator — Speed II

46 Working floodlights 67 Indicator — Speed I

68 Operation of additional control
47 Hazard warning switch circuit II
48 Pre-heat/ starter switch 69 Hydrostatic additional swing brake
49 Heater fan switch 70 Boom-mounted working floodlight
50 Air conditioning 71 Fog lamp
72 Steering change-over
51 Windshield wiper - wash/wipe
system 73 not assigned
52 Working hydraulics cut-off

HML 42 33
4 Operation

4.2 Engine 26
27
4.2.1 Starting the engine 28
29
Each time before putting the machine
into operation, the inspections in
compliance with Chapter 7.8 must be ,

carried out. P
!
0 4/4

Before switching on the engine,

ensure that no one is in the
immediate vicinity of the machine or
48
in the danger zone.
• All levers must be put into neutral position.
• Press parking brake switch (11/63); set
direction-of-travel pre-selector (11/15) to
“O”.
• Insert ignition key in pre-heat/ starter switch
(11/48).
• Turn clockwise to “1”, the indicator lamps
(11/26; 11/28) light up.
• Pre-heating starts; the indicator lamp
(11/27) lights up.
• Press down accelerator pedal (11/13) to
half-throttle position. P

• After the pre-heating indicator lamp (11/27) 63

has gone out, turn the pre-heat/ starter 13
switch to “2”. As soon as the engine is
running, turn the key back to “1” and
decrease the revs to low idle speed. The
indicator lamps should go out.
• If the engine has not started after max.
15 seconds, turn the ignition key to “1” or 15
“0”, and pause for at least 1 minute before
trying again. Repeat the start-up
procedure.
Do not drive the engine at full throttle
straight away. Drive with restraint
until the engine reaches operating
temperature.
HM32-011

Fig. 11 Operation

34 HML 42
 Operation 4

4.2.2 Monitoring during operation

The machine is equipped with a 26
warning buzzer emitting an interval
signal if the following malfunctions 28
29
occur: 30
41
Þ Battery charge indicator (12/26) 31
,

Þ Engine oil pressure (12/28) P

!
0 4/4

Þ Air filter service indicator (12/29)

39
Þ Hydraulic oil filter clogging
indicator (12/30) 48

Þ Insufficient hydraulic oil level

(12/31)
Þ Coolant temperature (12/41)
Þ Insufficient fuel level (12/43) HM32-012

If the engine and the machine are put Fig. 12 Operation

into operation without prior remedy
of the damage, severe damage to the
engine may result!
As soon as the warning buzzer comes up
check which indicator lamp is activated and
which indicator has reached the critical area
and proceed accordingly.
• If the battery charge indicator lamp (12/26)
or the engine oil pressure lamp (12/28) light
up, switch off the engine immediately and
determine the cause and, if necessary, call
for service personnel.
• If the hydraulic oil filter clogging indicator
(10/31) of the return filter lights up, perform
the necessary maintenance work and, if
necessary, determine the cause of
clogging.
If the hydraulic oil filter clogging
indicator is disregarded, this may
result in damage to the hydraulic
system.
If the hydraulic oil is cold, the
hydraulic oil filter clogging indicator
may light up briefly. It will go out
once the operating temperature is
reached.
• If the air filter service indicator (12/29)
lights up, perform the necessary air filter
maintenance work.

HML 42 35
4 Operation

• If the hydraulic oil deficiency indicator

(12/31) lights up, discontinue work
26
immediately and switch off the engine. Top
up hydraulic oil and, if necessary, 28
determine the cause. 29
30
• If the permitted coolant temperature (12/41) 31 41
is exceeded, stop work, open the engine ,

hood and keep the engine running at idle P

!
0 4/4

speed to allow it to cool down. Once the

engine has cooled down, turn it off and
39
determine the cause, or call for service
personnel. 48

• If the fuel reserve limit (12/43) is reached, a

residual fuel quantity of approx. 15 l is left
in the tank. There is a brief acoustic
warning. Replenish fuel.
• If the brake accumulator pressure indicator HM32-012

(12/39) lights up, switch off the engine and Fig. 12 Operation
determine the cause.
The machine is never to be
operated with insufficient brake
accumulator pressure.
Danger of accident!
No braking power!

4.2.3 Switching off the engine

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

36 HML 42
 Operation 4

4.3 Driver’s seat, height and tilt adjustment

of steering wheel

Driver's seat
The comfort seat is spring-mounted with oil- 5
pressure-operated shock absorbers.
The seat meets international quality and
safety standards (Fig. 13). 4
1. Horizontal adjustment of seat
1
2. Horizontal adjustment of seat console
3. Weight adjustment
3
4. Seat back adjustment
2
5. Lumbar support
6. Height adjustment 1
Raising seat:
Raise seat until it clicks audibly into place. 3 HM32-013
020717
Lowering seat:
Fig. 13 Driver's seat
Raise seat as far as the stop; it then sinks
to the lowest position.

Tilt adjustment of steering wheel

• Press down lever (14/7).
• Adjust the steering wheel tilt-wise. 49 50
• Release lever (14/7).

Height adjustment of steering wheel

• Lift lever (14/7). 7

• Adjust the steering wheel height-wise.

• Release lever (14/7).
25

17

HM32-014
010831

Fig. 14 Operation

HML 42 37
4 Operation

4.4 Heating / Ventilation / Air conditioning

Heating and air conditioning can only
be operated with the diesel engine
running.
Heating
• The heater is connected to the coolant
circuit and operated using the control
(14/17).
• The fan is operated using the switch
(14/49) and may be operated using fresh
air or re-circulating air.
• For recirculating air operation, open
aspirating holes (14/25) (pull out slide
control).
• The air is distributed by adjusting the
aspirating holes.
How to achieve efficient cooling
power:
• After switching on the air
conditioning system, open the
window(s) 2 – 3 min to allow the
hot air (stored heat) to escape.
• Keep window(s) and door(s)
closed.
• We recommend reducing the
interior temperature by no more
than 6 °C to 8 °C below exterior
temperature.

Ventilation
• In ventilating mode, the control for the
heater (14/17) remains in the "COLD" 49 50
position.
• The fan is operated using the switch
(14/49).
7

Air conditioning (option)

The air conditioning system has to be
switched on for approx. 5 min at least 25
once a month to lubricate the
compressor seals.
17
• Select "Recirculation Mode" and open the
aspirating holes (14/25).
• Control (14/17) in "COLD" position.
HM32-014
• Switch on the air conditioning system using 010831

the switch (14/50). Fig. 14 Operation of heater

• Switch on the fan (14/49)

38 HML 42
 Operation 4

4.5 Light switch

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

33 !

Setting 1 = Parking light

0 4/4
P

Setting 2 = Driving headlamps (low beam -

high beam) 44

Switch from one to the other by

lifting the turning indicator
(15/8); the indicator lamp
(15/33) lights up.

8
4.6 Front window
• To open the window, release the two levers
(16/1).
• Pull the window back and up at the same
HM32-015
time.
Fig. 15 Operation of lighting
• Lock the window in the upper position with
the levers (16/1).

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

vue vers l’avant

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

HR32-015

Fig. 16 Front window

HML 42 39
4 Operation

4.7 Travel operation • Travel speed is controlled using the

When driving on public roads, the accelerator pedal (17/13).
mobile excavator — as a self- • The direction of travel may be changed
propelled vehicle — is subject to quickly using the travel direction pre-
the traffic regulations valid in the selector switch (17/15).
user’s country.
HML 42 AL: When driving on
roads, all-wheel steering has to be
deactivated.
See Chapter 4.7.2
,

!
0 4/4
P

4.7.1 Driving 37
36 38
4.7.1.1 Driving using the accelerator pedal
When driving the mobile excavator
using the accelerator pedal (17/13),
the manual throttle (17/16) must
always be set to neutral position.
Non-compliance with the above 52
may result in uncontrolled
movements during driving. HML42AL

Driving off P 15

The direction of travel always refers 64 62 63

to the undercarriage (steering axle HML42S
I
to the front). II P P

• Direction pre-selector (17/15) in “0”-

position. 58 65 66 67 62 63 58 62 63
13
• Start the engine.
• Manual throttle (17/16) in neutral position.
• Raise stabilizers (support blade).
• Engage working gear or road gear (17/58;
17/64). 15

• HML 42 S: Select speed range I or II

(17/65). Observe indicator lamps (17/66, 16
17/67).
• Release the parking brake (17/63). The
indicator lamp (17/38) is OFF.
• Oscillating axle lock (17/62) "OFF".
• Adjust the desired direction of travel using HM42-017-N
the selector switch (17/15) (travel direction
arrows 17/36 or 17/37 light up) and press Fig. 17 Operation
the accelerator pedal (17/13).

40 HML 42
 Operation 4

Coming to a halt
• Speed is reduced by releasing the
accelerator pedal (18/13).
• The hydrostatic travel drive acts as wear-
resistant auxiliary brake.
See also Chapter 4.7.3, “Brakes”.
52

4.7.1.2 Sensitive travel using the rocker

HML42AL
accelerator pedal
15
When performing work where the work P

equipment of the excavator requires maximum

hydraulic power and, at the same time, where 64 59
HML42S
the excavator should (must) be moved with I
great sensitivity, the “additional accelerator II P P

pedal for sensitive travel” is used.

58 59 65 67 58 59
In this case, the direction of travel and travel
9 13
speed are controlled by operating the rocker
foot pedal.
With the working hydraulics switched
off, the “additional accelerator pedal”
is without function.
• Switch on the working hydraulics (18/52). 15

• HML 42, HML 42 S: Travel speed switch

(18/64) in "Work" (tortoise) position. 16

• HML 42 AL: Travel speed switch (18/64) in

"Work" position (tortoise standard steering
or round steering, or crab steering).
• HML 42 S: Select speed range I (18/65).
Observe indicator lamp (17/67). HM42-018-N

• Travel direction switch (18/15) in “0”

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

HML 42 41
4 Operation

4.7.2 Steering • The green indicator lamp in the Travel

Emergency steering system
With the diesel engine switched off,
power steering is deactivated.
Very high steering-wheel forces!
In case of malfunctions in the
steering system, determine the cause
immediately (see trouble chart,
Chapter 8), and call for service
personnel, if necessary.
speed / Steering mode switch (19/64) lights
up.
The lock ensures that there is no unintentional
activation of all-wheel steering. All-wheel
steering must always be intentionally activated
by raising the lever.
If all-wheel steering is chosen, only
travel speed "Work" is possible.

HML 42, HML 42 S

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

!
0 4/4
P

HML 42 AL
The mobile excavator features two fully 35
hydraulically steerable axles and an 34
emergency steering system.

Standard steering
• Travel speed / Steering mode switch
(19/64) in "Road — Standard" (hare) or
"Work — Standard" (tortoise) position.
When changing from all-wheel
steering to standard steering, the rear
axle must be in "Straight ahead"
position.
Indicator lamp (19/34) lights up.

All-wheel steering
• All-wheel steering is operated using the P

Travel speed / Steering mode switch

(19/64). 64 HM32-019-N

• Raise lever from "Work travel speed" Fig. 19 Operation

(tortoise) position to deactivate the lock and
move forward to "All-wheel steering"
"Round" or "Crab".

42 HML 42
 Operation 4

All-wheel steering "Round"

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

• "Straight ahead" indicator lamp (19/34) for P

!
0 4/4

rear axle lights up when the wheels are

straight.
35
• Travel speed / Steering mode switch 34
(19/64) in "Round" position.

All-wheel steering "Crab"

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

• "Straight ahead" indicator lamp (19/34) for

64
rear axle lights up. HM32-019-N

• Travel speed / Steering mode switch Fig. 19 Operation

(19/64) in "Crab" position.

HML 42 43
4 Operation

4.7.3 Brakes

Service brake
• The service brake (20/12) is to be applied
as required.
52
Parking brake
• The parking brake (20/63) is to be applied
when parking the machine.
Only apply brake when machine is
stationary.

Excavator brake
P

• The excavator brake (service brake, 20/12)

must be applied when performing 62 63
excavator operations (fully depress pedal 10 11 12
until the locking device (20/11) clicks in.)
With the excavator brake applied, the
oscillating axle is locked at the same
time.

4.7.4 Driving on roads 16

Buckets wider than 600 mm and

ditch-cleaning buckets/swing buckets
wider than 1,250 mm have to be
dismounted. 21

Ÿ Slew the superstructure to travel position

HM32-019
and fix in place with the bolts of the
superstructure slewing lock (20/21). Fig. 20 Operation
Ÿ HML 42 AL — Choose "Standard steering"
(see Chapter 4.7.2 "Steering").
Ÿ Fully raise boom.
• Slew the work equipment to transport
position using the sighting device (21/1).
• Fully retract the intermediate-boom
cylinder.

HM32-020

Fig. 21 Sighting device

44 HML 42
 Operation 4

• Place dipperstick vertically until the color

marks are in alignment.
If a clamshell grab is mounted, attach
the grab to the serrated pipe (23/1)
and close it.
Adjust the position of the dipperstick.
If a front dozer blade is installed, the
grab has to be dismounted before
driving on roads.
• Retract the bucket in compliance with the
color mark (22 A) above the tilt control
lever.
• Retract the ditch-cleaning bucket in
compliance with color mark (22 B) below
the tilt control lever, position horizontally
and fix in place so that it cannot oscillate.
• Fully raise the stabilizers and secure the
support pads mechanically with a chain.
• Fully raise the support blade (option) and
attach removable reflectors.
• Fully raise the front dozer blade (option).
HM32-021
• Switch off the working hydraulics
(20/52). Fig. 22 Lighting

• When driving on the road, the switch for the

oscillating axle lock (20/62) must be in
“OFF” position.
• Manual throttle (20/16) in neutral position.
• Affix the lighting unit to the bucket cylinder
(22/1) and connect at the socket (front side
of uppercarriage, next to cab) — only if
necessary, e.g. poor visibility, darkness,
etc.
• Check the function of turning indicators,
hazard warning system, horn, high beam
and low beam.
• Close the cab door.
HM32-022
Exercise caution when driving
downhill. Do not press the accelerator Fig. 23 Serrated pipe
pedal to the floor.
Before switching from fast gear to low
gear, travel speed must be reduced.

HML 42 45
4 Operation

4.8 Parking the machine 48

• Park the machine on a preferable level and
solid ground.
• Travel direction pre-selector (25/15) in "0"
position.
• Lower the work equipment to the ground.
52
• Lower the stabilizers/ support blade.
• Apply the parking brake (25/63).
• Switch off the working hydraulics (25/52). 15

• Turn off the engine and remove the ignition

key (25/48).
• Raise the exit barrier (25/6). P

• Windows and doors must be locked or

closed. 63

• Battery main switch (25/18) in "0" position,

if required.
If necessary, secure the machine with
chocks so that it cannot roll away.
6
15

18

HM32-025

Fig. 25 Operation

46 HML 42
 Working Operation 5

5 Working Operation
5.1 General
The excavator is equipped as standard with
an "ISO-control" (function of control levers
30/5 and 30/14), on which the following
description is based.
If the customer so wishes, the mobile
excavator can be equipped with a
special control. Your mobile
excavator must therefore be checked
to see whether or not a special
control is installed.
52
Incorrect handling may endanger
persons or objects.
When raising and lowering the exit
15
barrier (30/6), ensure that no other
control levers and/or pedals are
operated.
Danger of accident due to P

uncontrolled machine movements!

With the exit barrier (30/6) raised or 62
the service ladder (30/24) folded 12
down, all work and travel functions
are deactivated.
• Before working with the excavator,
memorize the lever controls well.
14
6
• Start at low rpm when familiarizing yourself 5 15
with the controls.
• Always apply the excavator brake (30/12).
• Travel direction pre-selector (30/15) in
"Neutral" position. Working hydraulics
(30/52) "ON".
When performing excavating 21
operations, the excavator brake
(30/12) and the oscillating axle lock
(30/62) must always be applied. In
addition, the excavator must be
supported by stabilizers and/or
24
support blade, whereby sufficient
HM32-030
wheel grip must continue to be
ensured. Fig. 30 Operation
This is the only way to ensure
optimum stability.
• Before operating the work function "Slew
superstructure", the superstructure lock
must be released (30/21).

HML 42 47
5 Working Operation

5.2 Moving the excavator at high engine

speed
To prevent the excavator from
15
moving off abruptly during work at
high engine speed, the following
activities must be performed in the
given sequence:
P

Risk of accident!
1. Foot on brake pedal (31/12). 62
11 12
2. Release excavator brake (31/11).
3. Switch off oscillating axle lock (31/62).
4. Select the travel direction (31/15).
5. Release the brake pedal slowly and
carefully until the machine starts to roll. 15

HM32-031

Fig. 31 Operation

48 HML 42
 Working Operation 5

5.3 Operation of work functions

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

5
14

HM32-032

Fig. 32 Operation

HML 42 49
5 Working Operation

5.3.2 Operation — intermediate boom/

articulation
• Press button (34/57) and keep pressed —
the "articulation" function is activated.
If wide work attachments, e.g. ditch-
cleaning buckets, swing buckets,
extra-wide buckets, non-standard 57
attachments, etc. are used, the driver
must exercise special care when
operating Knickmatik®.
10
Improper use may result in
personal injury and/or damage.

HM42-034

Fig. 34 Operation
5.3.3 Operation — Stabilizers / Support
blade
With the support blade mounted, the
control levers (35/2) and (35/3) must
be operated at the same time.

rechts
right
droite 3
links 2
left
gauche

HM32-035

Fig. 35 Operation

50 HML 42
 Working Operation 5

5.3.4 Operation — Front dozer blade

(option) P

• Change-over switch (36/61) – front dozer links

left
61
blade - stabilizer left

links 2
left
gauche

HM32-036

Fig. 36 Operation

HML 42 51
5 Working Operation

5.3.5 Operation — Additional control circuit

Additional control circuit I (37/55)

Grab operations (swing bucket, etc.)
• Change-over switch (37/53) in "Rock
53
breaker operations OFF" position (indicator
lamp in switch is off).
If necessary, the work speed of the
additional control circuit must be
adjusted. To do so, adjust wheel
68 55
(37/A).
Rock breaker operations
• Change-over switch (37/53) in "Rock
breaker operations ON" position (indicator
lamp in switch is on).

Additional control circuit II (37/68)

• Diverse hydraulically operated special tools
can be controlled by this control circuit.

5.3.6 Operation of oscillating axle lock

• The oscillating axle lock is controlled by the
excavator brake. With the excavator brake A
applied, the oscillating axle is locked
HM32-037
automatically.
• For special applications it is possible to Fig. 37 Operation
activate the oscillating axle lock
independently of the excavator brake.
• To do so, set the switch for oscillating axle
lock to "ON" (38/62).
• The red indicator lamp in the switch lights
up.
Upon completion of the special job,
immediately re-set the switch for the
oscillating axle lock to “OFF”. P

62

HM32-038

Fig. 38 Operation

52 HML 42
 Working Operation 5

5.4 Changing work attachments

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

HML 42 53
5 Working Operation

5.4.2 Assembly of work attachments

The bearings of the quick-mount hitch
and work attachment must be free of
dirt.
The system must be relieved of
pressure before hydraulic
connections are disconnected.

Procedure for changing work attachments

In the case of a hydraulically
controlled attachment, first of all the
hydraulic connection must be
disconnected (no pressure in
system).
• For replacement, the work attachment must
be lowered to the ground and positioned so
that it cannot tilt.
• Open the quick-mount hitch with the control
rod (40/1) until the locking bolts are
completely retracted.
• Check the function of the quick-mount hitch
lock and lubricate the bolts if required (see
note on lubricating, Chapter 7.8.3).
• Attach another work attachment and close
the quick-mount hitch until the locking bolts
are completely extended and the lock clicks 1
in. HR32-027

• The control rod must be kept in the driver’s Fig. 40 Quick-mount hitch
cab.

54 HML 42
 Working Operation 5

5.4.3 Clamshell grab

During grab operations the change-
over switch (41/53) must be in "Rock
breaker OFF" position.
The indicator lamp in the switch is
off. 53

links
Changing procedure left
gauche
• Attach the clamshell grab and close the
quick-mount hitch.
• Fully retract the bucket cylinder piston rod 4
and close the ball valves (51/3).
Whilst assembling and using a
clamshell grab with quick-attach 3
system, the bucket cylinder piston rod
must be fully retracted. 2 1
• Connect the swivel motor to the couplings
(51/1, additional control circuit) and the
“Open/ Close” function to the couplings
(51/2, Bucket cylinder).
rechts
right
When the grab has been dismantled, droite
re-open the ball valves (51/3).

2
1

HM32-041

Fig. 41 Additional control circuit

HML 42 55
5 Working Operation

5.4.4 Hydraulic rock breaker Maintenance

The maintenance of the hydraulic rock
Attachment
breaker must be performed in compliance with
Before mounting a rock breaker the instructions of the hydraulic rock breaker
supplied by a company other than manufacturer.
SCHAEFF-TEREX, it is absolutely
necessary to consult your dealer.
• The mounting and operating
instructions of the hydraulic rock
breaker manufacturer must be
observed!
• The hydraulic circuit of the rock
breaker must be secured in 53
compliance with the instructions of
links
the hydraulic rock breaker left
manufacturer. gauche

• Standard protection: 300 bar

• When working in or under water, 4
special rock breaker types must be
used.
• The hydraulic rock breaker is mechanically
attached in the same manner as a bucket
attachment. 2 1
• The hydraulic pressure supply for rock
breaker SMS 140 is connected to the lines
of the additional control circuit (42/1) by a
hose coupling.
rechts
• The hydraulic pressure supply for non- right
SCHAEFF-TEREX rock breakers is droite
connected to a line of the additional control
circuit (42/1) and the return line via the 3
open return line connection (42/4).
• Selector (42/53) in “Rock breaker
operation” position. The indicator lamp in
the switch lights up.
2
Working with the hydraulic rock breaker 1
The mounting and operating instructions of
the hydraulic rock breaker manufacturer must
be observed! HM32-042

The pressure force must be applied Fig. 42 Additional control circuit

axial to the rock breaker and
perpendicular to the surface of the
material.
Improper use may lead to severe
damage to the rock breaker, holder
and the excavator itself.

56 HML 42
 Working Operation 5

5.4.5 Using the machine for load hook Using the machine for load hook
applications applications
Earth-moving machines are only to • During load hook applications, the overload
be used for load hook applications if warning device (43/54) must be switched
they are equipped in the proper on and attention be paid to the load display
manner and if they have the license (43/40).
to this purpose.
As soon as the warning signal (buzzer
• During load hook applications, the safety sounding continuously) comes up
notes (Chapter 2.16) must be observed.
• immediately lower the load
• Only loads not exceeding the carrying
• reduce the reach and/or
capacity of the machine and the hoisting
appliance are to be used (Chapter 3.14). • reduce the load.

Overload warning device

In case of overload, a visual and
acoustic signal emit a warning. 40

There is still danger of tilting.

The integrated overload warning device ,

cannot completely exclude accidents as a P

!
0 4/4

result of incorrect operation.

In particular, this applies to:
• Hooking the load or the load holding
equipment from underneath
• Excessive deceleration or acceleration
forces (hard braking or strong swinging off
with the load to be moved)
• Loads falling into the cable
54
• Oblique lifting HM32-043

• The earth-moving machine is working on Fig. 43 Operation

steep ground
• Excessively high winds
Avoid these dangers by operating the
machine cautiously and with the proper care.

HML 42 57
5 Working Operation

Possible forms of attachment, attaching Checking the overload warning device

loads
The working order of the overload warning
Loads must be attached in such a device is to be checked every time before
way that they cannot slip or fall out. using the machine for load hook applications.

• Lift hook attached instead of a bucket, etc. • Switch on the overload warning device
(43/54).
• Hook with safety net welded onto the
bucket rod (in the case of quick-mounting • Move the boom completely upward
buckets with ejectors, the hook must be (extend boom cylinder)
dismounted). • The overload warning indicator (43/40)
• A suitable, appropriately sized loading enters the red area.
implement must be employed for picking up • An acoustic warning signal (continuous
the material to be lifted. signal) comes up.
Always wear protective gloves when • The overload warning device is in working
working with loading implements. order.
Attaching and guiding loads
Personnel guiding the machine and
attaching loads are not to leave the
machine operator’s field of vision.
The safety notes (Chapter 2.16) must be
observed.

58 HML 42
 Towing and Transport 6

6 Towing and Transport of the Opening the "Travel" oil circuit

Machine
• At both high-pressure relief valves (45/1)
6.1 Towing the machine with bypass (in the connecting plate of the
Absolute cleanliness is essential hydraulic pump), slacken the nut (46/1),
when working with the hydraulic and screw in the bolt (46/2) until it is level
system. Always secure the machine with the nut. Re-tighten the nut.
with chocks and relieve of hydraulic • After towing, slacken the nut (46/1) and
pressure before performing screw back in the bolt (46/2) until the stop.
maintenance and repairs. Re-tighten the nut (46/1).
To avoid damage to the hydrostatic travel Tightening torque: 30 Nm
drive, limit the towing of the machine to the
shortest distance, only to clear obstructions
such as road crossings or streets.
If possible, let the diesel engine run idle
during towing.
Emergency steering system
If the diesel engine is standing still,
power steering is deactivated.
Steering-wheel forces are very high!

Preparations for towing

1
HML 42, HML 42 AL HM32-046

• Open the "Travel" oil circuit so that the Fig. 45 Hydraulic pump
hydrostatic transmission no longer acts as
an auxiliary brake.
2
HML 42 S
1
• Manual transmission in neutral position.

HML 42, HML 42 AL, HML 42 S

• Release the spring-loaded cylinder.

Tow fixing points:

Front: on coupler head
Rear: lugs on the right-hand and left-hand
HM32-047
side of the undercarriage
Fig. 46 Valve
Max. load suspension of fixing points
approx. 9,000 kg.

HML 42 59
6 Towing and Transport

Neutral position of manual transmission

Vorderachse HML42S
• Draw or press the gearshift rod (47/1) to Front axle
neutral position (center position) using
appropriate tools.
When the diesel engine and the 1
hydraulic system are started the
preselected gear is automatically
engaged.

Releasing the spring-loaded brake in an

emergency
• Loosen the nuts (48/2) and screw back by
approx. 8 mm on the screws (48/1).
• Screw in the screws (48/1) until the stop
on the pressure plate. Screw in by turns
using a box wrench, each time ¼ turn. HM42-047-N

One full turn is the maximum for Fig. 47 Neutral position of manual transmission
screwing in.
After towing, re-adjust the spring-
loaded brake.
1 1
Adjusting the spring-loaded brake after
emergency release
• Unscrew the screws (48/1) along with the 1 1
nut (48/2) and the sealing washer (48/3).
Replace the sealing washer (spare part 31,5 0,5

no.: 5 370 651 868), grease or oil the

screw and re-mount.
• Screw in screws (48/1) until the adjusting 2
dimension 31 ± 0,5 mm is reached.
• Counter the screws with the nuts (48/2).
1
• Check again the adjusting dimension.
Vorderachse
Front axle
3 HM42-048

Fig. 48 Spring-loaded brake

60 HML 42
 Towing and Transport 6

6.2 Loading the machine using a crane

1
Use a crane with sufficient lifting
load capacity.
2

To load the excavator onto a flat bed trailer,

etc., the following activities must be carried
out:
• Empty and fold in the bucket.
• Position the work equipment straight
ahead.
HM32-049
• Slew the superstructure to travel position
(work equipment is above steering axle). Fig. 49 Loading the machine using a crane

• Secure the superstructure with the slewing

lock (50/21).
• Raise the boom.
• Pull in the intermediate boom cylinder.
• Retract the dipperstick.
• Switch off the engine.
• Dismount from the excavator and close
the doors.
• Attach the excavator to the 3-point hoisting 21
appliance at the points illustrated below
(Fig. 49) in the correct manner. HM32-050

Fig. 50 Superstructure slewing lock

HML 42 61
6 Towing and Transport

6.3 Transporting the machine

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

HM32-051

Fig. 51 Lashing for transport

62 HML 42
 Maintenance and Service 7

7 Maintenance and Service

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

7.2 Intervals
First inspection once before first putting into operation Chapter 7.8.1
1)
Daily jobs every 10 op. h* or every work shift Chapter 7.8.2
Weekly jobs weekly or after 50 op. h* 1) Chapter 7.8.2
100 operating hours once after first putting into operation 2) Chapter 7.8.4
Every 500 operating hours after every 500 operating hours Chapter 7.8.4
Every 1,000 operating hours after every 1,000 operating hours Chapter 7.8.4
Every 2,000 operating hours after every 2,000 operating hours Chapter 7.8.4
1)
whichever comes first
2)
also applicable when new or overhauled diesel engines are put into operation
* [op. h - operating hour]

HML 42 63
7 Maintenance and Service

7.3 Regular oil analyses

Oil analyses are not intended as a substitute for the oil change intervals but – apart from a possible
reduction of maintenance costs and as a form of preventive maintenance – they take into account
the increasing environmental awareness.

Advantages of an oil analysis

• Extension of the oil change intervals under standard or light-duty operating conditions.
• Minimum wear of high-quality components with optimum use of the lubricants.
• Periodic laboratory analyses enable an early detection of imminent damage.
• Repairs performed before they actually become absolutely necessary help prevent serious and
unexpected damage.
• Sequential damage can be avoided.

Oil analysis intervals

Periodic oil analyses reveal trends in the condition of the oil and the machine.
When the scheduled oil change intervals have been reached, the oils should be analyzed in the
following intervals to check their quality and thus extend the oil change intervals:
• Hydraulic oil: 1,000 operating hours
• Transmission oil: 500 operating hours
• Engine oil: 100 operating hours
Based on the first results, the laboratory recommends the interval for the next sampling.
Ask your SCHAEFF-TEREX dealer for an information booklet detailing the scope and procedures
of the oil analysis.

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

64 HML 42
 Maintenance and Service 7

7.5 Inspection parts and aids

Maintenance parts Spare part no.

Hydraulic oil filter insert (return filter)............................ 5 380 658 088
Hydraulic oil filter insert (suction filter).......................... 5 003 659 261
Breather ...................................................................... 5 501 655 650
Engine oil filter ............................................................. 5 411 656 298
Fuel filter...................................................................... 5 411 656 493
Filter insert of fuel line pre-filter.................................... 5 445 100 004
Air filter - main cartridge .............................................. 5 501 660 922
Air filter - safety cartridge ........................................... 5 501 660 924
Valve-cover gasket .................................................... 5 411 656 337
V-belt, breather 13x1,000 ............................................ 5 411 656 409
V-belt, generator 10x950 ............................................. 5 411 656 408
Cab ventilation dust filter ............................................. 5 501 661 034
Service Packs
Service Pack "Classic" — inspection after 100 h.......... MPS 420 001C
Service Pack "Classic" — inspection every 500 h ........ MPS 420 002 C
Service Pack "Classic" — inspection every 1,000 h ..... MPS 420 003 C
Extras

SCHAEFF-TEREX – hydraulic oil, mineral................... 4 312 005 050

SCHAEFF-TEREX – hydraulic oil, biodegradable........ For further information, please

contact your SCHAEFF-TEREX
dealer!
Transmission oil (SAE 85 W 90 LS) ............................ 4 314 005 775
Engine oil (SAE 15 W 40 ) .......................................... 4 312 905 759
Antifreeze and anti-corrosion agent
for engine cooling ........................................................ 4 440 305 025

Maintenance and wearing parts for inspections should be ordered well in advance!
Observe our offer on service packs for inspections. Contact your dealer!

Lubricants
• Availability and life expectancy of the machine largely depend upon the use of the
recommended lubricants and compliance with the specified maintenance intervals.
• If lubricants are used which have not been recommended by us and subsequent damage is
caused, we do not accept any liability under warranty, even within the warranty period.
• For lubricant specifications, see Chapter 3.9.

HML 42 65
7 Maintenance and Service
7.6 Care and cleaning
The machine must be cleaned on a
suitable surface with an oil separator.
• Neither a steam-jet appliance nor a high-
pressure cleaning apparatus are to be
used for cleaning during the first two
months after the machine is used for the
first time or when newly painted to ensure
that the paint can sufficiently harden.
• Do not use aggressive detergents for
cleaning the machine. We recommend
using commercially available cleaning
agents for passenger cars.
• When cleaning with a steam-jet appliance,
the hot water jet is not to exceed 80 °C
and a spray pressure of approx. 70 bar.
• Linings (insulating materials, etc.) are not
to be exposed directly to water, steam or
high pressure jets
• When cleaning with water or steam jets,
take care not to spray exhaust-gas and air
filter openings.
• If cleaning the engine with water or steam
jets, do not expose sensitive engine parts,
such as generator, cabling, oil pressure
switch, etc. directly to the jet.
• After each wet clean, the machine must be
lubricated in accordance with the
lubricating plan and a test of all work
cycles, support and travel functions carried
out.
66
7.7 Notes for use in winter
During operation in winter, the points
mentioned below and the notes in the engine
operating instructions must be observed:
Hydraulic oil
• When the machine has been out of use for
longer periods at temperatures around and
below freezing, it must be warmed up at
medium revs (approx. 3-5 min.).
Engine oil
• The ambient temperature at the site where
the machine is to be used is the deciding
criterion when selecting the viscosity class
(SAE-standard).
Coolant
• The effectiveness of the antifreeze must
be checked before the cold season starts
and adjusted to the ambient temperature if
necessary.
• The antifreeze is factory-set to approx. –
25 °C.
Battery
• For good cold start performance, always
keep the battery fully charged. By warming
up the battery to approx. +20 °C (remove
the battery after the engine has been
turned off and store it in a warm room), the
starting temperature range can be lowered
by approx. 4 °C — 5 °C.
• When installing the battery, ensure good
contact of terminal connections.
• Only tighten terminal screws so that they
are “hand tight“ in order to avoid
deformation of the terminal posts!
HML 42
 Maintenance and Service 7

Fuel
• Only use brand-name diesel fuel with
additives for cold temperatures to
+32 0
prevent clogging of the fuel system due
to paraffin separation. Even if winter +23 - 5
diesel fuel is used, disturbing paraffin A
separations (jelling) can occur at very +14 -10
low temperatures.
+ 5 -15
• If only summer diesel is available, or if
winter diesel must be used at very low - 4 -20
temperatures, we recommend the
-13 -25
addition of petroleum (Fig. 52) or B
additives. -22 -30

• These mixtures should only be used 0 10 20 30 40 50 60%

°F °C
temporarily, not for longer periods.
D2011 D C
D2012 HM23-052
Only mix the components in the
tank. First fill in the necessary Fig. 52 - Table for the addition of petroleum or
quantity of petroleum, then add the additives
diesel.
Additives should be chosen in A = Summer diesel
compliance with the
recommendations of your fuel B = Winter diesel
supplier. C = Added proportion of petroleum
Petrol is not to be added. D = Outside temperature
Danger of explosion!

HML 42 67
7 Maintenance and Service

7.8 Checking, maintenance and inspection plans

7.8.1 Initial inspection (delivery/ handing-over inspection)

HM42-053

7 6 3 2 6 7 4

5 1 9 8

Fig. 53 Initial inspection

68 HML 42
 Maintenance and Service 7

Jobs to be carried out by trained dealer personnel.

Chapter
1 Check whether machine-specific instruction book is in the machine --

2 Check engine oil level 7.9.1

3 Check coolant level 7.9.3

4 Check hydraulic oil level 7.9.8

5 Check fuel level 7.9.4

6 Oil check: axles 7.9.14

Check air pressure and condition of tires. 7.9.16

7
Check secure fastening of wheel nuts.

8 Battery fluid level and charge condition 7.9.21

9 Top up windshield washer system 7.9.20

10 Grease machine (all lubricating points) 7.8.3

11 Test run, hydraulic function check and test work --

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

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

14 Initial delivery / handing-over certificate and return to manufacturer 7.4

HML 42 69
7 Maintenance and Service

7.8.2 Daily and weekly tasks

Inspection and maintenance jobs to be performed by operating personnel:

20 16

HM32-054

21 17 3 15 2 19 17 1

5 6 24 4

Fig. 54 Inspection and maintenance plan

70 HML 42
 Maintenance and Service 7

Daily
Chapter
1 Check hydraulic oil level 7.9.8
2 Check engine oil level 7.9.1
3 Check coolant level 7.9.3
4 Check fuel pre-filter for water accumulation; drain if required 7.9.4
5 Check fuel level (fuel gauge on instrument panel) 7.9.4
6 Check water level for windshield wiper 7.9.20
7 General visual inspection for material cracks, external damage, completeness, --
etc.
8 Check for leaks in: pipes, hoses, control valve, hydraulic pumps, cylinders, etc.
--
When tightening hose and line connections, the screw-in couplings
must be locked to prevent rotation.
9 Check electrical indicating and warning elements, and the lighting system 7.9.21
10 Check smooth running of operator controls --
11 Grease machine in compliance with overview of lubricating points 7.8.3

Weekly
Chapter
15 Clean cooling fins of the combined hydraulic oil-water cooler 7.9.3
The cleaning intervals should be shortened if there is high exposure
to dust.
16 Check that door catches function perfectly --
17 Check tire pressure and wheel nuts 7.9.16
18 Check fastening of axles and propeller shaft 7.9.14
19 Check slewing drive fastening (hydraulic motor and transmission) 7.9.18
20 Check bearing bushings and bolts of the work equipment --
21 Check hydraulic axle lock 7.9.12
22 Check that pneumatic springs of the service covers and the front windshield --
function perfectly
23 Check function, condition and completeness of safety devices --
24 Check function "working hydraulics cut-off through service ladder" --
25 Grease machine in compliance with overview of lubricating points 7.8.3

HML 42 71
7 Maintenance and Service

7.8.3 Overview of lubricating points

Replace damaged grease nipples immediately and check if grease passes through!

9 10 11 12 13

6 29

5
4
3

2
1 HM42-055
03-05-14

14 15 18 19 20 21 21

1x

30 2x

24 2x
34
28
2x
27
30
4x

25 26 31

Fig. 55 Lubrication plan

72 HML 42
 Maintenance and Service 7

Grease all lubricating points with multi-purpose grease.

The intervals stated are valid for one-shift operation
Item Lubricating point Qty. daily weekly Chapter

1 Bucket rod – Quick-mount hitch 1 X --

2 Quick-mount hitch 2 X --
For lubrication, place the bucket on the ground,
open the quick-mount hitch — the bolts must be
fully retracted — and start to lubricate. Close
quick-mount hitch.
3 Bucket cylinder – bucket rod – tilt control lever 3 X --
4 Dipperstick — Quick-mount hitch 1 X --
5 Dipperstick — Tilt control lever 1 X --
6 Bucket cylinder – Dipperstick 1 X --
7 Intermediate boom – Dipperstick 1 X --
8 Dipperstick cylinder — Dipperstick 1 X --
9 Intermediate boom cylinder – Intermediate boom 3 X --
10 Dipperstick cylinder — Intermediate boom 1 X --
11 Intermediate boom — Boom 1 X --
12 Boom cylinder – Boom 1 X --
13 Intermediate boom cylinder — Boom 3 X --
14 Slewing column — Boom 1 X --
15 Boom cylinder — Slewing column 1 X --
--
--
18 Superstructure – Slewing column 2 X --
19 Stabilizer — Undercarriage 2 X --
20 Stabilizer cylinder — Undercarriage 2 X --
21 Stabilizer cylinder — Stabilizer 2 X --
24 Self-aligning bearing front/rear for front axle 2 X --
25 Ring gear — Bearing races 1 X 7.9.18
26 Ring gear — Toothing 1 X 7.9.18
27 Articulated cylinder — Superstructure (slewing column 1 X --
center pillar)
28 Articulated cylinder — Slewing column 1 X --
29 Door hinges 2 X --
30 Steering gear case each 2 X --
31 Hinges for service ladder 2 X --
Non-standard equipment
34 Clamshell grab type GS 3 11 X --
35 Swing bucket 2 X --
36 Swing bucket hydraulic cylinder 2 X --

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

HML 42 73
7 Maintenance and Service

7.8.4 Inspection plan

To be carried out by trained dealer personnel

O = Checking, maintenance Operating hours min min

X = Replacement 2x 1x
Perform work with machine at operating after every every every yearl yearl Chapte
temperature 100 500 1,000 2,000 y y r
1 Check whether machine-specific instruction O O --
book is in the machine
2 Change engine oil X X 7.9.1
3 Change engine oil filter X X 7.9.2
4 Drain fuel tank O O O 7.9.4
5 Replace fuel filter X X 7.9.4
6 Replace fuel pre-filter X X 7.9.4
7 Check air intake O O 7.9.5
8 Change air filter main cartridge to service indicator X 7.9.5
1)
9 Change air filter safety cartridge as required 7.9.5
10 Clean cooling fins of combined hydraulic oil- O O O 7.9.3
water cooler
In case of high exposure to dust, shorten the
cleaning intervals.
11 Check antifreeze level in coolant O 7.9.3
1)
12 Change coolant as required 7.9.3
13 Check V-belt tension O O 7.9.6
14 Check engine mounts and pump attachments O O --
15 Check engine speed adjustment, top-end and O O --
low idle speed
16 Check valve lash of engine and adjust if O 7.9.7
necessary
17 Check acid level and battery connections O O 7.9.21
18 Replace cab ventilation dust filter X X 7.9.19
19 Check condition of tires, tire pressure and O O 7.9.16
tightness of wheel nuts
20 Check secure fastening of axles and propeller O O --
shaft
21 Check bearing bushings and bolts of work O O --
equipment and replace if necessary
22 Check that door catches are in perfect condition O O --
and replace if necessary
23 Check electrical indicating and warning O O --
elements, and lighting system
24 Check smooth running of operator controls and O O --
adjust if necessary
25 Check function of hydraulic axle lock and vent O O 7.9.12
plunger cylinders
26 Check function of steering O O --

74 HML 42
 Maintenance and Service 7

O = Checking, maintenance Operating hours min min

X = Replacement 2x 1x
Perform work with machine at operating after every every every yearl yearl Chapte
temperature 100 500 1,000 2,000 y y r
27 Check condition and function of support O O --
equipment
28 Check line rupture valves of support equipment O O 7.9.13
29 Check tightness of all pipes, hoses, control O O --
valve, hydraulic pumps, cylinders, etc.
When tightening hose and line
connections, the screw-in couplings
must be locked to prevent rotation.
2)
30 Check or change hydraulic oil O O X 7.9.8
31 Replace insert of hydraulic oil return filter X in compliance X 7.9.9
with service
indicator
32 Replace insert of hydraulic oil suction filter X X X 7.9.10
33 Replace breather X X 7.9.11
34 Check function of brakes and play of brake O O 7.9.15
discs
35 Differential of rear axle - oil check or oil change X X X 7.9.14
36 Differential of front axle - oil check or oil change X X X 7.9.14
37 Front axle transmission - oil check or oil change X X X 7.9.14
38 Wheel hubs of front and rear axles - oil check or X X X 7.9.14
oil change
39 Check that ring gear attachment screws are O O 7.9.18
securely fastened
40 Check that swing-drive attachment (hydraulic O O 7.9.18
motor and transmission) is securely fastened
41 Grease machine in compliance with overview of O O 7.8.3
lubricating points
42 Check function, condition and completeness of O O --
safety equipment
43 Hydraulic function check with pressure function O O --
test
44 Test run and test work O O --
3)
45 Initial inspection cards and return to O O 7.4
manufacturer
1. at least every 2 years
2. Extension of oil change intervals in compliance with oil sample analysis and lab report.
For further information see Chapter 7.3
3. within warranty

HML 42 75
7 Maintenance and Service

7.9 Inspection and maintenance work

7.9.1 Engine oil

Checking the engine oil level

• The oil level must be checked daily before
start-up, with the machine standing on level
ground.
• The notches on the oil dipstick (56/2)
indicate the minimum and maximum oil 1
levels.
• Top up engine oil if necessary. Open the
cap (56/1) and add oil using a clean
container.

Engine oil change

Collect the waste oil, do not allow it to
seep into the ground.
Dispose of in compliance with
regulations!
• Run the engine until it reaches operating
temperature, engine oil temperature
approx. 80 °C.
• Park the machine on a level surface. 2 3 HR42-041
• Slew the superstructure by 90° across the
undercarriage. Fig. 56 Engine oil

• Switch off the engine.

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

76 HML 42
 Maintenance and Service 7

7.9.2 Engine oil filter

The engine oil filter must be replaced with
every oil change.
• Place drip pan below the engine oil filter.
• Clean the outside of the engine oil filter.
• Loosen the filter cartridge (57/1) using a
commercially available tool and unscrew it.
Check if the fastening stud is firmly seated
in the filter head.
• Dispose of the filter cartridge in compliance
with regulations.
• Clean the filter head and check its
condition.
• Fill the new filter with oil, wet seal ring with
oil and screw on firmly by hand until the
seal is securely in place.
• With one more half turn, tighten the filter
1 HR42-042
cartridge.
Fig. 57 Engine oil filter
• After a test run, check the tightness of the
engine oil filter cartridge.

HML 42 77
7 Maintenance and Service

7.9.3 Cooling system — Combined

hydraulic oil-water cooler

Coolant level
Only open the cooler cap with the
engine cooled down. Hot coolant 1
carries a risk of scalding!
• Remove the cap (59/1) and top up the
water level. With the engine cooled down,
the expansion tank should be half full.
Refill with a 50%-50% mixture of water
and antifreeze.

Checking the level of antifreeze

• Before the beginning of the cold season,
check the level of antifreeze.
HR32-044
• At the factory, the antifreeze protection is
set to approx. minus 25 °C. If temperatures Fig. 59 Coolant
are lower, the level of antifreeze must be
increased accordingly.

Cleaning cooling fins

Dirt accumulation in coolers causes the
engine and/or the hydraulic oil to
overheat.
• The combined cooler is cleaned from the
outlet side (60) with compressed air.
• If necessary, e.g. in case of an oiled cooler,
clean with cold cleaner or a steam jet
device.
• After cleaning, the engine must be brought HR32-045

to operating temperature in order to dry the Fig. 60 Cooler

cooler.

78 HML 42
 Maintenance and Service 7

Changing coolant
Only open the cooler cap when the
engine is cold. Hot cooling water
carries a risk of scalding!
• Park the machine on level ground.
• Switch off the engine and let cooling
system cool down.
• Remove the cooler cap (59/1).
1
• Unscrew the water drain plug (61/1) on the
cylinder block and drain coolant.
• Remove the drain plug from the water
cooler and drain coolant.
• Flush the cooling system with clean water if
necessary.
• Re-fit the drain plug to the engine and the
water cooler.
• Fill cooling system with coolant (see HR32-046

Technical Data, Chapter 3.9) and close the Fig. 61 Engine block
cap.
• Start the engine and bring to operating
temperature, then turn off and allow to cool.

• Check the coolant level and top up (several

times, if necessary).

HML 42 79
7 Maintenance and Service

7.9.4 Fuel system

Fuel level
• Check the fuel level on the fuel gauge
(62/43).
• To prevent condensation from forming ,

before the next time the machine is used, P

!
0 4/4
43
top up fuel after daily use.
When topping up fuel using the
electrical refueling pump the fuel tank
cap must be opened to avoid
excessive pressure in the fuel tank!
HM32-062
Fuel filter
Fig. 62 Operation
• Clean the outside of the fuel filter.
• Unscrew the filter cartridge (63/1).
Collect fuel!

• Dispose of the filter cartridge in compliance

with regulations.
• Clean the filter head and check its
condition.
• Wet the seal or fuel filter cartridge with oil
or diesel fuel respectively.
• Screw on the cartridge by hand until the
seal is securely in place.
• With one more half turn, tighten the filter
cartridge.
1 HR42-048

The fuel system does not have to be Fig. 63 Fuel filter

vented.
• After a test run, check the tightness.
2
Fuel tank
• Drain water from the fuel tank through the
drain plug (64/1).
• Clean the filling strainer (64/2) and check
for damage.

1
HM42-064

Fig. 64 Fuel tank

80 HML 42
 Maintenance and Service 7

Draining the fuel pre-filter

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

Replacing the filter insert of the fuel pre-

filter
• Clean the outside of the fuel filter.
• Drain fuel through the drain plug (65/1).

Collect fuel!

• Unscrew the center screw and remove the

cover.
• Pull out the filter insert by turning.
• Flush the filter housing with clean fuel.
• Install new or cleaned filter insert.

Cleaning the filter insert of the fuel pre-

filter
1
When cleaning, ensure that no dust
lands on the inside (clean side) of the HM42-065
insert.
Fig. 65 Fuel pre-filter
• Immerse the screen insert of the fuel pre-
filter in clean fuel. Meanwhile, blow out
from the inside and brush off using a
medium-hard cleaning brush.
Only use brushes with synthetic or
natural bristles.
Do not use wire brushes!
• After brushing, immerse the insert in clean
fuel and blow out from the inside.
• Remove the filter insert from the bath and
blow out hard from the inside until there is
no more fuel foam on the surface of the
insert.
• Check that the filter insert is undamaged
and that there is no dirt on the inside.
• The insert is ready to be re-installed.

HML 42 81
7 Maintenance and Service

7.9.5 Air filter, air intake

All maintenance work on the air
intake system must be carried out
with the engine off.
Do not start the engine while the filter
cartridge is removed.

Preparation of machine for maintenance

• Slew the uppercarriage from the travel 2 3 1
direction to the right by approx. 75°
(Fig. 66).
• Position the work equipment until it is

°
straight as compared to the uppercarriage

75
and place it on the ground.
• Switch off the engine.
• Open the engine hood.
• With your left hand, hold on to the frame
(66/1) above the flush-fitted headlamp and
step on the undercarriage access stairs.
• With your right hand, hold on to the handle
(66/2) and climb on the top step of the
access stairs. HM42-066

• Standing on the service access, you can Fig. 66 Air filter maintenance
easily replace the air filter cartridge (66/3).

82 HML 42
 Maintenance and Service 7

7.9.5.1 Air intake

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

1
HM32-066

7.9.5.2 Cartridge maintenance interval

Fig. 67 Air filter
Air filter — main cartridge
• The air filter main cartridge must be
replaced as soon as the indicator lamp for
filter maintenance (68/29) on the
instrument panel lights up during operation.
• A brief delay in maintenance does not 29
result in lower filter efficiency.

Air filter — safety cartridge ,

!
0 4/4

The air filter safety cartridge must be replaced P

in the following cases:

• after the fifth maintenance of the main
cartridge
• when it has reached the maximum service
life of two years HM32-067

• if the service indicator switches on after Fig. 68 Operation

maintenance of the main cartridge has just
been performed
• if the main cartridge is damaged
• if the safety cartridge is damaged

HML 42 83
7 Maintenance and Service

7.9.5.3 Cartridge replacement

Main cartridge
• Release the wire fasteners (69/1) and
remove the bottom of the housing (69/4). 1.
1 2.
• Withdraw the main cartridge (69/2) by
twisting slightly to and fro. 4
• Check whether the safety cartridge (69/3)
must be replaced.
Remove safety cartridge only in the 3.
case of necessary maintenance work.
Only open the seal (69/5) of the
safety cartridge for the purpose of
replacement.

• Note down the date of maintenance in the

appropriate sections of the safety cartridge
(69/3). 2
• Insert the new or cleaned main cartridge
carefully into the filter housing and check
that it is correctly positioned.
• Fit on the lower part of the housing. (Pay
attention to the position of the dust
extraction valve).
• Place the wire fasteners in the groove of
3
the flange on the filter housing and tighten.

Safety cartridge
• Remove the main cartridge.
5
Do not clean the safety cartridge and,
once it has been removed, do not
use it again.
6
• Using a suitable tool (e.g. screwdriver),
pierce the seal (69/5) of the safety cartridge
(69/3) from the inside, then lift up the two
clips (69/6).
• Grasp the safety cartridge (69/3) by the two HM32-068

clips (69/6), withdraw by twisting slightly to Fig. 69 Air filter

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

84 HML 42
 Maintenance and Service 7

7.9.5.4 Cleaning the main cartridge

Never wash or brush out the main
cartridge.
When blowing out, ensure that dust
does not land on the inside of the
main cartridge.
• The main cartridge can be cleaned up to 5x
if necessary. It must be replaced once it
reaches its maximum service life of two
years, at the latest. A note must be made max. 5 bar
of the number of times it is cleaned.
• For cleaning, a pipe the end of which is
bent at 90° should be attached to the
compressed-air pistol. It must be
sufficiently long to reach the floor of the
cartridge. Blow out the filter cartridge from
the inside to the outside with dry
compressed air (max. 5 bar) by moving the
pipe up and down in the cartridge.
Continue until no more dust escapes.
• Check the clean main cartridge for damage HR32-054

to the paper bellows and rubber seals. Fig. 70 Cleaning the main cartridge
Tears and perforations in the paper bellows
can be determined using a torch.
Never continue to use damaged main
cartridges. If in doubt, use a new one.

HML 42 85
7 Maintenance and Service

7.9.6 V-belts Tensioning V-belts — generator

Check and replace V-belts only with
the engine turned off.
Risk of injury!
• Check the complete V-belts (visual
inspection) and make sure that they are not
damaged.
Replace damaged or worn V-belts
immediately.
• Slacken the fastening screws (71/3, x3) of
the generator (71/5).
• Rotate the generator using the screw (71/4)
until the V-belt tension is correct.
• Tighten the fastening screws (71/3).

Checking the V-belt tension

To check the V-belt tension, a tension 1
measuring device is recommended. 5
Check the tension in compliance with 2
the manufacturer’s operating 4
instructions. 1
When new V-belts are fitted, their
tension must be checked and 3
adjusted if necessary after the first
15 minutes.
HR42-056
Checking the V-belt tension without a
Fig. 71 V-belts
measuring device
• To check the tension, press the V-belt with
your thumb in the middle of the greatest
free length, and measure the sag.
• Using medium thumb pressure of approx.
45 N, the V-belt sag should equal 10 mm.

Tensioning V-belts — coolant pump / fuel

pump
• Slacken the fastening screws (71/1, x2) on
the adjuster.
• Rotate the fuel pump (71/2) until the
tension is correct.
• Tighten the fastening screws (71/1) of the
adjuster.
• Check the tension again.

86 HML 42
 Maintenance and Service 7

7.9.7 Checking the valve lash

• The valve lash (72/1) is tested by placing a
reed gauge between the valve (72/3) and
the rocker arm (72/2) on the cold engine.
• The correct valve lash is 0.30 mm for the 5 2
intake valve and 0.50 mm for the outlet
valve.

Checking and adjusting

4
1
Before adjusting the valve lash, let
the engine cool down for at least
30 min. 3
Oil temperature below 80 °C.
• Detach the vent valve and swivel to the
side.
• Remove the cylinder head cover.

Crankshaft position "1"

• Turn the crankshaft until both valves 1
1 2 3 4
intersect at the 1st cylinder (outlet valve not
yet closed, intake valve begins to open).
• The valves marked black can be adjusted.
To check the completed adjustment, mark
the respective valve with chalk.

Adjust valve lash if necessary. To do so:

2 1 2 3 4
Þ Slacken the lock nut (72/4).
Þ Using a screwdriver (72/5), adjust the HM32-072-N
setting screw so that the correct valve lash
(72/1) is obtained when the lock nut is Fig. 72 Valve lash
tightened.

Crankshaft adjustment "2"

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

HML 42 87
7 Maintenance and Service

7.9.8 Hydraulic oil tank

Checking the hydraulic oil level

• Check the oil level using the sight glass
(74/1). Top up hydraulic oil if required.
The hydraulic cylinders of the work 1 3 2 4
equipment should be retracted as far
as possible.

Hydraulic oil change

Danger of scalding when hot oil is 5
drained.

• Bring the hydraulic oil to operating

temperature.
• Retract all hydraulic cylinders.
HM42-074
• Stop the engine.
Fig. 74 Hydraulic oil tank
• Unscrew the breather (74/2).
• Place suitable oil drip pans below the oil
outlet. 1 = Sight glass
2 = Breather
• Screw the oil drain hose onto the oil-
change valve (74/5). 3 = Return filter

Collect waste oil, do not allow it to 4 = Suction filter

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

88 HML 42
 Maintenance and Service 7

7.9.9 Hydraulic oil return filter

Cartridge maintenance interval

• The filter cartridge must be serviced as
soon as the indicator lamp for filter 30
maintenance (75/30) in the instrument
panel lights up during operation. ,

After a larger repair job, following the P

0 4/4

test run the filter cartridge of the

return filter (74/3) must be replaced
as well.
Damaged hydraulic work attachments
may shorten the life of the return
HM32-075
filter.
Fig. 75 Operation
Replacing the filter insert:
• Switch off the engine. 1 3 2 4
• Detach the filter (74/2).
• Remove the cover (76/1) of the return filter.
• Pull out the filter bowl (76/2) together with
the filter insert (76/3). 5
Always place a receptacle for the
collection of waste oil under the
working area when removing the filter
insert.
• Remove the filter element from the filter
bowl by turning and pulling at the same HM42-074
time.
Fig. 74 Hydraulic oil tank
• Clean the filter bowl with petroleum ether or
similar. 1
• Check O-rings (76/4; 76/5; 76/6) and
replace any damaged parts. 4
• Insert a new filter element in the filter bowl. 5
• Install the filter bowl in the tank, together
with the new insert.
2
• Apply a light coat of grease to the cover
seal and tighten the cover by hand. 3
• Screw back in the filter.
• Check the tightness of the filter.
6
HR32-062

Fig. 76 Return filter

HML 42 89
7 Maintenance and Service

7.9.10 Hydraulic oil suction filter • Tighten the filter cover further with the aid
After a larger repair job on the of a tool.
hydraulic system, following the test • Screw back in the breather.
run the filter cartridge of the suction
filter (74/4) must be renewed as well. • Check the tightness of the filter by means
of a test run.
Replacing the filter insert
• Release the breather (74/2).
• With the aid of a tool, remove the filter
cover (77/1). The valve (77/2) in the end
plate of the paper insert (77/9) closes. 1 3 2 4
• Remove the assembly (77/10) by turning
and completely removing the filter cover.
While doing so, pay attention to the O-ring
(77/3).
Always place a receptacle for the
collection of waste oil under the
working area when removing the filter
insert.
• Grasp the assembly by the filter cover
(77/1) and unscrew the valve (77/2). HM42-074

• Pull out the filter insert and dispose of in Fig. 74 Hydraulic oil tank
compliance with regulations.
• Clean the filter cover with center rod (77/8)
and valve with diesel oil or petroleum ether.
While doing so, pay attention to the
A 1
retaining plate (77/6), seals (77/5, 77/7) 3
and compression spring (77/4).
4
• Check the O-ring (77/3) and seals (77/5,
77/7, 77/11), and replace any damaged 5
parts. 6 10
• Place surface “A” of the filter cover on a 8
solid base, push a new filter insert onto the
center rod and fit the seal (77/5). 7
• Push the filter insert downward against the 9
12
springs and tighten the valve (77/2) by
hand. 11
• Push the assembly (77/10) into the housing 2
(77/12), screw on the filter cover tightly by HM32-077
hand and check that the O-ring (77/3) is in
exactly the right position. Fig. 77 Suction filter

90 HML 42
 Maintenance and Service 7

7.9.11 Hydraulic oil tank breather

• Remove the breather (74/2), replace it by a 1 3 2 4
new one and tighten so that it is hand-tight.
Replace the filter if the cap is dirty,
e.g. due to oil vapor.

HM42-074

Fig. 74 Hydraulic oil tank

HML 42 91
7 Maintenance and Service

7.9.12 Venting the plunger cylinders

• The pressure is supplied by the circulation
of flushing oil in the hydrostatic drive.
• The oscillating axle is locked by means of a
locking valve which blocks the connecting
line between the plunger cylinders and is
activated by pressing the excavator brake P

(78/12) or pressing the “oscillating axle

lock” toggle switch (78/62). 62 63
• With the excavator brake applied or the 11 12
oscillating axle lock toggle switch pressed,
the axle is not to swing.

Venting
• Secure the machine so that it cannot roll
away.
• Release the excavator brake (78/11).
• Release the parking brake (78/63).
• Oscillating axle lock toggle switch (78/62)
in “OFF” position.
• Let the engine run at medium revs.
• Open the right and left-hand vent screws HM32-078
(79/1) on the plunger cylinder one after the
other, until hydraulic oil escapes without Fig. 78 Operation
bubbles.
• Close the vent screws.
1

7.9.13 Line-rupture valves for stabilizers

During this test, the machine must be
secured in such a way as to ensure
that there can never be a danger to
persons or objects in the event of a
fault in the line-rupture valves!
• Subject the stabilizer to a load applied in
the non-operating direction.
• Switch off the engine; switch on the HM32-079

ignition. Fig. 79 Plunger cylinder

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

92 HML 42
 Maintenance and Service 7

7.9.14 Axles

General
The axle oil must be checked at operating
temperature.
Collect the waste oil, do not allow it to
seep into the ground.
Dispose of in compliance with
regulations!
After topping up the axles with oil,
drive the machine for approx. 5 min.
to make sure that the oil is evenly
distributed.
Check the oil level again, top up if
required. HML42, HML42AL
3

7.9.14.1 Differential of front axle

Checking the axle oil level

• Remove the inspection plug (81/1), check
oil level and top up oil if required (filler hole
81/3). 1
Changing axle oil 2
• Park the machine on level ground. HML42S

• Open the inspection plug (81/1) and filler

3
plug (81/3).
• Open the drain plugs on the differential
(81/2) and the brake housing, and drain the
oil.
• Flush out the axle if necessary.
• Carefully close the drain plug.
• Pour in oil via the filler hole (81/3) until oil
1
escapes from the inspection hole (81/1). 2 HM42-081-N

• Carefully close both the filler and the

inspection holes. Fig. 81 Front axle differential

HML 42 93
7 Maintenance and Service

7.9.14.2 Differential of rear axle HML42, HML42S

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

Changing axle oil

• Park the machine on level ground.
• Open the inspection plug (82/1) and the 1
filler plug (82/3).
2
• Open the drain plugs on the differential
(82/2) and the bottom housing and drain HML42AL
oil. 3
• Flush out the axle if necessary.
• Carefully close the drain plugs.
• Pour in oil via the filler hole (82/3) until oil
escapes from the inspection hole (82/1).
• Carefully close both the filler and inspection
holes.
1
2
HM42-082-N

Fig. 82 Rear axle differential

94 HML 42
 Maintenance and Service 7

7.9.14.3 Front axle transmission HML42, HML42AL

Checking the oil level

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

Changing oil 1 1
• Park the machine on level ground.
• Open the inspection plug (83/1) on the
transmission.
• Open the drain plug (83/2) on the 2
transmission and drain oil.
HML42S
• Flush out the transmission if necessary.
• Carefully close the drain plug.
• Pour in oil via the inspection and filler hole
(83/1) until oil escapes.
• Carefully close the filler and inspection
plug. 1
2
HM42-083-N

Fig. 83 Reduction gear

HML 42 95
7 Maintenance and Service

7.9.14.4 Wheel hub

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

Checking the oil level

The wheel hub has a combined hole
for inspection, filling and draining.
• Turn the wheel hub to the inspection Vorderachse HML42, HML42S, HML42AL
position. Front axle
Hinterachse HML42AL
• Remove the screw plug, check the oil level Rear axle
and top up oil if required.

Changing oil 1
• Turn the wheel until the screw plug (84/1)
is at the bottom of the hub.
• Open the screw plug and catch the
escaping oil.
• Flush out if necessary. Hinterachse HML42, HML42S
Rear axle
• Turn the wheel to the filling and inspection
position. The inspection mark must be
horizontal.
2
• Fill in oil up to the lower edge of the hole.
• Carefully close the filler hole.

HML 42, HML 42 S: Rear axle

Checking the oil level

• Turn the wheel hub to the inspection
position.
• Remove the screw plug (84/2), check the
oil level and top up oil if required.

Changing oil
• Turn the wheel until the screw plug (84/2)
is at the bottom of the hub.
3
• Open the plug (84/2) and the drain plug
(84/3) and catch the escaping oil. HM42-084-N

• Flush out if necessary. Fig. 84 Wheel hub

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

96 HML 42
 Maintenance and Service 7

7.9.15 Brakes Vorderachse/Front axle - HML42, HML42AL, HLM42S

Hinterachse/Rear axle - HML42AL
HML 42, HML 42 S, HML 42 AL: Front axle
HML 42 AL: Rear axle 1
Checking the brake disc play
• Apply the parking brake (86/63).
• Open the inspection hole (85/1).
• Check the wear of the brake discs using a
test gauge.
• Minimum thickness S = 4.5 mm

HML 42, HML 42 S: Rear axle

The brake plates of the disc brakes in the
wheel hubs cannot be examined.

1
HM42-085-N

Fig. 85 Brake discs

12 63

Fig. 86 Operation

HML 42 97
7 Maintenance and Service

Bleeding the service brake Vorderachse HML42, HML42S, HML42AL

Front axle

This task is to be performed by two 1

persons.
• Let the engine run at medium revs. 1
2
2
• Press down brake pedal (86/12) by 50%. 2 1
1
2

• Open the vent screws (87/2) on both front 2 1 2

axle brake cases one after the other, until
brake fluid (hydraulic oil) runs out without 1
2

bubbles. 2
1
1
1
2
2

Collect the waste oil, do not allow it to

seep into the ground.
Dispose of it in compliance with
regulations!
• Close the vent screws.
• Open the vent screws (HML 42, HML 42 S, Hinterachse HML42, HML42S
Rear axle
- 87/3; HML 42 AL – 87/4) on both rear axle
wheel hubs one after the other, until brake 3
fluid (hydraulic oil) runs out without
bubbles.
• Close the vent screws.
• Open the vent screw on the brake inching
device (hydraulic pump for travel) until
brake fluid (hydraulic oil) runs out without
bubbles.
• Close the vent screw.

Bleeding the spring-loaded brake Hinterachse HML42AL

Rear axle
This task must be done by two
persons!
• Secure the machine so that it cannot roll
away, e.g. by supporting it.
• Let the engine run at medium revs.
• Release the excavator brake and the
parking brake.
• Open the vent screw (87/1) on the front
axle brake case until brake fluid (hydraulic 4
oil) runs out without bubbles.
HM42-087-N
• Close the vent screw.
Fig. 87 Bleeding the brake

98 HML 42
 Maintenance and Service 7

7.9.16 Wheels

Checking the tire pressure

• Check the tire pressure in accordance with
the pressure chart, Chapter 3.8, at regular
intervals.

Checking the tire condition

• The tires must be inspected for cracks,
cuts, foreign bodies, etc.
• Tightness of wheel nuts.
• During the first 50 operating hours, check
the tightness of the wheel nuts (type A 22)
daily, and subsequently at regular intervals,
and tighten to the required torque if
necessary.
• Tightening torque: 610 Nm
When changing a wheel, always tighten the
nuts to the specified torque crosswise in
several steps.

HML 42 99
7 Maintenance and Service

7.9.17 Swing gear

The swing gear is maintenance-free.
1
Circulation lubrication provided by 3
hydraulic system.

7.9.18 Swing bearing

Lubrication of toothing
• The lubricating nipple (90/1) mounted in the
driver’s cab lubricates the toothing of the
ring gear via a nozzle (90/2). 1 3
• To this purpose, slowly turn the
superstructure and lubricate it thoroughly at
the same time using a grease gun. 4
5
Lubrication of bearing races
• The bearing races are lubricated via the
lubricating nipple (90/3) mounted in the
driver’s cab and through a lubricating pipe
(90/4).
• Slowly turn the superstructure clockwise 2
and anti-clockwise, and lubricate it 5
thoroughly until both gaskets have a collar HM42-090

(90/5) of fresh grease. Fig. 90 Swing bearing

100 HML 42
 Maintenance and Service 7

Checking the secure fastening

If the screws are mounted for the first

time, they must also be checked after MA = 72 Nm
100 operating hours.
The following mounting instructions are the
prerequisite for a perfect screw connection on MA = 195 Nm
the undercarriage and the superstructure:
• The contact faces of screw heads must be
of bright metal, i.e. absolutely free of
grease and paint.
• The thread and the screw head, in
particular the toothing of the head, are not
to be damaged.
Damaged screws must be replaced
by new ones!
All accessible screws must be examined to
ensure that they are tightened to the MA = 325 Nm
MA = 325 Nm
torques specified in Figure 91. HM42-091

Fig. 91 Tightening torques

HML 42 101
7 Maintenance and Service

7.9.19 Cab ventilation dust filter

2 1
Removal
• Slew the superstructure 90° (across
undercarriage).
• Remove the cover (92/3) on the bottom of
the superstructure below the cab.
• Remove the filter bracket along with the
filter (92/1).
• Replace filter (92/2).

Installation
• Position new filter in bracket. 3
HM32-092
Observe the mounting position! 010905

The air flow arrows must point Fig. 92 Cab ventilation dust filter
towards the heater.
• Attach the filter bracket along with the filter.
• Re-mount the cover on the bottom of the
superstructure.

7.9.20 Windshield washer system

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

HM32-093

Fig. 93 Windshield washer tank

102 HML 42
 Maintenance and Service 7

7.9.21 Electrical equipment Lighting and warning equipment

Battery • Check function of lighting equipment.

The battery is located under the cover (94/2) • Check function of indicator lamps.
of the service ladder. • Check function of warning equipment.
The instructions of the battery
manufacturer must be observed
when using the battery for the first
time.
• The acid level should be approx. 10 mm 1
above the plates. If necessary, top up with
pure distilled water.
• Only check the battery when the engine is
turned off.
Maintenance-free batteries do not
have to be checked.

Disconnecting the battery

• Fold down the service ladder and remove
the cover (94/1).
• Disconnect first the battery ground cable
(-), then the positive cable (+).
• Lift out the battery.

Installing the battery

1
• Place the battery into the machine.
• Connect the positive cable (+), then the
battery ground cable (-).
Ensure that the negative terminal is
attached to the negative pole (-) and
HM42-094
the positive terminal to the positive
pole (+). Fig. 94 Battery

• Re-fit the cover (94/1).

In winter, in particular, ensure that the battery
is well charged.

HML 42 103
7 Maintenance and Service
7.10 Shutdown
7.10.1 Preservation (temporary shutdown)
To prevent damage (corrosion, etc.) from
storage during shutdown periods over three
months, certain preservation measures must
be taken:
• We recommend keeping the machine in a
dry, dust-free room during the storage
period.
• Clean the inside and outside of the
machine, including the engine.
• Lubricate the machine in compliance with
the lubrication plan.
• Check the oil levels of all assemblies, such
as transmission(s), etc. and top up if
necessary.
• Check the hydraulic oil level and top up if
necessary.
• Repair paint damage.
• Fill the diesel tank completely, in order to
prevent corrosion of the tank walls.
• Check the antifreeze level in the coolant
and adjust if necessary.
• Perform all the preservation measures
contained in the diesel engine operating
instructions.
• Check the tire pressure in compliance with
the prescribed values and protect the tires
(rubber crawler chains) from direct sunlight.
• Treat bare piston rods with a commercially
available anti-corrosion agent.
• Remove and clean the battery and keep it
in compliance with regulations in a dry - in
winter, frost-proof - room. Coat connections
with a little pole grease.
• Seal off the air intake opening of the air
filter system and the exhaust pipe opening.
104
7.10.2 During shutdown
• When the machine is out of use for 6
months, after this time all assemblies must
be brought to operating temperature and
maneuvered for approx. 15 minutes.
• Beforehand, the anti-corrosion coat must be
removed from the piston rods, and the
openings of the air filter system and the
exhaust pipe freed.
• After the maneuvering cycle, preserve the
machine once more as previously described.
7.10.3 After shutdown
Before putting the machine into operation
once more, the following measures must be
carried out:
• Anti-corrosion coat must be cleaned from
the piston rods.
• The openings of the air filter and exhaust
pipe must be freed.
• Check the condition of the air filter main
cartridge / safety cartridge and replace if
required.
• Clean the machine with a neutral
detergent.
• Check and - if required - re-charge and
install the battery.
• Carry out all measures for putting the
diesel engine back into operation stated in
the engine operating instructions.
• If the machine has been out of use for
more than 6 months, the oil in the
assemblies such as transmission(s), etc.
must be changed.
• If hydraulic oil filters (return and suction
filters, breathers — if installed) have been
out of use for 6 months, they must be
replaced.
• Lubricate the machine in compliance with
the lubrication plan.
HML 42
 Trouble-Shooting 8

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

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

Fault Possible cause Remedy

8.3 No steering movement
1 Oil supply to pump interrupted Check and repair suction line
2 Hydraulic pump damaged Check, repair or replace
3 Priority valve damaged Remedy fault (call Service Agent)
4 Steering control unit damaged Remedy fault (call Service Agent)
5 Steering cylinders damaged Repair
6 Mechanical fault Repair
8.4 Insufficient performance of service brake
1 Brake discs worn Repair
2 Braking system damaged Repair or replace
3 Mechanical fault Repair
8.5 Parking brake without function
Spring-loaded brake mechanically
1 Activate spring-loaded brake
released
Hydraulic fault in actuation of spring-
2 Repair
loaded brake
8.6 Insufficient braking power of swing brake
1 Brake linings worn Replace brake linings
2 Fault in brake actuation Repair

HML 42 105
8 Trouble-Shooting

Fault Possible cause Remedy

8.7 No zero position of travel direction
1 Switch for travel direction damaged Repair or replace
(short circuit)
2 Solenoid sticks or is damaged Repair or replace
3 Hydr. cylinder without zero position Check, re-calibrate (call Service Agent)
4 Internal damage to variable Replace complete pump unit
displacement pump
8.8 Hydraulic oil exceeds max. admissible temperature
1 Thermostat damaged Replace
2 Oil level too low Top up oil to mark on sight glass
3 Oil cooler clogged or faulty Clean, check, replace if necessary
4 Suction filter clogged Replace
5 High pressure valves do not respond Check high pressure valves, re-adjust if
all the time necessary
6 Flushing circulation does not function Check pressure of flushing and charge
pump, possible back pressure in circuit,
check housing pressure
7 Variable displ. pump and/or variable- Replace
capacity motor damaged (worn)
8.9 Sluggish acceleration and deceleration, too little propulsive power
1 Insufficient engine power Check diesel engine
2 A brake is sticking Check, remedy damage
3 No tank pressurization Check tank cap, replace
4 Suction filter clogged Replace filter
5 Oil loss in rotary joint Re-seal rotary joint
6 Charge pump (travel) sucks up air Check, re-seal
7 Charge pressure too low Check pressure, re-adjust
8 Pressure limiting valve of filling circuit Check, re-adjust or replace
clogged or faulty
9 High pressure too low Check high pressure (pressure cut-off), and
re-adjust if necessary
10 Variable displacement pump does not Insufficient pilot pressure. Mechanical
open fully damage to pump displacement control.
Check, adjust or repair
11 No flow adjustment of variable-capacity Start of control set too high. Mech. damage
motor to regulator or displacement control.
Adjust, or call Service Agent
12 Internal damage to variable displacem. Replace unit
pump or variable-capacity motor

106 HML 42
 Trouble-Shooting 8

Fault Possible cause Remedy

8.10 Transmission works in one direction only
1 Switch for travel direction damaged Repair or replace
2 Solenoid valve sticks or is damaged Check and replace if necessary
3 Power supply to travel direction switch Check and repair (incl. ground connection)
or solenoid valve interrupted
4 Non-return valve of filling circuit faulty Check and replace if necessary
5 High pressure limiting valve is faulty or Swap valves around. If machine now
incorrectly set travels in the other direction, examine
valve, clean and replace if necessary
6 Leakage at actuating piston Check actuating pressure at piston (behind
actuating time nozzle)
7 Mechanical damage to variable Check, call Service Agent if necessary
displacement pump and/or variable-
capacity motor
8.11 Transmission works in neither direction
1 Too little hydraulic oil in tank Top up to mark on sight glass
2 Mechanical connection to diesel engine Check, repair
faulty
3 Charge pump damaged, no charge Replace variable displacement pump
pressure
4 Switch for direction of travel damaged Check and replace if necessary
5 Valve for direction of travel damaged Check, repair and replace if necessary
6 Power supply to direction switch and/or Check and repair
solenoid valve interrupted
7 Pressure limiting valve (charge Check and replace if necessary
pressure) damaged
8 Suction filter clogged Replace filter
9 Suction line from tank to pump kinked Check
10 No or insufficient charge pressure Check pressure and search for fault
11 Trigger of variable displacement pump Check pressure and search for fault
interrupted
12 Mechanical damage to variable Check, call Service Agent if necessary
displacement pump and/or variable-
capacity motor
13 Internal damage to variable Replace complete unit
displacement pump and/or variable-
capacity motor
14 Mech. connection between variable- Check, repair
capacity motor and axle interrupted

HML 42 107
8 Trouble-Shooting

Fault Possible cause Remedy

8.12 Excavator installation is not working
1 Working hydraulics toggle switch in Change to "ON"
“OFF" position
2 Travel speed switch in “FAST" Change to "slow"
position
3 Left work panel raised, or switch Check, repair or replace if necessary
damaged
4 Oil supply to hydraulic pump Check lines
interrupted
5 Hydraulic pump has stopped working Get hydraulic pump checked by a specialist,
replace if necessary
6 Main pressure relief valves have Check main pressure relief valves and
stopped working replace if necessary
7 Service ladder is folded down Fold up service ladder
8 Switch on service ladder damaged Repair or replace
8.13 Decrease in machine’s performance
1 Insufficient engine power Check diesel engine
2 Hydraulic oil level too low Top up hydraulic oil to the mark
3 Pump is sucking up air Tighten hose connections. Replace O-ring
or seals
4 Insufficient operating pressure Re-adjust main pressure relief valves
(pressure cut-off), replace valves if
necessary
8.14 Machine is working too slowly and hydraulic oil is becoming hot
1 Main pressure relief valves (pressure Re-adjust main pressure relief valves
cut-off) set too low or faulty (pressure cut-off), replace if necessary
2 Hydraulic pump has impermissible Replace hydraulic pump
degree of wear
3 Insufficient hydraulic oil level Top up hydraulic oil to mark
4 Incorrect hydraulic oil Quality of hydraulic oil must conform to our
recommendation
5 Air in hydraulic system Tighten connections with engine off and
system relieved of pressure
6 Oil cooler dirty or damaged Clean, check and replace if necessary

108 HML 42
 Trouble-Shooting 8

Fault Possible cause Remedy

8.15 Superstructure slews too far
1 Swing brake damaged Check condition of brake, repair or replace if
necessary
2 Impermissible degree of wear in swing Check or replace
drive
8.16 Working cylinders are not working satisfactorily
1 Seals in cylinders worn Re-seal cylinders
2 Secondary valves faulty Check secondary valves and replace
complete valves if necessary
8.17 Plunger cylinders fail to lock or lock insufficiently
1 Mechanical fault Check switch valves, replace if necessary
2 Electrical fault Check switches, cables, connections and
fuses
3 No pressure build-up Check hydraulic supply
4 Inexact lock Vent plunger cylinders
8.18 Overload warning device malfunctions
1 No visual indicator Overload warning device sensor or indicator
module damaged.
Have checked by service specialist
2 No acoustic warning Overload warning device not switched on.
Overload warning device sensor or indicator
module damaged.
Have checked by service specialist

HML 42 109
8 Trouble-Shooting

Fault Possible cause Remedy

8.19 Trouble in the electrical system
1 Outside and/or internal lighting does Check cables, connections, bulbs and fuses
not come on
2 Windshield wiper does not work
3 Horn does not work
4 Control organs are imprecise
5 Starting system does not
satisfactorily
Check cables, connections and fuses.
Examine windshield wiper for mechanical
damage.
Replace complete wiper motor if necessary
Check cables, connections and fuses.
Replace complete horn
Determine the fault or source of the problem,
call Service Agent if necessary
work Check charge capacity of battery.
Test starter function. Check connection and
condition of power and battery ground
cables.
Check function of ignition lock, replace
complete unit if necessary.

110 HML 42
 Appendix 9

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

A A B

10

12
13
14
11
1

2
3
4
5
6
7

9
FB1 FA1
15

16
17
18
19
20
21
K1 K2 K3
C
K01 K11

D K02

B C
HM42-E01
A = Instrument panel B = Service ladder C = Starter box D = Relay K03

Fuses Fuses

Position Amps assigned to Position Amps assigned to

F1 10 Interior light, radio, F17 10 Side marker lamp, left

immobilizer F18 10 Side marker lamp, right
F2 20 Socket, additional F19 10 Additional module
heating (option)
F20 10 All-wheel steering
F3 10 Hazard lamp, headlamp (option)
flasher, rotating beacon
F21 10 Option
F4 15 Working floodlight, front
F5 15 Working floodlight, rear
F6 15 Fuel-filling pump, FA1 50 Main fuse
electrical seat heating FB1 40 Pre-heating
(option) FC1 175 Heating flange (K03)
F7 10 Horn, switch lighting,
immobilizer
Colors of fuses
F8 15 Heater fan, air 5A brown 10 A red
conditioning 15 A blue 20 A yellow
F9 10 Wish-wash system, radio Relays
F 10 5 Hydr. oil level, overload
warning, rock breaker, Position Function
additional control circuit
F11 5 Travel, parking brake, K 01 Pre-heating relay
brake light switch K 02 Start-up relay
F12 5 Working hydraulics K 03 Power relay
F13 10 Brake light K1 Working floodlight, front
F14 10 Hazard lamp K2 Working floodlight, rear
F 15 15 High beam K3 not assigned (air condit. — option)
F 16 15 Low beam K11 Directional indicator

HML 42 111
9 Appendix

Power supply Start-up Shut-off Interior light, Fuel-filling pump

system socket

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8

sw 2,5ø sw 2,5ø
20 rt 2,5ø
/3.1
S1
1 1 1
30 F1 2 F2 F6
sw 4,0ø 15 sw/bl 2,5ø rt 2
2
54
19

rt 2,5ø
120 7 5
17
sw 10ø

/3.4 X2 X2 /1.15
50A 3 1 133
sw 4,0ø

rt 0,5ø

rt/ge
12
2 2 XM2
FA1 FB1

sw/bl 2,5ø
1 1 BE1 BE1
X3:1
sw 2,5ø

sw 6,0ø X2:17
XK1 13

ge 2,5ø

ge 2,5ø
rt 2,5ø
rt

13
8
X2
sw 4,0ø

rt/ge
4
rt

1
sw 10ø

X5 1 11
2 5 XM1
XM1 1 XM2
5 1 11
rt

100 E21
/3.5
15
sw/bl 2,5ø

86 30
2 XB1
K02

ge 2,5ø
85 87
1
rt 2,5ø

rt X1
2
16 3 1
17 XMOT XMOT XMOT
XMOT 16 3 1
rt 2,5ø

17
1 1
G+ sw 4,0ø +
30
D+ B+ + M 50a Y2 Y1 M7 M
G1 50b 2 2
31 M1 -
B- G2
-
2
4
XMOT
2
XMOT
2 4 2
FC1
br 2,5ø

br 2,5ø
br 2,5ø

1
br 2,5ø

1
S0
br
br

br
br

/3.4
30
br 10ø HM42-E02
31

Path Code Device Path Code Device

Power supply Shut-off
1.1 X5 Service ladder socket 1.4 Y2 Extra-large quantity for start-up
1.2 G1 Generator 1.5 Y1 Shut-off
1.2 FA 1 Fuse Interior light, socket
1.2 FB 1 Fuse 1.6 F1 Fuse
1.2 G2 Battery 1.6 E21 Interior light
1.2 SO Battery disconnect switch 1.7 F2 Fuse
Start-up system 1.7 X1 Instrument panel socket
1.3 FC1 Fuse (heating flange)
1.3 S1 Pre-heat starter switch Fuel-filling pump
1.3 M1 Starter 1.8 F6 Fuse
1.3 K02 Start-up relay 1.8 M7 Fuel-filling pump

112 HML 42
 Appendix 9

Horn Heater fan, air Wish-wash Radio

conditioning system

1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16

133
1 1 1 /1.6
F7 F8 F9 2 F1
2
2
ge
104

ge
ge

ge

/1.13

ge

sw
/2.7
/2.1 gn/sw

ge
10 5 B1 A4
S3 S11
XM2 13 S18 6
6 XK1
13 1 C1 A2 2
X2 9 6
ge/sw

3
ge

2 A3 A1
31 6 5
5 XK1
12 7
1 XB2 5
B10 12 9
ge/sw

10
bl/rt

ge
2

ge
ge

bl/sw
10 31

gn/vi
bl
B2
br/gn

sw
1 10 /1.10
3 9 104 4
7 XK1
XM1 14 S34 9 4 XRADIO 7
XM2 2 B3
14 3 4
gn

8 XK1 XRADIO L-
XB1 3
br/gn

13 8 L+ R+
XB2 15 30 R-
13 2
XK1
gn

2 B1
31
gn/sw

86 30
gn/gr
gn/bl

XRADIO
bl

gn/vi

K3 8
bl/sw

1
85 87 87a
br/gn

br

A
ge/gn

S90 +SP- +SP-

2 243
+ 1 2
br 2,5ø

br 2,5ø
17
XM2 M M
/2.5 17 M5 XK1
1
150
M6
ge/gn

- 1
1 11 12
XK1 XK1
br/ws

11 12
1
S35 M
2 1
M4 X0
br 2,5ø

br 2,5ø
gn
br

br

br

br
br
br

1
YMK

HM42-E03
03-06-27
Path Code Device Path Code Device
Horn Wish-wash system
1.9 F7 Fuse 1.13 M5 Washer pump
1.9 B10 Horn 1.13 S11 Wish-wash switch
1.9 S90 Coordinate lever horn button 1.13 F9 Fuse
Heater fan, air conditioning 1.13 M4 Wiper motor
1.10 S18 Air conditioning switch Radio
1.10 S34 Air conditioning temperature 1.15 B1 Radio
switch
1.10 K3 Relay 1.16 B2 Loudspeaker
1.10 S35 Air conditioning pressure 1.16 B3 Loudspeaker
switch
1.10 YMK Compressor magnetic
coupling
1.11 F8 Fuse 1.16 A Central mass, cab
1.12 S3 Heater fan switch
1.12 M6 Heater fan

HML 42 113
9 Appendix

Rotating beacon Lighting system

2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10

1 1 104

sw
sw
F3 F14 /1.10
2 L1
2 /2.6 1
XB2 1
L 6
rt

F13
ge

/2.6 1 10 8 3
150 S30 2
sw/ws
sw/ws
104 /1.10
rt

II I 0

sw
/1.10 9 2 1
2 8 3

ge
8 XB2
S16

L0 R
8
10 5 S8

rt
6 1 5 10 br/gn 8
S4 4 br
br

1 2 XB2 X1:3
9 1 ws 3 rt
7 7
sw/ws/gn

6 5
BE2

gr/sw

gr/rt
sw/gn
sw/gn

30

ws/ge
5 7
sw/ws/gn

110
sw

31
5 XB2
ws/ge XB2 /4.13 X1:2
1 1

sw/gn

sw 0,75ø
1 6 6

sw/ws
1
2 F15 F16 F17 2 F18
2 2
4 gr /2.11
3 /3.7
vi/ws

XB2 S10

gr/rt 0,75ø
/2.7 3 XB2 P1
4
ws/ge

R 2
ws 0,5ø

:58

gr/rt
XBL 11
ws/ge

/2.7 XB2 /2.4 /2.3

2 L R
ws
ws

R1 11
sw/ws/gn sw/rt
49a
gr/sw

49 sw/rt
K11 C L R 31
sw/ws/gn 0,5ø

/2.3 /2.3
L1 7 XBL R1 8 XBL gr/rt 0,75ø
sw/ws

7 8 13 14
5 6 XBL XBL
14 XBL XBL
XK1 13 14
1 5 2 6
14 XBL XBL
sw 0,75øsw/ws 0,75ø

sw 0,75ø sw/gn0,75ø

1 2

gr/rt 0,75ø
gr/rt 0,75ø
3 4 10
XBL 9
sw/ws 0,75ø
vi/ws

XBL XBL XBL

sw/gn0,75ø
gr/sw 0,75ø

gr/sw0,75ø

gr/rt 0,75ø

BE1 BE1 3 9 4 10
gr/rt 0,75ø

gr/rt

X3:28 X3:34
ws/ge

ws/ge

sw/rt
sw/rt
ws

ws

1 56b
56a 1 2 43 5 2 56a 56b 1 2 43 52
E5 E1 E2 1 X10
E3 E4
2 31 1 31 1 2
1 1
E13 E14
2 2
br

br

br

br

br
br

br
br

br

HM42-E04
03-06-27

Path Code Device Path Code Device

Rotating beacon 2.6 E3 Rear light, left
2.1 S4 Rotating beacon switch 2.8 S30 Light switch
2.2 E5 Rotating beacon 2.7 E2 Headlamp, right
2.2 F3 Fuse 2.7 F17 Fuse
Lighting system 2.8 F18 Fuse
2.3 F14 Fuse 2.8 E4 Rear light, right
2.3 S16 Hazard warning switch 2.9 F13 Fuse
2.3 K11 Directional indicator 2.9 BE2 Additional module
2.6 S8 Steering column switch 2.9 X10 Side marker lamp socket
2.5 F15 Fuse 2.10 E13 License-plate illumination
2.6 F16 Fuse 2.10 E14 License-plate illumination
2.5 E1 Headlamp, left

114 HML 42
 Appendix 9

Working floodlights Rear fog lamp

2.10 2.11 2.12 2.13 2.14 2.15 2.16

1 1
F4 F5
2 2
104 104 104
/1.10 /1.10 /1.10

/2.10 gr gr 16 16 gr gr
F17 10 8 6 3 S10 XB1 10 5 10 5
II I 0 S20 S51
9 2 1 9 1 9 1
gr/sw 0,5ø

31 31 31
rt 2,5ø
gr/rt 0,5ø

gr/ws
rt 2,5ø

gr/rt

17 18
XB1 18 XB1
17

gr/ws
86 30 86 30
K1 K2
87a 87a
85 87 85 87 XBL 12
12
gr/sw

gr/sw

gr/rt
gr/rt

gr/rt

gr/ws

8 XK1 10 7 XM2 10
XK1 XK1 XK1 9
8 10 7 9 10
gr/sw

gr/sw
gr/rt

gr/rt

gr/rt

1 1 1 1 1 1
E9 E10 E6 E7 E8 E12
2 2 2 2 2 2
br

br

br

br

br

br

br

br

HM42-E05

Path Code Device Path Code Device

Working floodlights 2.12 E6 Working floodlight, rear
2.7 F17 Fuse 2.13 E7 Working floodlight, rear
2.10 S10 Switch for working floodlights, 2.14 S20 Switch for boom-mounted
front & rear working floodlight
2.11 K1 Floodlight relay, front 2.14 E8 Boom-mounted working
floodlight
2.11 E9 Working floodlight, front
2.11 E10 Working floodlight, front Rear fog lamp
2.11 F4 Fuse 2.16 S51 Rear fog lamp switch
2.12 F5 Fuse 2.16 E12 Rear fog lamp
2.12 K2 Floodlight relay, rear

HML 42 115
9 Appendix

Control module Pre-heat Instruments, warning devices

system

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11

100
/1.1 /2.7
1 /3.11

gr/bl
20/1.4 2
F19

bl
br br
gr/bl gr/bl
sw sw

br
2 15 15
58 58 15 58
XM1 Q 31 t° 31 p 31
2
P1 P3
sw
sw
sw

ge
ge

31 br P2 G 31 br
rt

G G 31

bl 0,5ø

br
sw

ws
BE1

ws
ws
X1:2
X1:1

X1:3
X1:5

BE1 X7 X7 X7 X7 X7
X1:4

BE1 X3:20 1 2 3 4 5
X2:9
BE1
vi/ws

120
/1.2
BE1 BE1 BE1 BE1 BE1 BE1 BE1
X3:18 X3:3 X3:4 X3:5 X3:19 X3:17 X3:6
1
XVor1
sw 6,0ø

gn/ws/vi 0,5ø
bl/ws 0,5ø

gn/ge 0,5ø

rt/ws 0,5ø

sw/vi 0,5ø
gn 0,5ø

86 30

ge
K01
3 6 2 4 4
BE2 85 87 XM1 XM1 XM2 XM1 XM2 XM2 5
sw 6,0ø

X4:2 3 6 2 4 4 5
X4:3 X2:12 6
X4:5 X2:15 1 XM2
ws 0,5ø XVor2 6
gn/ge

X4:7 X2:9
sw/vi
bl/ws

rt/ws
sw4,0ø

ws 0,5ø
gn

X4:8 X2:8

ge
ws 0,5ø
X4:9 X2:7 1
XK03

gn/ws/vi
X2:10 11
1 6
sw 4,0ø

X2:11
XMOT
11 6 XMOT
K03
rt/ws
gn

30 50a
M 31
br 0,5ø

1 1 1
1 1 Q 1
31 S5 S4 S7 B2 B1 B20
br

br 4,0ø

3
br
br

2 2 2 2 1 2
X
2 K03 1
R1
br

br

br

br

2
30 2
br 4,0ø

/1.3
br

HM42-E06
03-06-27

Path Code Device Path Code Device

Control module Instruments, warning devices
3.1 BE1 Control module 3.5 S5 Oil pressure switch
3.3 F19 Fuse 3.6 S4 Air filter maintenance
3.3 BE2 Additional module 3.7 P1 Fuel gauge
Pre-heating 3.7 S7 Hydraulic oil filter
3.4 K01 Pre-heat relay 3.8 P2 Temperature indicator
3.4 K03 Power relay 3.8 B2 Coolant temperature
3.4 R1 Glow plugs 3.9 P3 Overload warning device
3.9 B1 Tank sensor
3.10 B20 Hydraulic oil level
2.12 F10 Fuse

116 HML 42
 Appendix 9

Overload warning device Hydraulic functions

3.11 3.12 3.13 3.14 3.15 3.16

1
F10 XB1 ge 0,75ø 136
/3.10 2 ge 0,75ø
B20 1 1 1
XM2 /4.2
104 1

ge
/1.10 200

ge

ge
/4.1
10 5 ge
1 1 1
S9 S40 S41 S44
9 2 2 2
7 1

rt/sw
sw/rt

bl/br
31
2 3 8
XB1 XB1 XM1
gn/rt 0,5ø

BE1 2 3 8
X3:36

rt/sw 0,5ø

rt/sw 0,5ø

bl/br 0,5ø
gn/rt 0,5ø
ge

BE1 BE1 BE1 BE1

X3:9 X3:21 X3:22 X3:23

XM2 7
7
8
XM2
8
ge
gn/rt

2
3
B7
1
br

HM42-E07

Path Code Device Path Code Device

Overload warning device Hydraulic functions
3.11 B7 Overload warning signal 3.14 S40 Brake light pressure switch
sensor
3.12 F10 Fuse 3.14 S41 Axle lock pressure switch
3.12 S9 Overload warning switch 3.15 S44 Accumulator pressure

HML 42 117
9 Appendix

Hydraulic functions

4.1 4.2 4.3 4.4 4.5

200
1
/3.13
136 F11
/3.16 2

104 104 104

140

ge
/1.10 /5.2 /1.10 /1.10
ge
ge

ge ge ge /4.6
10 5 S15 10 6 5 10 5 S37 10 5 S8 S6
S42

9 1 9 8 27 1 9 1 9 1

rt/sw 0,5ø

rt/sw 0,5ø
sw/bl/gn 0,5ø
br/ge 0,5ø

31 31 31 31

BE1 BE1 BE1 BE1

X3:12 X3:27 X3:26 X3:31

BE1
X2:10
bl/rt

BE1 BE1 BE1

X2:2 X2:8 X2:7 XU1 1
1
sw/bl/gn

bl/rt
br/ge

rt/sw

1 2

3 7 1 XDDF2 2
XB1 14 XM2 XB1 7 PE
7 DDF PE
14 3 7
sw/bl/gn

7 XDDF8 8
rt/sw
br/ge

7 8
bl/rt

br

1 1 1 1
Y4 Y10 Y17
Y11
2 2 2 2
br
br

br

br

HM42-E08

Path Code Device Path Code Device

Hydraulic functions 4.4 S37 Axle lock switch
4.1 S15 Rock breaker switch 4.4 Y11 Axle lock valve
4.1 Y4 Rock breaker valve 4.5 S8 Front dozer blade switch
4.2 F11 Fuse 4.5 Y17 Front dozer blade valve
4.2 S42 Parking brake switch
4.2 Y10 Parking brake valve DDF Rotary joint

118 HML 42
 Appendix 9

Travel drive Working hydraulics cut-off

4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16

1
F12
2 11 11
ge XB1

ge
104 104 104 104 1
/1.10 /1.10 /1.10 /1.10 S29
S43 2

ge
/4.5 ge ge ge ge

bl/ge
3 1

ge
S8 10 5 S6 10 5 S39 10 5 S5 A1 C1 10 5
S5a S36
3 2
9 rt/ge 0,5ø III II I 0 A3 A2 B1 12
1 gn/ge 0,5ø 9 1 9 1 9 1
A5
rt/ge 0,5ø

12 XB1

bl/ge 0,5ø
5
gn/ws 0,5ø

gn/rt 0,5ø

XM3 gn/ws0,5ø

bl/ge 0,5ø
rt/bl 0,5ø

31 31 31
5 31

sw 0,5ø
gr 0,5ø
6
gn/ge

XM3
6
BE1 S45 1 BE1 BE1 BE1 BE1 BE1 BE1 BE1 BE1 BE1
X3:16 X3:30 X3:14 X3:13 X3:15 X3:32 X3:24 X3:10 X3:29 X3:11
2

bl/ge/gn 0,5ø
gn/ws

9
XM1
9

BE1 BE1 BE1 BE1 BE1 BE1 10 BE1

X2:4 X2:6 X2:11 XM1
X2:5 X2:14 X2:12 X2:1
10
sw/ws

sw 1,0ø

ge

bl/ge
bl/rt

rt
gn

gr

bl/ge/gn

110
20 /2.8 13
15
XM2 9 XM2 18 XM2 XM2 21 XM2 19 XM2 XB1
13
9 18 15 21 19 20
bl/ge
sw/ws
rt 1,0ø

rt 1,0ø

sw
bl/rt

gr
gn

1 1 1 1 B 1
1 1
1
H10 Y13 Y6 Y5 Y16 Y14 Y15 B9 C Y3
A
2 2 2 2 2 2 2 2
br

br

br

br
br

br
br
br

br

HM42-E09

Path Code Device Path Code Device

Travel drive 4.12 Y14 Valve for travel, forward
4.6 S6 Travel motion alarm switch 4.12 S43 "Forward/Reverse" switch
4.6 H10 Travel motion alarm horn 4.13 Y15 Valve for travel, reverse
4.7 S45 Travel motion alarm pressure 4.11 Y16 Valve for flushing (travel motor)
switch
4.8 S39 Accelerator pedal switch Working hydraulics cut-off
4.8 Y13 Accelerator pedal valve 4.13 B9 Service ladder proximity switch
4.9 S5 "FAST/SLOW" switch 4.15 F12 Fuse
4.9 Y6 "FAST" valve 4.15 S36 Working hydraulics cut-off
4.10 Y5 "FAST" valve 4.16 S29 Armrest switch
4.11 S5a All-wheel steering switch 4.16 Y3 Working hydraulics valve

HML 42 119
9 Appendix

Coordinate lever, right Coordinate lever, left Armrest, left

5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11

140
/4.2
ge

ge 1 ge 5 5 ge 3 ge 1 ge ge
3
S25 S24 XB1 S21 S22 10 5 S50 10 5 S38

9 1 9 1
2 1 2 2 1 2 rt/bl rt/bl

rt/bl
bl/rt

rt/bl
bl/sw rt/sw 31 31
bl/sw 0,5ø

rt/sw 0,5ø

or 0,5ø

4 6 9 10 11
4 XB1 6 XB1 9 XB2 10 XB2 11 XB2
bl/sw

0,5ø
0,5ø

rt/sw

0,5ø
0,5ø

0,5ø

rt/bl
bl/rt

rt/bl
BE1 BE1 BE1 BE1 BE1 BE1 BE1 BE1
X1:7 X1:8 X1:11 X1:9 X1:10 X1:12 X1:13 X3:33

BE1 BE1 BE1 BE1 BE1 BE1 BE1 BE1

X2:13 X2:14 X2:16 X2:18 X2:19 X2:20 X2:21 X2:13
rt/sw
bl/sw

bl/rt

rt/bl
bl/sw

rt/sw

rt/bl
or

12 13 3 4
XM1
11
XM1 XM1 XM3 2 XM3 XM1 16 XM3
1 XM3
11 12 13 2 3 16 1 4
bl/sw

rt/sw

rt/sw
bl/sw

bl/rt

rt/bl
or 1,0ø

or 1,0ø

rt/bl

1 1 1 1 1 1 1 1 1
Y18 Y19 Y20 Y21 Y23 Y24 Y22 Y25 Y12
2 2 2 2 2 2 2 2 2
br
br
br

br

br

br

br

br

br

HM42-E10

Path Code Device Path Code Device

Coordinate lever, right Coordinate lever, left
5.2 S25 Push-button for additional 5.6 S21 Push-button for additional
control circuit 1 control circuit 2
5.1 Y18 Valve for additional control 5.6 Y23 Valve for additional control
circuit 1 circuit 2
5.2 Y19 Valve for additional control 5.7 Y24 Valve for additional control
circuit 1 circuit 2
5.4 S24 Articulation changeover switch 5.8 S22 Swing pressure boost
5.4 Y20 Valve for articulation 5.8 Y22 Swing pressure valve
5.5 Y21 Valve for articulation Armrest, left
5.10 S50 Switch for option
5.10 Y25 Valve for option
5.11 S38 Steering changeover switch
5.11 Y12 Steering changeover valve

120 HML 42
 Appendix 9

Steering Option

6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10

1 1
F20 F21
2 2

ge
ge

ge

ge

ge
X1:1 X1:6
BE2 BE1 BE1 14 15
bl/ge/gn 0,5ø X3:25 X3:35 XB2 XB2

X1:4 X1:5

rt/gn/vi
gn/ws
gn/rt

XU1 5 XU1 6 XU1 2 XU1 3 4

XU1
5 6 2 3 4
gn/ws

bl/ge/gn
gn/rt

rt/gn/vi
ge

5 6 1 2 3
5 XDDF6 6 XDDF6 1 XDDF62 XDDF6 3 XDDF6
5 6 1 2 3
DDF 5 DDF 6 DDF 1DDF 2 DDF 3
5 6 1 2 3
XDDF8 XDDF8 XDDF8 XDDF8 XDDF8
5 6 1 2 3
gn/ws

ge 0,5ø

ge 0,5ø
gn/rt

rt/gn/vi
bl/ge/gn

1 1 BE2 BE1 BE1

B B X2:17 X2:15 X2:3
Y7 Y8 C C
B11 B12
2 2 A A
gn
vi

rt
br

br

br
br

4 Option
14 15 16
XDDF8 4 XM1 XM1 XM2

4
DDF 4

4
XDDF6
4
br

HM42-E11
03-06-27

Path Code Device Path Code Device

Steering
6.2 F20 Fuse 6.4 B11 Front axle proximity switch,
steering angle
6.2 BE2 Additional module 6.5 B12 Rear axle proximity switch,
steering angle
6.2 Y7 Valve round/crab (steering) 6.9 F21 Fuse (option)
6.3 Y8 Valve round/crab (steering) DDF Rotary joint

HML 42 121
9 Appendix

Control module BE1

Control module
X1 Power supply
1 Power supply Terminal 30
2 Power supply Terminal 30
3 Power supply Terminal 30
4 Central mass
5 Power supply Terminal 15
6 --
7 --
8 --
9 --
X2 Signal outputs
1 Working hydraulics
2 Rock breaker
3 FAST – SLOW
4 FAST – SLOW
5 Travel motion alarm
6 Flushing
7 Axle lock
8 Parking brake
9 Pre-heating
10 Front dozer blade
11 Travel, forward
12 Travel, reverse
13 Steering changeover
14 Accelerator pedal
15 Option
16 --
17 Start-up magnetic switch terminal 50A
18 --
X3 Signal inputs
1 Start-up ignition lock terminal 50A
HM32-E15
2 --
3 Oil pressure switch
4 Air filter clogging
5 Hydraulic oil filter clogging
6 Hydraulic oil float switch
7 --
8 --
9 Overload warning switch
10 Service ladder proximity switch
11 Armrest switch

122 HML 42
 Appendix 9

Additional module BE2

12 Rock breaker switch X1 Plug
13 -- 1 --
14 FAST – SLOW switch 2 Brake lights
15 -- 3 Power supply Terminal 15
4 --
16 Travel motion alarm switch
5 --
17 Tank sensor
6 --
18 Central mass
7 Additional control circuit 1 push-button
19 Coolant temperature
8 Additional control circuit 1 push-button
20 Charge control
9 Additional control circuit 2 push-button
21 Brake light signal
10 Additional control circuit 2 push-button
22 Axle lock signal 11 Articulation changeover push-button
23 Accumulator pressure signal 12 Swing pressure boost push-button
24 Switch for travel, reverse 13 Bucket changeover switch (option)
25 Front axle steering angle signal 14 --
26 Axle lock switch 15 --
27 Parking brake switch 16 --
28 Direction indicator lamp signal 17 --
29 Working hydraulics switch 18 --
30 Accelerator pedal switch X2 Plug

31 Front dozer blade switch 1 --

2 --
32 Switch for travel, forward
3 --
33 Steering changeover switch
4 --
34 High beam signal
5 --
35 Rear axle steering angle signal
6 --
36 Overload warning signal
7 Connection control module X4:9
37 -- 8 Connection control module X4:8
X4 Interface 9 Connection control module X4:7
1 -- 10 Central mass
2 -- 11 Central mass
3 -- 12 Power supply Terminal 15
4 -- 13 Valve additional control circuit 1
5 -- 14 Valve additional control circuit 1
6 -- 15 Power supply Terminal 15
7 Connection additional module X2:9 16 Valve for articulation
8 Connection additional module X2:8 17 Valve for articulation
18 Valve for additional control circuit 2
9 Connection additional module X2:7
19 Valve for additional control circuit 2
20 Swing pressure boost
21 Bucket changeover (option)

HML 42 123
9 Appendix

9.2 Hydraulic system

S
T
P A P
1 0,6 R 0,8
140 bar
T L T
S2

2 5
S S1 P R 6
100/250

100/250

LS
4
CF P

A B EF

P 7
HÜV
24 230
bar
S 110
bar P

HM42-H01
02-02-06
A

T
33
BB

22
A

32
B

31
10
DDF

30
B

150 T
T bar

9
1bar
11
X

13
14

20 3/2 MV
23
T 12
A

B
300 300 300 300 300

300 300 300 150 300

29
A

28
-1
P=67 kW n=2000 min

15
A

Deutz BF4M2012

27
4/3 MV
A

26
21 16
A

25
HÜV LS
300 280
bar bar
P T

17

18
K
T

19
34
5bar

Fig. H01 "TPA" hydraulic installation

124 HML 42
 Appendix 9

1 Swing drive
2 Valve for swing brake release
3 --
4 Priority valve
5 Steering unit
6 Steering cylinder
7 Cut-off valve
8 --
9 Accumulator valve (braking system)
10 Travel motor
11 Variable-capacity pump — excavation
12 Travel pump
13 Suction filter
14 Gear pump — steering, excavating, braking
15 Hydraulic oil tank
16 Diesel engine
17 Hydraulic oil cooler
18 Hydraulic oil temperature control
19 Return filter
20 Operation — Rock breaker (3/2 directional control valve)
21 Operation — Additional control circuit (4/3 directional control valve)
22 Emergency steering
23 Control valve 1
24 Control valve 2
25 Dipperstick
26 Additional control circuit / Rock breaker
27 Bucket
28 Intermediate boom
29 Boom
30 Stabilizer
31 Stabilizer
32 Articulation
33 Slewing
34 Return collector

HML 42 125
9 Appendix

9.3 Immobilizer 9.3.2 Deactivating the system

The AUTO-SCAN Immobilizer, type
Mini AR2000, is a self-activating
immobilizer.
The Immobilizer provides effective
protection against theft of the
machine.
The AUTO-SCAN Immobilizer
Mini AR2000 is recognized as anti-
theft protection by almost all
insurance companies.
The Immobilizer may only be
installed by the manufacturer of the
machine or a qualified specialist
workshop.
The manufacturer or the specialist
workshop has to fill out the certificate
confirming the correct installation for
presentation to the insurance
company.
Your machine cannot be started as long as
the immobilizer is activated.
If somebody tries to start the machine
with the immobilizer activated, an
alarm sounds.
For deactivation, proceed as follows:
• With the electronic code key, touch the
operating unit (Position 1).
• LED is OFF.
• Switch on the ignition on the machine
within 30 seconds and start.
If the machine is not started within
30 seconds, the immobilizer again activates
itself automatically.

2 1
9.3.1 Activating the system

The immobilizer is self-activating.

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

Fig. 101 Immobilizer

1 = operating unit
2 = LED (luminous diode)

126 HML 42
 Appendix 9

9.3.3 Operating malfunctions 9.3.4 Damaged or lost code keys

In the event of malfunctions or With the delivery and handing over of the
damage to the immobilizer, the machine you receive 2 code keys and one
system is never to be removed key code card.
without the instructions provided by
If a code key is lost, a new key can be
the specialist workshop (otherwise,
ordered from your specialist workshop by
system becomes useless).
presenting the key code card.
If voltage is lost (for example, if the
battery is disconnected), the
immobilizer returns to the status
activated before the voltage loss
once the supply voltage is
reapplied.

Possible sources of malfunction

• No deactivation of immobilizer
Þ use second key
• LED OFF and machine cannot be started
Þ replace fuse
If these measure do not help, contact
your specialist workshop.

HML 42 127
9 Appendix

128 HML 42
 DELIVERY AND HANDING-OVER INST RUCT IONS
The following checklist is to be adhered to when handing over the machine
to the customer:
1. Operating instructions
The operating instructions should be read side by side, and be explained in
detail through practical training on the machine.
The following items are of special importance:
• Regulations for the prevention of accidents published by the employer’s
liability insurance associations in the user’s country
• Technical data
• Operator controls, indicating and warning elements
• Checks before putting the machine into operation
• Specifications for diesel engine start-up Mobile Excavator
• Turning on and off the diesel engine
• Explanation of hydrostatic travel drive
• Travel, speed ranges and notes for driving on roads
• Towing and transport of the machine
HML 42
• Operation of all functions
• Oscillating axle lock
• Explanation of maintenance and inspection intervals in compliance with
Maintenance and Inspection Plan by demonstrating maintenance points Maintenance and Inspection Plan
on machine
• Lubrication intervals and points of lubrication in compliance with overview
of lubricating points and demonstration of these points on the machine The careful performance of all prescribed inspections is the best prerequisite
• Handing over of the diesel engine operating instructions for the machine’s continuous readiness for operation.
2. Spare parts list All maintenance work mentioned should therefore be performed in the
• Structure of spare parts list, of figures and the respective descriptions prescribed sequence with the machine at operating temperature.
• Instructions for ordering spare parts: always state the type of machine, The inspections are obligatory.
the vehicle identification number (Fz-Id.Nr.), parts designation, complete
spare part number, piece number, delivery address, etc. If omitted, this may affect the warranty covered by us.

3. Warranty The machine must be thoroughly cleaned before inspection takes place.

• Explanation of warranty covered by manufacturer

• Explanation of inspection cards and note on maintenance and inspection
plan
• Explanation of how to fill out and return the warranty-handing-over card
correctly
 Inspection plan
To be carried out by trained specialist dealer personnel

O = Checking, maintenance O = Checking, maintenance

min. min. min. min.
X = Replacement Operating hours 2x 1x
X = Replacement Operating hours 2x 1x
Perform work with machine at operating after every every every yearly yearly Perform work with machine at operating after every every every yearly yearly
100 500 1000 2000 100 500 1000 2000
temperature temperature
1 Check whether machine-specific instruction O O 28 Check line rupture valves of support O O
book is in the machine equipment
2 Change engine oil X X 29 Check tightness of all pipes, hoses, control O O
3 Change engine oil filter X X valve, hydraulic pumps, cylinders, etc.
4 Drain fuel tank O O O .
When tightening hose and line
5 Replace fuel filter X X connections, the screw-in couplings must be
6 Replace fuel pre-filter X X locked to prevent rotation
7 Check air intake O O 30 Check or change hydraulic oil O O X 2)
8 Change air filter main cartridge to service indicator X 31 Replace insert of hydraulic oil return filter X in compliance X
9 Change air filter safety cartridge as required 1) with service
indicator
10 Clean cooling fins of combined hydraulic oil/ O O O
water cooler. 32 Replace insert of hydraulic oil suction filter X X X
33 Replace breather X X
In case of high exposure to dust, 34 Check function of brakes and play of brake O O
shorten the cleaning intervals. discs
11 Check antifreeze level in coolant O 35 Differential of rear axle - oil check or oil X X X
12 Change coolant as required 1) change
13 Check V-belt tension O O 36 Differential of front axle - oil check or oil X X X
change
14 Check engine mounts and pump attachments O O
37 Transfer gear - oil check or oil change X X X
15 Check engine speed adjustment, top-end and O O
low idle speed 38 Wheel hubs of front and rear axles - oil check X X X
or oil change
16 Check valve lash of engine and adjust if O
necessary 39 Check that ring gear attachment screws are O O
securely fastened
17 Check acid level and battery connections O O
40 Check that swing-drive attachment (hydraulic O O
18 Replace cab ventilation dust filter X X
motor and transmission) is securely fastened
19 Check condition of tires, tire pressure and O O
41 Grease machine in compliance with overview O O
tightness of wheel nuts
of lubricating points
20 Check secure fast.of axles and propeller shaft O O
42 Check function, condition and completeness O O
21 Check bearing bushings and bolts of work O O of safety equipment
equipment and replace if necessary
43 Hydraulic function check with pressure O O
22 Check that door catches are in perfect O O function test
condition and replace if necessary
44 Test run and test work O O
23 Check electrical indicating and warning O O
45 Initial inspection cards and return to O O 3)
elements, and lighting system
manufacturer
24 Check smooth running of operator controls O O
and adjust if necessary 1. at least every 2 years
25 Check function of hydraulic axle lock and vent O O 2. Extension of oil change interval in compliance with oil sample analysis and lab report. For
plunger cylinders further information see Chapter 7.3
26 Check function of steering O O 3. within warranty
27 Check condition and function of support O O
equipment